Solutions for the Steel and Metallurgical IndustryReliability and flexibility from a single source

X12CrNi18-8

Whether in the automotive industry, aerospace industry, energy supply, civil engineering or medical technology – steel and other high-quality metals are indispensable for our world. Steel is the me-tallic material used most. This is because steel is extremely versatile and fulfills the highest demands.

The consistent high quality of steel is ensured by state-of-the-art procedures. This is the only way to attain continuous reproduction of properties such as corrosion protection, low weight or best ductility.

The production of steel is highly complex and is carried out using high temperature, shock and vibration under the most difficult conditions. This places high demands on producers and mechanical engineers. They must guarantee a reliable process with best quality management. A fundamental prerequisite for this is the top quality of systems and machines. This calls for the best technology.

Balluff Solutions for the Steel and Metallurgical Industry

For all types of steel production, Balluff provides first-class sensors and systems with a suitable and up-to-date connectivity product line. Developed for rough environments, they are resistant to high temperature, shock and vibration as well as extremely robust and reliable. Thanks to their excellent technology, they are also ideal for producing other high-quality metals.

Thus Balluff technology ensures greatest system availability and pro-vides consistent use of machine performance. In the coke plant, at the blast furnace, in hot and cold rolling or during surface treatment. Balluff products are internationally approved and available worldwide.

The global service offers individual support in the best quality, for Balluff is on site everywhere.

Excellent Technology 4Coke Plant Machines, Coke Oven Battery and Conveying Equipment 6Blast Furnace and Electric Arc Furnace 8Continuous Casting Line 10Hot Rolling and Heavy Plate Production 12Cold Rolling and Surface Treatment 14

Balluff Product Overviews Special Connectors 16Fieldbus Modules for Global Use 17Industrial RFID Data Carriers for High Temperatures up to 220 °C 18BVS Vision Sensors for Data Matrix and Bar Codes 19Standard Sensors for Object Detection 20High-temperature Resistant Inductive Sensors up to 160 °C 22Capacitive Sensors for High Pressures and Temperatures 23Ultrasonic Sensors 24Color and Contrast Sensors 25Rapid Replacement of Micropulse Transducers 26Micropulse Transducer with Explosion Protection 27Micropulse Transducers up to 100 °C 28P111 Module 28ProCompact Micropulse Transducer with IP 69K 29Redundant Micropulse Transducers 30Inclination Sensors 31Pressure Sensors 32Intelligent Power Supplies 33Accessories 34Safety Screen for Photoelectric Sensors 34HALT Test 35

Hot rolling and

heavy plate production line

Blast furnace

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Full-range assortment Our full-range assortment with all effective principles guarantees that steelworkers and plant engineers have excellent technology that solves a wide variety of applications – whether for an electric arc furnace, a continuous casting line or a rolling mill.

For the entire metal-producing industry and machine building indus-try, Balluff provides inductive, photoelectric, capacitive, magnetic, ultrasonic and pressure sensors as well as position measuring systems and RFID systems – ideal for the extreme conditions in the steel mill.

Our networking and connectivity product line, ideally equipped for the steel and metallurgical industry, is optimally designed for this; for example, with PTFE cables up to 200 °C. All accessories for easy mounting and installation or quick sensor replacement are likewise part of our product line.

Excellent TechnologyFor a wide variety of tasks in the entire process

Cold rolling and

surface treatment

Continuous

casting line

Sinter plant

Coke plantConverter

Electric arc furnace

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Object Detection

Linear Position Sensing and Measurement

Condition Monitoring and Fluid Sensors

Industrial Identification

Industrial Networking and Connectivity

Accessories

Systems and ServiceHALT-testedBalluff quality for steel production means media-resistant as well as resistant to high temperature, shock and vibration. Our products are extremely robust and reliable, since they are rigorously tested in our own accredited laboratory using Highly Accelerated Life Tests. HALT tests help to optimize the resistance of our technology under extreme loads even before they are put into use: for high require-ments, optimum quality and best system availability.

Individual solutionsBalluff gives you the best service and comprehensive services, including personal consulting and customized solutions. Contact us.

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A continuous process is the foremost priority in the steel mill. Balluff provides steelworkers with extremely reliable solutions for a wide variety of tasks pertaining to coke plant machines, the coke oven battery and conveying equipment.

Where the process in the coke plant runs hottest is precisely where the robust position measuring system BTL 100 °C performs persua-sively. It reliably controls all movements related to furnace charging. Control of the oven itself is handled by a micropulse transducer with explosion protection, which is ideally implemented in an environment with gas. At the coke oven battery, industrial RFID enables correct and fully autonomous positioning of the larry, pusher and transfer cars. With a large read/write distance, super-fast data transmission and no line-of-sight contact.

Coke Plant Machines, Coke Oven Battery and Conveying EquipmentSteel production begins with coke

For all movements at the coke oven batteryThe BTL Micropulse transducer in the hydraulic cylinder controls all movements at the coke oven battery up to 100 °C. Its robust metal housing with IP 67 and PTFE cable for up to 200 °C makes it ideal for particularly hot environments.

Position detection at the pusher machineInductive sensors that are high-temperature resistant up to 160 °C provide the best results at the pusher machine for position sensing and detection of end positions.

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Controlling the pusher carsIndustrial RFID systems position larry, pusher and transfer cars at the coke oven battery. Any number of write-enabled data carriers are embedded in the floor and read via a read/write device without a direct line of sight. This technology provides data exchange in real time. Even from a long distance.

Controlling the coke oven batteryThe high-precision transducer with explosion protection is optimally implemented if a gas environment requires high reliability – for example when regulating the oven control system.

At no other place in the steel mill is process reliability as important as at blast and electric arc furnaces. For once it is commissioned, a blast furnace is used around the clock over the course of years. For every steelworker, therefore, the importance of continuous and absolutely reliable management of high temperature and of magnetic fields is beyond dispute.

