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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S 32/KA_ _Micropulse Linear TransducerDigital Output / Profile Housing

Technical Description / User’s Guide

28 0711 30 0762 32 0813 36 0914 40 1016

inches mm 15 0381 16 0407 18 0457 20 0508 22 0560 24 0610 26 0661

Rugged,CompactRod Style

Compact,bolt-inRod Style

Rod Style

Explosion-proofRod Style

Balluff - Linear Transducer

Generation 5

Output Type

Supply Voltage1 = 24 Vdc ±20%2 = ±15 Vdc ±2%

Normal Stroke Length

Housing TypeP = Standard Profile Housing

Connection Type

S 3 2

K A 0 5

= 8-pin quick disconnect metal connector

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

Differential start/stop with tri-stateDifferential stop - leading edge activeDifferential pulse-width modulatedDifferential start/stop - leading edge activeSingle ended start/stop - leading edge activeDifferential start/stop - trailing edge active

IKLMNP

======

K A 0 5

0 3 0 5 = 305mm active stroke

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

B T L - 5 - P 1 - M 0 3 0 5 - P - S 3 2

Standard Stroke Lengths (consult factory for additional lengths)

inches mm 148 3759 156 3962

Electrical Stroke

inches mm 2 0051 3 0077 4 0102 5 0127 6 0152 7 0178 8 0203 9 0230 10 0254 11 0280 12 0305 13 0330

inches mm 42 1067 48 1220 50 1270 60 1524 70 1778 80 2032 90 2286 100 2540 110 2794 120 3048 130 3302 142 3606

BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear TransducerDigital Output / Profile Housing

Read this manual before installing and operating the MicropulseTransducer.

1.1 Proper application

The BTL5 Micropulse transducer is intended to be installed in amachine or system. Together with a controller (PLC) or a proces-sor (BTA) it comprises a position measuring system and may onlybe used for this purpose.

Unauthorized modifications and non-permitted usage will result inthe loss of warranty and liability claims.

1.2 Qualified personnel

This guide is intended for specialized personnel who will performthe installation and setup of the system.

1.3 Use and inspection

The relevant safety regulations must be followed when using thetransducer system. In particular, steps must be taken to ensurethat should the transducer system become defective no hazards topersons or property can result. This includes the installation ofadditional safety limit switches, emergency shutoff switches andmaintaining the permissible ambient conditions.

1.4 Scope

This guide applies to the modelBTL5-P/I/K/L/M...P... Micropulsetransducer.

An overview of the various modelscan be found in section 6 Versions(indicated on product label)on page 7.

1 Safety AdvisoryContents1 Safety Advisory ............... 21.1 Proper application .............. 21.2 Qualified personnel ............ 21.3 Use and inspection ............ 21.4 Scope ................................ 2

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

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

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

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

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

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

6 Versions(indicated on part label) 7

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

ambient conditions ............ 87.2 Supply voltage (external) .... 87.3 Control signals .................. 87.4 Connection to processor ... 87.5 Included in shipment ......... 87.6 Magnets (order separately) 87.7 Accessories (optional) ....... 87.8 Compatible processors

and displays ...................... 8

Note: For special versions,which are indicated by an -SU_ _ _ designation in thepart number, other technicaldata may apply (affectingcalibration, wiring, dimen-sions etc.).

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

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

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

EN 61000-4-4Severity level 3Surge

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

EN 61000-4-6Severity level 3Magnetic fields

EN 61000-4-8Severity level 4

The CE Mark verifies thatour products meet therequirements ofEC Directive

89/336/EEC (EMC Directive)

and the EMC Law. Testing in ourEMC Laboratory, which is accreditedby DATech for Testing Electromag-netic Compatibility, has confirmedthat Balluff products meet the EMCrequirements of the followingGeneric Standards:

EN 50081-2 (emission)

EN 61000-6-2 (noise immunity) Emission tests: RF Emission EN 55011

The following patentshave been granted inconnection with thisproduct:

US Patent 5 923 164Apparatus and Method forAutomatically Tuning theGain of an Amplifier

US Patent 5 903 426Overvoltage ProtectionApparatus for DataInterface

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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear Transducer

Digital Output / Profile Housing

2 Function and Characteristics

2.1 Characteristics

Micropulse transducers feature:

— Very high resolution,repeatability and linearity

— Bus-compatible interface(BTL5-I...)

— Immunity to shock, vibration,contamination and electricalnoise

— An absolute output signal

— BTL to processor cablelengths up to 500 m

— IP 67 per IEC 529

2.2 Function

The Micropulse transducercontains a tubular waveguideenclosed by an extrudedaluminum housing. A magnetattached to the moving memberof the machine is moved acrossthe top of the housing and itsposition constantly updated.