Some of its important tasks are water cooling, safe supply and discharge of gas when producing pig iron in a blast furnace or positioning of electrodes in an electric arc furnace.

Blast Furnace and Electric Arc FurnaceContinuously manage magnetic fields and high temperatures

Positioning of electrodesSensors for detecting color and contrast support the positioning of electrodes in the electric arc furnace. The sensor, which is pro-tected in the gripper, uses color markings on the electrode to check whether it has been gripped correctly. The color markings are reliably and flexibly detected even when their spectrum changes due to temperature differences.

Assurance of the correct electrode positionWeld-immune BES inductive sensors operate extremely reliably with insensitivity to magnetic fields at the electric arc furnace; this provides assurance of the correct electrode position.

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Regulating the air and gas suppliesBTL Micropulse transducers are used for controlling flaps and valves around the blast furnace in order to regulate the supply and exhaust air during production of pig iron. Alternatively, standard BES induc-tive sensors deliver convincing performance.Additional security: A temperature sensor is integrated in the elec-tronics head for all BTL Micropulse transducers with a bus interface. This guarantees correct temperature measurement.

Pressure measurement for the water cooling Their exceptionally low drift makes BSP pressure sensors of particu-lar interest for pressure measurement of the water cooling at blast and electric arc furnaces, because they guarantee a long stable pro-cess. This makes Balluff pressure sensors unrivaled in the steel mill.

Level monitoring of charges and cokeBUS ultrasonic sensors monitor stack heights of the bulk material being conveyed on conveyor belts and the level in silos. In the case of extreme dust and dirt from charges and coke, they provide for reliable charging of the blast furnaces.

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Large forces, vibrations and shock have to be controlled in the continuous casting line: at the ingot mold movement for the homo-geneity of the fluid metal or at the walking-beam for transport of slabs or billets.

The steel quality is determined at the continuous casting segments. The desired properties are achieved depending on the degree, temperature and time of the reshaping. Therefore maximum flex-ibility and peak reliability are required for the technology used in the continuous casting line. Balluff sensors and systems provide security and guarantee a consistent, continuous process for a wide variety of product formats.

Continuous Casting LineMaximum flexibility for various formats

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Monitoring of the casting ladleBTL7 Micropulse transducers (2 and 3 times redundant) provide absolute safety for the continuous casting process, since the iron ladle movement requires maximum reliability.

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Checking slab lengthPhotoelectric distance sensors are used at the cooling section. They check for the correct length after the slabs or billets have been cut.

Position sensing at the dummy barBOS photoelectric sensors ensure reliable position sensing of the dummy bar. This reliably controls the beginning of the process.

Fast replacement without leaks Balluff provides the rapid replacement module for fast and easy replacement of BTL Micropulse transducers in the hydraulic cylinders. Replacement entails replacing the entire sensor unit with the integrated waveguide elements. The hydraulic circuit remains closed.

RapidReplacement

Module

RRM

Transport of slabs on the walking-beamBSI inclination sensors with contactless angle measurement guarantee ultimate precision when transporting the slabs on the walking-beam. The mechanical coupling is unnecessary, as with rotary encoders.

From the hot rolling to the heavy plate production, shock, vibration and large forces repeatedly develop. Water cooling is often required at the rolling stand. The equipment used here is subjected to high moisture. For the great demands associated with reshaping, you receive first-class technology, which comprehensively manages a wide variety of work steps from the slab to the coil.

Hot Rolling and Heavy Plate ProductionFor a continuously reliable process

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BNI fieldbus modules up to 70 °C for all bus systemsBNI fieldbus modules are available for all important bus systems to simplify the network topology. They enable the network to have a modular structure. In the steel mill, they delivery convincing perfor-mance to a high degree with their functional reliability up to 70 °C.

IO-Link versions permit effective and cost-effective wiring of all sensors – standard sensors included.

Guiding the slabsBTL Micropulse transducers in the hydraulic cylinder are ideal for positioning and guiding the slabs. They check for the correct configuration of the lateral guides and accompany the slabs on their path through the rolling stand. The large forces in the reshaping are reliably compensated for in this process.

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Quality assurance at the rolling stand BIS M industrial RFID systems guarantee the automatic recording and identification of all tools used. For example, they check whether the correct rolls are being used or whether the roll pairs match. At the same time, reworking of the rolls is documented. This consis-tently prevents errors and guarantees maintenance at the right time.An added benefit: RFID handhelds also enable mobile communica-tion right in the system.

Correct assignmentBarcodes and color codes are used to clearly identify coils and other products. The BVS vision sensor quickly and reliably checks for their correct assignment – independent of their position.

Setting the roll gap preciselyThe roll gap can be set with high accuracy using the BTL Micropulse transducer with IP 69K. The insensitive and vacuum-sealed BTL is perfect for use without additional protection for continuous water cooling of the rolling stand.

Before the steel leaves the plant, it is processed for later use as much as possible. Rolled as a plate, wire or rail and provided with surface refinement. Even the smallest errors here are irreversible, since the quality of the finish is visible later in the product. Therefore the greatest measure of precision is sought.

For cold rolling and surface treatment Balluff provides high precision: quality products for best performance even in the final stretch. For the dancer roll, winder, coating system or quality control.

Cold Rolling and Surface TreatmentMaximum precision for the finish

Correct roll position at the winder and unwinderBTL Micropulse transducers are used to achieve high accuracy when winding the coils. The pressure roller is guided, for example, depending on the roll diameter. Ultrasonics are used as well in this process.

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Reliable pressure measurement during surface refinementHCL-resistant BSP pressure sensors provide functional reliability during the surface refinement process. They enable reliable pressure measurement of process media, even if they come into contact with aggressive medias like hydrochloric acid.

Plate guidance at the dancer rollBUS ultrasonic sensors detect plates on rolls and coils and provide for the correct roller drive. In addition, they readjust the correct mate-rial feed at the dancer roll corresponding to the plate sag. Thus the plate tension is always perfect.

Quality control at the coating systemThe BFS color sensor is ideally used for inspecting plate coatings. It detects the finest color nuances or whether a plate leaves produc-tion polished or unpolished. Even in the case of temperature fluctua-tions, it reliably identifies the plates. Thus the BFS provides unrivaled good quality.

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A large selection of plug connectors and connecting cables in different materials, colors and lengths can be found in our catalog Industrial Networking and Connectivity or online at

www.balluff.com

Our comprehensive range of connectors includes connecting lines, assembled, customized and bus connectors as well as bus acces-sories. With variants specially designed for the harsh conditions in steel plants.We offer PUR, PVC, PTFE as well as TPE connections for the Ameri-can market to provide you with a range of versions that are resistant to aggressive media, high temperatures and weld spatter up to 200 °C. We also offer torsion-protected, drag chain compatible, non-halogen and halogen variants.

Special ConnectorsFor high temperatures, aggressive media and weld spatter

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Balluff offers fieldbus and network solutions for the system level and IO-Link functionality for the sensor/actuator level regardless of the controller manufacturer.Balluff has developed fieldbus modules for the perfect connection of IO-Link systems to industrial communications systems such as Profinet, Profibus or Ethernet/IP. These modules leave conventional variants far behind in terms of function and practicality. Enclosed in a

Fieldbus Modules for Global UseIn all network technologies

sturdy, IP 67 metal housing suitable for steel plants, the new genera-tion is characterized by a wide range of configuration and diagnostic options visible via a display, LEDs and an integral web server.Ethernet-based modules also have an integral 2-port switch that simplifies the network design because without external switches, all modules can be connected directly with the controller in a line topology. A complex star topology is no longer required.

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The powerful, high-frequency BIS M data carrier is ideal for use in steel production because it has proven to be reliable in all appli-cations that require rapid data transmission over long read/write distances in a harsh environment where high temperatures prevail.

It records all data without making contact and makes it traceable. Unlimited read/write cycles ensure rapid, flexible communication, even when large quantities of data are processed. As a result, the wear-free system can be integrated in all types of controllers.

The most important features■n High-temperature resistant up to 220 °C ■n Extremely hard-wearing under mechanical and thermal loads

■n Rugged housing■n Global RFID standard ISO 15693, ISO 14443A ■n Typical read/write distance 45 cm

Industrial RFID Data Carriers for High Temperatures up to 220 °CRobust HF data carriers with 13.56 MHz

RFID handhelds – Flexible mobile communicationRFID handheld readers in LF, HF and UHF technology are convenient to handle and guarantee flexible mobile communication because they do not have a cable guide. Software individually adapted to the application offers outstanding additional features: individual menus that are intuitive to operate, information displayed in plain text and protection from unauthorized access. Our RFID handhelds can iden-tify RFID and 1D/2D codes and can therefore overcome changes in media format.

Data carrier for high temperatures (–40...+220 °C)

112 bytes NXP ICODE SLIISO15693

BIS00YE Ø 25×5 mmBIS00Y4 51.5×51.5×6.5 mmBIS00Y1 128×52×11 mm

736 bytes NXP MifareISO14443A

BIS00YA Ø 25×5 mmBIS00Y7 Ø 50×5 mm

1 Kbytes InfineonISO15693

BIS00Y2 51.5×51.5×6.5 mm

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More information can be found in our Industrial Identification catalogs or online at

www.balluff.com

The BVS-E Ident reads all the most common bar codes and data matrix codes quickly, safely and reliably up to 40 times per second. Irregularities in position such as those experienced during coil trans-portation are irrelevant because the sensor compensates for them. It also checks that the content of the code is correct and evalu-ates the code quality according to ISO standards, which increases process reliability because codes that are difficult to read are reliably ejected. Slabs and coils can therefore be identified continuously.

■n Simple and intuitive operation■n Read and verify bar codes and data matrix codes at the same time■n Evaluate the code quality according to ISO standards■n Code is read regardless of the position, even under difficult conditions■n Verify character strings■n Output of code data via RS232 or Ethernet interface■n CE certified lighting – "eye-safe", even in infrared■n External monitor available for better process tracking■n Extensive range of accessories that meet industrial standards

Readable bar codes■n Interleaved 2-of-5■n Code 39■n Code 128■n Pharmacode, Codabar■n EAN 8, EAN 13 ■n UPC-A, UPC-E ■n PDF 417

Readable data matrix codes■n At high and low contrast■n For shiny and reflective surfaces

■n For directly marked and mirrored codes

BVS Vision Sensors for Data Matrix and Bar CodesRead, check and evaluate

Series BVS-E Identification BVS-E Identification BVS-E IdentificationLens, focal length Standard lens, 8 mm Telephoto lens, 12 mm Telephoto lens, 16 mmPNP, red light

Ordering code BVS0001 BVS000T BVS000YPart number BVS ID-3-001-E BVS ID-3-003-E BVS ID-3-007-E

PNP, infrared

Ordering code BVS0019 BVS001A BVS001EPart number BVS ID-3-101-E BVS ID-3-103-E BVS ID-3-107-E

Supply voltage UB 24 V DC ±10 % 24 V DC ±10 % 24 V DC ±10 %Switching inputs 1× Trigger, 1× Select 1× Trigger, 1× Select 1× Trigger, 1× SelectSwitching outputs 1× lighting synchron., 1× PNP 1× lighting synchron., 1× PNP 1× lighting synchron., 1× PNPInterface RS232 RS232 RS232Configuration interface Ethernet 10/100 Base T Ethernet 10/100 Base T Ethernet 10/100 Base TTyp. detection rate 3...40 Hz (depending on

evaluation function)3...40 Hz (depending on evaluation function)

3...40 Hz (depending on evaluation function)