The magnet defines themeasured position on thewaveguide. An externallygenerated INIT pulse interactswith the magnetic field of themagnet to generate a magneto-strictive torsional wave in thewaveguide which propagates atultrasonic speed.

The torsional wave arriving at theend of the waveguide is absorbedin the damping zone. The wavearriving at the beginning of thewaveguide creates an electricalsignal in the coil surrounding thewaveguide. The propagation timeof the wave is used to determinethe position, which is presentedon the output in various digitalformats. This takes place withhigh precision and repeatabilitywithin the measuring rangeindicated as the nominalstroke length.

On both ends of the nominalstroke length is an area whichprovides an unreliable signal, butwhich may be entered.

The electrical connection betweenthe transducer, the processor/controller and the power supply isvia a cable, which depending onthe version is either fixed orconnected using a femaleconnector.

Dimensions for installing theMicropulse transducer and for themagnets and control arm arefound on pages 4 and 5.

2.3 Available stroke length

To provide for optimum fit in anyapplication, a wide range ofstandard stroke lengths andmagnets in various form factorsare available. Magnets and controlarms must therefore be orderedseparately.

See inside front cover foravailable stroke lengths.

3.1 Transducer installation

Ensure that no strongelectrical or magnetic fieldsare present in theimmediate vicinity of thetransducer.

Any orientation is permitted.The mounting brackets andcylinder head screws allow thetransducer to be mounted on aflat machine surface. Theseshould be evenly spaced (Figs.3-1 and 3-5). The recom-mended spacing for longtransducers and extremeconditions (e.g. strong shock orvibration):

A = 80 mm; spacing betweenthe individual bracketsB = 250 mm.

The isolation bushings are usedto electrically insulate thetransducer from the machine(Fig. 3-1and 3-5 and chapter 5.6Noise elimination).

The Micropulse transducer inprofile housing is suitable bothfor floating, i.e. non-contactingmagnets (Page 4) and forcaptive magnets (Page 5).

3 Installation

Notch on housing to mark the beginning of the stroke range

Current position of magnet

Micropulse Transducer

Nominal stroke =Measuring range

Fig. 2-1: Basic arrangement

El.

conn

ectio

n

Dam

ping

zon

eMoving machinepart

and magnets

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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear TransducerDigital Output / Profile Housing

3 Installation (cont.)

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

NL

Nominal stroke

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

55

28

45

21

Ø 4.2

20

61 +

101

15

E E C

D

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

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

max. permissibletightening torque 2 Nm

3.2 Floating magnets

The floating magnet (Figs. 3-2to 3-4) is attached to themoving member of the machineusing non-magnetizable screws(brass, aluminum). To ensurethe accuracy of the transducersystem, the moving membermust carry the magnet on atrack parallel to the transducer.

The following table providesfigures in [mm] for the spacingwhich must be maintainedbetween magnet and transducerand for the permissible centeroffset:

Magnet type Distance" D "

Offset" C "

BTL5-P-3800-2 0.1 ... 4 ± 2

BTL5-P-5500-2 5 ... 15 ± 15

BTL5-P-4500-1 0.1 ... 2 ± 2

BTL5-P-4500-1 magnet,special features: Multiplemagnets on the sametransducer can be turned onand off individually (PLC controlsignal).

The stroke range is offset 4mm towards the BTLconnector/cable (Fig. 3-4).

Ensure that thedistance E betweenparts made ofmagnetizable

material and theBTL5-P-5500-2 magnet is atleast 12 mm (Fig. 3-3).

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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear Transducer

Digital Output / Profile Housing

3 Installation (cont.)

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

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

Black,roundmarking

NL

Nominal stroke

Ball joint "B"DIN 71805,rotates horizontally

Black, roundmarking

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

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

Mechanically joined to M5stud using 2 nuts Max. angle offset

Max. parallel offset

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

3.3 Captive magnets

Lateral forces are to be avoidedwhen using captive magnets(Figs. 3-6 and 3-7). Connectionsare required here which permit thecorresponding degree of freedomwith respect to the direction ofmovement of the magnet alongthe stroke range. It is assumedthat the BTL5-F-2814-1S magnetis connected to the machinemember using a connecting rod.The BTL2-GS08...A connectingrod (Fig. 3-8) is available as anaccessory (please indicate lengthLS when ordering).

Jam nut DIN 934 M5

Swivel eye DIN 648

Ball joint "B" DIN 71805,rotates horizontally (part ofBTL5-F-2814-1S) magnet)

Fig. 3-8: BTL2-GS08-_ _ _ _-Aconnecting rod

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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear TransducerDigital Output / Profile Housing

4 Wiring

straigntBKS-S 32M-00

right-angleBKS-S 33M-00

Cable entry(PG 9 fitting)

Note the followingwhen makingelectrical connec-tions:

System and control cabinetmust be at the sameground potential.