Working range 50...1000 mm 50...1000 mm 150...1000 mmWorking distance, 50 mm, 1000 mm, 50 mm, 1000 mm, 150 mm, 1000 mm,Field of view (horizontal × vertical) 25×18 mm 500×360 mm 16×12 mm 312×237 mm 34×26 mm 229×172 mmLighting LED, incident light, deselectable LED, incident light, deselectable LED, incident light, deselectableEye safety per IEC 62471 Exempt group Exempt group Exempt groupConnection 2× M12 connectors

(8 and 4 pin)2× M12 connectors (8 and 4 pin)

2× M12 connectors (8 and 4 pin)

Degree of protection per IEC 60529 IP 54 IP 54 IP 54

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Photoelectric sensors check presence, size, color, distance and thickness. They are excellent specialists with different focuses:

■n Part recognition and counting■n Stack height monitoring■n Detection through glass■n Small parts alignment■n Brand recognition■n Fill level detection

and much more

Inductive sensors are used to control, position and check processes in automation technology. The robust sensors detect objects in the metal range.

■n Non-contact, wear-free, contamination-resistant, short-circuit protected

■n Available in designs from Ø 3 mm to 80×80 mm square dimensions

Photoelectric sensors Inductive sensors

Standard Sensors for Object DetectionPowerful sensors in outstanding quality

Different working principles for object detection are available for the wide range of tasks in the iron and steel industry: reliable level monitoring, the detection of markings, sensing in hydraulic cylinders or robust applications in the metal industry. Select the best solution.

HOT ZONE

Ultra-high temperature-resistant BNS single and multiple position switches – for extreme applications up to 180 °C Ultra-high temperature-resistant single and multiple position switches are suitable for temperatures up to 180 °C. Enclosed in a robust die casting housing, they require minimal space and are ideal for harsh environments in the steel production industry, for example.

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Capacitive sensors detect objects and fill levels of all liquids, granular materials and powders, including non-conductive materials, directly or through a container wall.

■n Non-contact, wear-free, non-reactive, bounce-free output signal

■n Simple sensor replacement, container seal is unnecessary

The primary application for magnetic cylinder sensors is scanning piston positions on pneumatic and hydraulic cylinders.

■n For universal use■n Very precise, reliable switching behavior ■n Long service life due to lack of contact and wear■n Vibration-resistant ■n Space-saving attachment thanks to small sizes

Capacitive sensors Magnetic cylinder sensors

Detailed information on our range of object detection products can be found in the object detection, global sensors and mechanical product line catalogs or online at

www.balluff.com

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Size M12×1 M12×1 M18×1 M18×1 M30×1.5 M30×1.5Installation type Flush Not flush Flush Not flush Flush Not flushRated switching distance sn 2 mm 4 mm 5 mm 8 mm 10 mm 15 mmPNP, NO contact

Ordering code BES04CK BES04CL BES043T BES043U BES043W BES043YPart number BES 515-325-SA74-D-TF-02 BES 515-356-SA35-D-TF-02 BES 515-326-SA49-D-TF-02 BES 515-360-SA13-D-TF-02 BES 515-327-SA22-D-TF-02 BES 515-362-SA4-D-TF-02

Supply voltage UB 10...30 V DC 10...30 V DC 10...30 V DC 10...30 V DC 10...30 V DC 10...30 V DCAmbient temperature range –25...+160 °C –25...+160 °C –25...+160 °C –25...+160 °C –25...+160 °C –25...+160 °CDegree of protection per IEC 60529 IP 69K IP 69K IP 69K IP 69K IP 69K IP 69KMaterial Housing Stainless

steelStainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Sensing surface PEEK PEEK PEEK PEEK PEEK PEEKConnection 2 m cable FEP 2 m cable FEP 2 m cable FEP 2 m cable FEP 2 m cable FEP 2 m cable FEP

Variants with 5 m fixed cable are available on request to eliminate contact points in the hot zone.

BES high-temperature resistant inductive sensors perform outstand-ingly in forging and foundry processes in the harsh environment of the steel industry. They are resistant to temperatures up to 160 °C and have degree of protection IP 69K that guarantees an outstand-ing waterproof seal. The sensors also demonstrate a high degree of functional reliability during continuous operation, eliminating the need for additional processing electronics.

High-temperature resistant BES inductive sensors■n Maximize system availability■n Reduce maintenance costs■n Increase process quality

High-temperature Resistant Inductive Sensors up to 160 °CFor use in the hot zone

HOT ZONE

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Connected to Balluff sensor amplifier for capacitive high-temperature resistant sensors via triax sensor cable. Information on these and a wide range of other sensors can be found in the object detection catalog.

Size M12×1 M18×1 M30×1.5 M18×1 R 3/8“ NPTF 3/8"Installation type Flush Not flush Not flush Not flush Not flush Not flushRated switching distance sn 0…2 mm 1…10 mm 1…20 mm Level adjustable Level adjustable Level adjustableOrdering code BCS00TC BCS00A1 BCS00A2 BCS00A3 BCS00A4 BCS00A5Part number BCS S104407-XXS20D-SZ02-T09 BCS M18T4H1-XXS10H-SZ02-T08 BCS M30T4G1-XXS20H-SZ02-T08 BCS S10T401-XXSFNC-SZ02-T07 BCS S10T402-XXSFNC-SZ02-T07 BCS S10T403-XXSFNC-SZ02-T07Supply voltage UB 4…8 V DC 4…8 V DC 4…8 V DC 4…8 V DC 4…8 V DC 4…8 V DCAmbient temperature range Ta 0…+180 °C –180…+250 °C –180…+250 °C –10…+180 °C –10…+180 °C –10…+180 °CPressure rating 150 barDegree of protection per IEC 60529 IP 68, IP 54

on connectorIP 54 IP 54 IP 54 (IP 68

at max. 6 bar)IP 54 (IP 68 at max. 6 bar)

IP 54 (IP 68 at max. 6 bar)

Material Housing Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steelSensing surface Stainless steel, EP PTFE PTFE PTFE PTFE PTFE

Connection Triax cable Triax cable Triax cable Triax cable Triax cable Triax cable

Capacitive sensors detect non-metallic materials extremely well and prevent extreme levels of dust and dirt from affecting their performance by compensating for any adhesions. They are therefore ideal for monitoring the level of bulk goods in silos.