To ensure the electromagneticcompatibility (EMC) whichBalluff warrants with the CEMark, the following instruc-tions must be strictlyfollowed.

BTL transducer and theprocessor/control must beconnected usingshielded cable.

Shielding: Copper filamentbraided, 80% coverage.

The shield must be tied to theconnector housing in theBKS connector (Fig. 4-1); seeinstructions accompanyingthe connector.

In the cable version the cableshield is connected to thehousing in the PG fitting.

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

Pin assignments can befound in Table 4-1. Connec-tions on the controller sidemay vary according to thecontroller and configurationused.

When routing the cable betweenthe transducer, controller andpower supply, avoid proximity tohigh voltage lines to prevent noisecoupling.

Especially critical is inductivenoise caused by AC harmonics(e.g. from phase-control devices),against which the cable shieldprovides only limited protection.

Cable length max. 500 m ;Ø 6 to 8 mm.

High noise immunity on the linebetween the transducer andprocessor is provided by thedifferential line drivers used forthe RS 485/422 interface. Thedifferential signal is carried to theprocessor, which makes itavailable as analog or digitalinformation forfurther processing.

Fig. 4-1: Connector (optional)

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

BKS connector,view towardssolder side offemale BKS-S32M-00 or BKS-S33M-00

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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear Transducer

Digital Output / Profile Housing

4 Wiring (cont.)

INIT

START/STOP

INIT

START/STOP

GND

+24 V

YE

GY

PK

GN

BU

BN

BTL

5-P

1...K

A_

_

pro

cess

or o

rco

ntro

ller

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

5 Startup

5.1 Check connections

Although the connections arepolarity reversal protected,components can be damagedby improper connections andovervoltage. Before you applypower, check the connec-tions carefully.

5.2 Turning on the system

Note that the system mayexecute uncontrolled move-ments when first turned on orwhen the transducer is part of aclosed-loop system whoseparameters have not yet beenset. Therefore make sure thatno hazards could result fromthese situations.

5.3 Check output values

After replacing or repairing atransducer, it is advisable to verifythe values for the start and endposition of the magnet in manualmode. If values other* than thosepresent before the replacement orrepair are found, a correction shouldbe made.

* Transducers are subject tomodification or manufacturingtolerances.

5.4 Check functionality

The functionality of the transducersystem and all its associatedcomponents should be regularlychecked and recorded.

5.5 Fault conditions

When there is evidence that thetransducer system is notoperating properly, it should betaken out of service andguarded against unauthor-ized use.

5.6 Noise elimination

Any difference in potential -current flow - through the cableshield should be avoided.Therefore:

– Use the isolation bushings,and

– Make sure the controlcabinet and the system inwhich the BTL5 is containedare at the sameground potential.

Mic

ropu

lse

Line

ar T

rans

duc

er

6 Versions (indicated on part label)

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

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

Profile form factor

Nominal stroke (4 digits): M = Metric units [mm]U = Inch units [1/10 in.]

Digital output signals: BTL5-N... BTL5-P... BTL5-M... BTL5-I... BTL5-K... BTL5-L...

Start Stop Start Stop Start Stop Start Stop Stop Gate(Trailing Edge Active)

(Leading Edge Active)

(RS-485Multiplex)

(Leading Edge Active)

(Pulse-width- Modulated)

Single Ended

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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear TransducerDigital Output / Profile Housing

7 Technical Data

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

Resolution < 2 µmHysteresis < 4 µmRepeatability < 6 µm(resolution + hysteresis)System resolution (BTL5-.... + BTA)is determined by the processor orexternal controller.

Recommended sampling rate:Nominal length fStandard

< 1000 mm 0.5 to 2 kHz< 2000 mm 0.5 to 1 kHz> 2000 mm 0.5 kHz

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

±100 µm ±0.02 %

Temperature coefficient< (6 µm + 5 ppm * nominal length)/KShock loading 100 g/6 msper IEC 68-2-27 1

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

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

1 Individual specifications as per

Balluff factory standard

7.1 Dimensions, weights, ambientconditions

• Nominal length < 4000 mm• Dimensions pages 4 and 5• Weight approx. 1.4 kg/m• Housing anodized aluminum• Housing attachment:

Mounting clamps with isolation bushings and screws

• Operating temp. –40 °C to +85 °C• Humidity < 90%, non-condensing• Protection class per IEC 529 IP 67 when closed up

7.2 Supply voltage (external)

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

BTL5-_2... DC ±14.7 to ±15.3 VCurrent draw < 90 mA (at 1 kHz)Inrush < 3 A/0.5 msPolarity reversal protection built-inOvervoltage protectionTranszorb diodesElectric strengthGND to housing 500 V

Control arm (optional)BTL2-GS08-_ _ _ _-AAluminum, dimensions Fig. 3-8Various standard lengths LSavailable (please specify whenordering)

7.7 Accessories (optional)

Connectors Fig. 4-1

7.8 Compatible processors and

... for BTL5-P1

Analog output processor cards:BTA-A 0...10 and 10...0 VBTA-C 0...20 or 20...0 mA *BTA-E 4...20 or 20...4 mA *BTA-G -10...10 and 10...-10 V* also: 0...10 V and 10...0 V

Digital output processor cards:BTA-D11 20 bit, binaryBTA-S11 16 setpoint outputsBTA-H11 22 bit,BCD, Gray/binary orSSD, GrayBTA-V11 Velocity output cardParallel, digital and analog output

Displays:BDD-07-9 digital display, 7-digitfor BTA-H, BTA-S and BTA-VBDD-AM10-1-P display andcontroller with 2 relay outputsBDD-CC08-1-P display andcontroller with 8 setpoints

7.3 Control signals

INIT pulseLevel +5 V RS 485/422 driverLength 1 µs (max. 3 µs)

Pulse lengths over 3 µscan damage the unit.

Shielded cable,max. length 500 m, Ø 6 to 8 mm.

7.5 Included in shipmentTransducer Fig. 3-1or Fig. 3-5(with mounting brackets,isolation bushings and screws,not incl. magnet)

7.6 Magnets (order separately)

• Spacing, offset and installationpages 4 and 5

Operating temp. –40 °C to +85 °C

BTL5-P-3800-2 Fig. 3-2 Weight approx. 12 g Housing plastic

BTL5-P-5500-2 Fig. 3-3 Weight ca. 40 g Housing plastic Non-linearity: Nom. length < 500 mm > 500 mm

±150 µm ±0.03 % FS

BTL5-P-4500-1 Fig. 3-4Weight approx. 90 gHousing plasticOperating temp. –40 °C to +60 °C

BTL5-F-2814-1S Fig. 3-6Weight approx. 28 gHousing plastic

BTL5-M-2814-1S Fig. 3-7Weight approx. 32 gHousing anodized

aluminumContact surface plastic

BTL5-N-2814-1S Fig. 3-7Weight approx. 35 gHousing anodized

aluminumContact surface plastic

7.4 Connection to processor

displays

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BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _Micropulse Linear Transducer

Digital Output / Profile Housing

7 Magnet and Control Arm Diagram Refernces

55

28

45

21

Ø 4.2

20

61 +

101

15

E E C

D

Fig. 3-1: Dimensionaldrawing (BTL5...P-S 32transducer with floatingmagnet BTL5-P-3800-2)

NL

Nominal stroke

Mounting brackets with isolation bushings and M5 x 22 cylinderhead screws, DIN 912, max. tightening torque 2 Nm

Fig. 3-5: Dimensionaldrawing (BTL5...P-KAtransducer with captivemagnet BTL5-F-2814-1S)

Mounting brackets with isolation bushings and M5 x 22 cylinder headscrews, DIN 912, max. tightening torque 2 Nm

NL

Nominal stroke

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

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

max. permissibletightening torque 2 Nm

Ball joint "B"DIN 71805,rotates horizontally

Black, roundmarking

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

Mechanically joined to M5stud using 2 nuts

Max. angle offsetMax. parallel offset

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

straigntBKS-S 32M-00

right-angleBKS-S 33M-00Cable entry(PG 9 fitting)

Fig. 4-1: Connector (optional)

Jam nut DIN 934 M5Swivel eye DIN 648

Ball joint "B" DIN 71805,rotates horizontally (part ofBTL5-F-2814-1S) magnet)

Fig. 3-8: BTL2-GS08-_ _ _ _-Aconnecting rod

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GermanyGlobal HeadquartersBalluff GmbHSchurwaldstraße 973765 Neuhausen a.d.F.Telefon: +49 (0)71 58/1 73-0Telefax: +49 (0)71 58/50 10Hotline: +49 (0)71 58/1 73-370Web: www.balluff.deE-mail: balluff@balluff.de

USANorth American HeadquartersBalluff Inc.8125 Holton DriveFlorence, KY 41042Phone: (859) 727-2200Toll-free: 1-800-543-8390Fax: (859) 727-4823Web: www.balluff.comE-Mail: balluff@balluff.com

CanadaBalluff Canada, Inc.2840 Argentia Road, Unit #2Mississauga, Ontario L5N 8G4Phone: (905) 816-1494Toll-free: 1-800-927-9654Fax: (905) 816-1411Web: www.balluff.caE-mail: balluff.canada@balluff.ca

MexicoBalluff de Mexico S.A. de C.VProl. Av. Luis M. Vega #109Col. Ampliacion CimatarioQueretaro, QRO 76030Phone: (++52 442) 212-4882,224-3583, 224-3171Fax: (++52 442) 214-0536E-mail: balluff.mexico@balluff.com

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