High-pressure variants are also available for installation in steel plants. They can be used at pressures of 150 bar and temperatures of 180 °C.

In contrast to conventional capacitive sensors, high-pressure and high-temperature resistant capacitive sensors are fitted with external stainless steel electrodes and offer the following advantages:

■n High degree of mechanical stability■n Resistant to abrasive media■n Specially polished surface prevents adhesive media from sticking

Capacitive Sensors for High Pressures and TemperaturesReliable level monitoring in extremely dusty, dirty environments

HOT ZONE

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Ultrasonic SensorsReliable level measurement, even with heavy soiling

Further information can be found in the BUS ultrasonic sensors brochure or online at

www.balluff.com

Whether position detection, distance measurement or the detec-tion of solid, powder or liquid media: BUS ultrasonic sensors are precision all-rounders. The sensors always perform outstandingly, irrespective of color, transparency and surface properties. Even under the harshest conditions of a steel plant, they are able to detect the following:

■n Objects made from almost any material ■n Fluids, granulate, powder (direct)

BUS ultrasonic sensors differ form one another in their output signal. By means of a switching version and an analog version, they are able to both reliably detect and count objects as well as determine distances with extreme precision. This guarantees use in diverse applications. Our ultrasonic sensors have different output functions and can be used as NC or NO contacts.

All the benefits at a glance■n Non-contact detection ■n Reliable detection in dirty, dusty or misty environments

■n Irrespective of color, transparency, reflection properties and surface finish on the object

■n Precision detection of small objects possible ■n Rectangular and cylindrical heads allow for greater freedom of design

Scanning range 600…6000 mm (blind zone 600 mm)With switching output 

2× PNP, NO/NC contact

Ordering code BUS000APart number BUS Q80K0-PWXER-600-S92K

2× NPN, NO/NC contact

Ordering code BUS000CPart number BUS Q80K0-NWXER-600-S92K

With analog output

0...10 V Ordering code BUS000EPart number BUS Q80K0-XAER-600-S92K

4...20 mA Ordering code BUS000FPart number BUS Q80K0-XBER-600-S92K

Supply voltage UB 18...30 V DC, polarity reversal protectedOutput current 500 mAResolution 1 mmDegree of protection per IEC 60529 IP 65Operating temperature –15...+70 °CMaterial Housing PBT

Sensing surface Epoxy resin - hollow-glass sphere/PURConnection M12 connector, 5-pin

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The BFS 33M True Color sensor is in a completely different league to conventional RGB sensors. Thanks to its high resolution, it not only detects colors but also reliably distinguishes between different nuances. The True Color sensor can detect marked slabs conveyed between continuous casting and hot rolling units and distinguish between a polished and unpolished metal finish. The sensor uses three digital outputs and a serial interface to perform evaluations. The lab color space values are transmitted directly via this interface.

■n Detection of and distinguishing between a random number of colors■n Reliably distinguishes between the smallest of color nuances■n Large sensing distance up to 400 mm■n Simple configuration and visualization using software■n Rugged metal housing

Type BFS True Color SensorOrdering code BFS000LPart number BFS 33M-GSS-F01-PU-02Channels (outputs) 3 (7 colors + background)Color space CIELabSwitching frequency 1.5 kHz (on 3 products)Resolution 8 enhancement settings, 12 bitColor resolution < 0.5 dERepeat accuracy < 1 dEProtection class IP 54Ambient temperature range Ta –10...+55 °CHousing material Aluminum-coated

Balluff also offers a wide selection of glass fiber optics suitable for temperatures up to +170 °C or +250 °C when installed permanently.

High-resolution BKT 21M contrast sensors are used to distinguish between gray values and detect color markings. The sensors reliably detect markings affixed to the electrodes. Temperature-resistant fiber optics also allow the contrast sensors to be positioned close to hot objects.

Color and Contrast SensorsIdeal for detecting markings

Series BKT Contrast sensorOrdering code BKT000YPart number BKT 21M-002-P-S4Working distance 19 mm ±2 mmSupply voltage US 10...30 V DCSwitching type Light/dark switching (adjustable)Emitter, light type LED, white light (400...700 nm)Switching frequency 5 kHzDegree of protection per IEC 60529 IP 67Ambient temperature range Ta –25...+55 °CHousing material Cast zinc/aluminumOptical surface material Glass

PNP, NO/NC

HOT ZONE

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The rapid replacement module allows the quick replacement of BTL7 Micropulse transducers in the hydraulic cylinder without losing pressure or oil. The complete sensor unit is replaced together with the integral waveguide so that the hydraulic circuit remains closed, thereby guaranteeing quick and easy maintenance at the place of installation.

■n Hydraulic seal remains intact: oil does not escape, special environmental measures are not required

■n No risk of air entering the hydraulic system■n Hydraulic system cannot become contaminated ■n Simple method for replacing the sensor unit prevents errors■n All dimensions are identical to those of standard rod transducers

■n Sensor units can be installed quickly and safely in the existing outer tube

■n Available for all interfaces

Rapid Replacement of Micropulse TransducersNo pressure or oil losses

Replacement sensor unit (without outer tube): BTL7-_ _ _ _-M_ _ _ _-ZR-_ _ _ _Transducer incl. outer tube: BTL7-_ _ _ _-M_ _ _ _-ZM-_ _ _ _ (e.g.: BTL7-A510-M0305-ZM-S115)

Mounting thread 3/4"-16 UNF, flange with mounting surface, outer tube diameter 10.2 mm, null point at 50.8 mm

Transducer incl. outer tube: BTL7-_ _ _ _-M_ _ _ _-ZN-_ _ _ _ (e.g.: BTL7-E500-M1829-ZN-S32)

Mounting thread 3/4"-16 UNF, flange without mounting surface, outer tube diameter 10.2 mm, null point at 50.8 mm

Replacement sensor unit (without outer tube): BTL7-_ _ _ _-M_ _ _ _-BR-_ _ _ _Transducer incl. outer tube: BTL7-_ _ _ _-M_ _ _ _-BM-_ _ _ _ (e.g.: BTL7-S510-M1016-BM-KA05)

Mounting thread M18×1.5, flange with mounting surface, outer tube diameter 10.2 mm, null point at 30 mm

Transducer incl. outer tube: BTL7-_ _ _ _-M_ _ _ _-BN-_ _ _ _ (e.g.: BTL7-S501B-M0305-BN-S115)

Mounting thread M18×1.5, flange without mounting surface, outer tube diameter 10.2 mm, null point at 30 mm

RapidReplacement

Module

RRM

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Class I, Division 1, Groups A, B, C, and DClass II, Division 1, Groups E, F, and G; Class III T6 Ta=65°C, T5 Ta=80°C Type 4X/6P; IP 68Class I, Zone 1 AEx d IIC T6 Ta=65°C, T5 Ta=80°CClass I, Zone 1 Ex d IIC T6 Ta=65°C, T5 Ta=80°C

SIRA 11ATEX1104XIECEx SIR 11.0048X

C US11-2411253X

II 1/2GDEx d IIC T6/T5 Ga/Gb Ta +65°C (T6) +80°C (T5)Ex t IIIC T85/T100°C Da IP 68 Ta +65°C (T85) +80°C (T100)

0518

Zone 1

partition

Zone 0

ATEX

IECIECEx

Micropulse Transducer with Explosion ProtectionPressure rated to 600 bar. Approved for safety areas

For measuring ranges between 25 and 4000 mmThe robust BTL Micropulse transducer with explosion protection performs outstandingly under the extreme conditions of the iron and steel industry. The non-contact measuring system is available in different versions for use within Europe and overseas.

For Europe: explosion protection type "d" – flameproof encapsulationTransducers designated Ex d IIB + H2 T6 Ga/Gb meet the require-ments for electrical equipment in potentially explosive areas. The relevant safety regulations must be observed (EX-RL, EN 60079-14, EN 60079-1). Category II 1/2 G transducers with the designa-tion Ex d IIB+H2 T6 are approved for areas containing potentially explosive gases and category II 3D transducers with the designation Ex tD IP 67 T85°C, A Zone 22 for areas containing flammable dust.

For USA and CanadaThe Micropulse transducer J-DEXC was specially developed for use in the USA and Canada. The J-DEXC system fulfills all the requirements of the American regulatory authorities and allows easy servicing. J-DEXC comprises a robust flameproof housing and an electronics module that is easy to access and exchange.

Applications■n Hydraulically or pneumatically actuated valves and flaps■n Clutch travel monitoring for compressors ■n Level monitoring■n Level control■n Actual value sensing in hydraulic cylinders in hazardous areas

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BTL Micropulse transducers are suitable for particularly hot environ-ments reaching temperatures of 100 °C. Protected in a hydraulic cylinder, they reliably control all movements to fully utilize all the advantages of non-contact, wear-free distance measurement, even at high temperatures. Installed inside a robust metal housing, they can be fitted with PTFE cables (200 °C).

P111 Profibus modules are de-signed for connecting Micropulse transducers – robust, versatile distance measurement systems for extreme ambient condi-tions. With a hard-wearing metal housing ideal for steel plants, the P111 Profibus modules satisfies the most demanding mechanical requirements.

The modules are fitted with four interdependent ports for BTL Micropulse transducers. A maximum of 16 magnets can be used per BTL port at a maximum nominal length of 7500 mm. Four additional ports can be configured with digital or analog sensors, depending on the version.

Micropulse Transducers up to 100 °CIn a robust metal housing, can be fitted with PTFE cables

P111 ModuleEconomical integration of Micropulse transducers

The maximum number of magnets is 16 per BTL, but only a total of 60 per module.

Fieldbus/version Profibus/4× P111, 8× DI Profibus/4× P111, 4× AI (0...10 V/4...20 mA)

Inputs digital analogOrdering code BNI0064 BNI0065Part number BNI-PBS-551-001-Z001 BNI-PBS-552-001-Z001No. of I/O ports 8 8No. of digital inputs 8 PNPNo. of analog inputs 4 (0...10 V/4...20 mA)No. of P111 inputs 4 4

Micropulse transducersto 100 °C

PTFE cableto 200 °C

HOT ZONE

BSPBSP

BSPBSP

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Micropulse ProCompact with cable protection systemTypical applications for ProCompact Micropulse transducers include locations such as steel plants with extreme ambient conditions, where high reliability and impermeability are required over long periods. The non-contact working principle of the systems ensures a complete absence of wear and extended service life. The high-precision output signal is used as an absolute signal for the controller in a wide range of different interfaces.

ProCompact Micropulse Transducer with IP 69KThe cylinder feedback system for extreme environments

Series BTL5 Pro Compact HB/WB rodPart number/output signal BTL5-A11-M...-HB/WB-...-C/analog 0...10 VPart number/output signal BTL5-E1-M...-HB/WB-...-C/analog 4...20 mAPart number/output signal BTL5-C1-M...-HB/WB-...-C/analog 0...20 mAPart number/output signal BTL5-G11-M...-HB/WB-...-C/analog –10...10 VPart number/output signal BTL5-P1-M...-HB/WB-...-C/digital pulsePart number/output signal BTL5-S1-M...-HB/WB-...-C/digital SSIPart number/output signal BTL5-H1-M...-HB/WB-...-C/BUS CANopenShock load 100 g/6 ms per IEC 60068-2-27 and

100 g/2 ms per IEC 60068-2-29Vibration 12 g, 10...2000 Hz per IEC 60068-2-6Degree of protection per IEC 60529

IP 68 (5 bar with cable); IP 69K (with cable protection system); IP 68 (40 bar with cable protection system)

Housing material Stainless steel 1.4404Flange and tube material Flange 1.4404, stainless steel tube 1.4571Operating and storage temperature range –40...+85 °C, –40...+100 °CCable connection PTFE/–40...+200 °CStandard nominal lengths [mm] 0025...5080 or in 1-mm increments on request

Series AdapterOrdering code BAM01JWPart number BAM AD-XA-007-M18×1.5/D12-2Housing material Brass (not seawater-resistant)Ordering code BAM01JYPart number BAM AD-XA-007-M18×1.5/D12-4Housing material Stainless steel V2A (conditionally seawater-resistant)

Series PUR protective tubePart number BAM PT-XA-001-095-0-_ _ _Tube length 02, 05, 10, 15, 20, 30, 50 and 100 mDegree of protection IP 68 (40 bar), IP 69K (installed and attached)Inner/outer diameter 9.5 mm/16 mmTemperature range –40...+95 °CMin. bending radius (static) 51 mm

Adapter

Protective hose

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Redundant Micropulse TransducersFor maximum safety

More information can be found in the linear position sensing catalog or online at

www.balluff.com

Series Rod Redundant BTL7Shock load 100 g/6 ms per EN 60068-2-27Vibration 12 g, 10 to 2000 Hz per EN 60068-2-6Polarity reversal protected to 36 VOvervoltage protection to 36 VDielectric strength 500 V AC (GND to housing)Degree of protection per IEC 60529 IP 67Housing material Aluminum anodized/protective tube stainless 1.4571, flange stainless 1.4571Mounting Model TB thread M18×1.5, Model TZ thread 3/4" 16 UNF

Model TK, 18h6 with 6 cheese head screws, Model TT thread M30×1.5

Pressure rating with 10.2 mm protective tube

600 bars if installed in a hydraulic cylinder up to 2000 mm in rated length300 bar for rated length > 2000 mm

Pressure rating with 21 mm protective tube 250 bars if installed in hydraulic cylinder up to 2000 mm rated lengthConnection Plug connector or cable connectionEMC testing

RF emission EN 55016-2-3 (industrial and residential area)Static electricity (ESD) EN 61000-4-2 Severity level 3Electromagnetic fields (RFI) EN 61000-4-3 Severity level 3Fast transient interference pulses (BURST) EN 61000-4-4 Severity level 3Surge voltage (SURGE) EN 61000-4-5 Severity level 2Conducted interference induced by high-frequency fields

EN 61000-4-6 Severity level 3

Magnetic fields EN 61000-4-8 Severity level 4Standard nominal lengths [mm] 25...7620 mm in 1-mm increments

Pressure-resistant up to 600 bar, high reproducibility, redundant, non-contactMultiple redundant BTL Micropulse transducers can satisfy demanding requirements for safety and availability. Reliable in opera-tion when installed in safety-relevant valves and hydraulic cylinders, they offer measuring ranges between 25 and 7620 mm for steel production.

Up to 3 independent distant measuring systems in the same housing guarantee safe operation. Two different interfaces provide diverse redundancy. BTL Triple Micropulse transducers are suitable for the failsafe detection of distances on safety valves, for example, and independently monitoring positions and adjustment speeds.

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Size 79×28×20 mm 79×28×20 mmInterface 4...20 mA Modbus RTU RS-485Measuring range 0 to 360°

Ordering code BSI0004 BSI0003Part number BSI R11A0-XB-CXP360-S75G BSI R11A0-XXR-CXP360-S75G

Measuring range ±45°

Ordering code BSI0002Part number BSI R11A0-XB-CXS045-S75G

Supply voltage UB 10...30 V DC 10...30 V DCCurrent consumption < 31 mA < 20 mAResolution max. ±0.01° ±0.01°Characteristic deviation max. ±0.1% (min. 0.1°) ±0.1° at 10...40 °C,

±0.15° in any other temperature rangeTemperature drift ±0.01%/10 KSampling rate < 150 ms < 150 msSettling time < 1 s < 1 sPolarity reversal/short-circuit protected Yes/Yes Yes/YesDegree of protection as per IEC 60529 IP 67 IP 67Ambient temperature range Ta –40...+85 °C –40...+85 °CWeight Approx. 80 g Approx. 80 gHousing material Aluminum AluminumCalibration, measurement protocol Optional OptionalConnection M8 connector, 4-pin M8 connector, 4-pin

Inclination axis

Our BSI inclination sensors are ideal for precision position monitoring and continuous monitoring of rotary movements on a lifting beam.

The sensors measure the deviation from the horizontal on an axis of up to 360°. They also require little space, have a very robust metal housing and can be used between –40 and 85 °C.

■n Non-contact and absolute measuring principle■n High repeat accuracy and precision■n Extremely low temperature drift

Inclination Sensors360° high-precision sensors for non-contact angle measurement

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The standard version of BSP pressure sensors is ideal for monitor-ing coolant on the roll stand or pressure on hydraulic drives in steel plants, for example. From –25 to 125 °C. The wide range of pressure ranges and output signals are suitable for almost every application.

Ideal for the steel industry, the pressure sensors have an acid-resis-tant process connection made from PVDF and can reliably monitor cleaning processes during surface finishing.

With an acid-resistant process connection made from PVDF, the sensor can also be used in the difficult conditions experienced during surface finishing.

Pressure ranges –1...50 barSupply voltage UB 18...36 V DCSwitching frequency f max. 200 HzAccuracy ≤ ±0.5 % FSO BFSLTemperature error ≤ ±0.3 % FSO/10 KAmbient/media temperature –25…+85 °C/–25...+125 °CDegree of protection per IEC 60529 IP 67 (when connected)Material Housing PA 6.6, stainless steel

Membranes Ceramic Al2O3

Seal FluoroelastomerProcess connection PVDF

Connection Connector M12 connector, 4-pinProcess connection G 1/2"

Further information on the standard and high-end versions can be found in our BSP pressure sensor catalog or online at

www.balluff.com

Pressure SensorsResistant to hydrochloric acid

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Output current/power/voltage 5 A/120 W/24 V DC (SELV) 10 A/240 W/24 V DC (SELV)Input voltage 100...240 V AC, single-phase 100...240 V AC, single-phaseOrdering code BAE00EK BAE00EUPart number BAE PS-XA-1W-24-050-013 BAE PS-XA-1W-24-100-014Input voltage range 90...264 V AC/135...340 V DC 90...264 V AC/135...340 V DCInrush current 1.14 at 230 V AC/2,1 A at 110 V AC 2.11 at 230 V AC/4.4 A at 110 V ACFrequency range 48...62 Hz 48...62 HzInput fuse 6.3 A/250 V AC internal 6.3 A/250 V AC internalVoltage adjustment range 22...28 V DC 22...28 V DCTemperature coefficient max. ±0.03 %/°C 0.03 %/°CHoldup time > 150 ms at 230 V AC/> 25 ms at 115 V AC > 120 ms at 230 V AC/> 15 ms at 115 V ACStatus indicator Stress level, lifetime, load level Stress level, lifetime, load levelPower boost 150 % for 4 s 150 % for 4 sEfficiency High efficiency, typically > 89 %. High efficiency, typically > 91 %.Response Forward characteristic Forward characteristicAmbient/storage temperature range –25...+70 °C/–40...+80 °C –25...+70 °C /–40...+80 °CMounting DIN rail mounting DIN rail mountingParallel mode Yes (with external diodes) Yes (with external diodes)Degree of protection per IEC 60529 IP 20 IP 20Derating –2.5 %/°C above +60 °C –2.5 %/°C above +60 °CCooling Free convection Free convectionHousing material Metal, partly enclosed Metal, partly enclosedService life (at 80 % load and 40 °C) 15 years 15 yearsWarranty 2 years 2 yearsApprovals CE CE

IP20 power supplies – general data■n High efficiency of max. 92 % ■n Minimal heat loss and generation■n Increased system efficiency■n 3-stage status indication■n Power boost (150 % for 4 sec.)■n Extremely compact■n More efficient utilization of the power supply units■n Planned reserves are not wasted■n No overload prevents failures ■n Scheduled maintenance and repairs no longer necessary■n Higher productivity■n PSU replaced only at the end of its service life■n Service life of 15 years (at 80 % load and 40 °C)■n Enclosed housing guarantees high degree of resistance to vibration and shock loads

■n also with potential-free alarm contacts

Balluff manufactures intelligent power supplies designed for efficient plant operation that can be installed locally. Ideal for operation at a continuously high capacity. The condition is visualized via dynamic optical displays (heartbeat): including load level, stress level and lifetime. The lifetime LED changes color to indicate that a device change is imminent.

Condition monitoring renders the standard reserves of 30 to 50 % superfluous and prevents overloading. As a result, unexpected failures are avoided and maintenance workload is reduced.

Versions with 5 A have a compact, partly enclosed housing and tolerate high shock and vibration loads, which is why they are ideal for steel production.

Intelligent Power SuppliesFor maximum system availability

Load level

Stress level

LifetimeAlso available with IP 67!

Also available with IP 67!

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Description Weld protection Weld protectionUse for BOS 23K photoelectric sensors for BOS 50K photoelectric sensorsOrdering code BAM01L8 BAM01U6Part number BAM PC-XO-006-23K-1 BAM PC-XO-006-50K-1

Sensor not included in the standard scope of delivery!

Sensor not included in the standard scope of delivery!

Further information can be found in the accessories catalog or online at

www.balluff.com

AccessoriesFor flexible assembly

Safety Screen for Photoelectric SensorsProtection against high temperatures and weld spatter

All of our sensors and systems come with matching mechanical accessories for flexible installation. They guarantee quick and easy assembly, precision positioning and the rapid replacement of sensors. Our accessories are therefore pivotal in maintaining a high degree of machine availability.

Safety screens are available to protect photoelectric sensors against weld spatter and high temperatures.

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For more comprehensive information, refer to the test laboratory brochure or visit

www.balluff.com

HALT TestHighly Accelerated Life Tests guarantee quality

Highly Accelerated Life Tests (HALT) ensure that our products are of the highest quality. They are exposed to an accelerated aging pro-cess during the development phase in order to identify and improve potential weaknesses.

ProcessPhase 1: Temperature level test – cold and heat. The function

and destruction limits are established during this phase.Phase 2: Rapid temperature change. First practical test Extreme

stress = rapid agingPhase 3: Vibration test. Determining the vibration limitPhase 4: Combined environment – rapid temperature change with

vibration: combined cycles are run in line with the results obtained in phase 1 and 3. The combination of loads above the specification makes this phase a high stress factor for the product.

Technical dataManufacturer: Thermotron Industries, USADimensions H×W×D: 230×164×227 cmTest bench: 106×106 cmFrequency range: 2...10,000 HzAcceleration: up to 50 g rmsExcitation: 9 pneumatic cylinders, noise spectrum, 3-axis,

3 linear and 3 rotary degrees of freedomTemperature range: –100...+200 °CTemperature gradient: 70 K/minPower: 96 kWProcess: electric heating, cooled by liquid

nitrogen (17 l/min.)

Headquarters Balluff GmbH Schurwaldstrasse 973765 Neuhausen a.d.F.GermanyPhone +49 7158 173-0Fax +49 7158 5010balluff@balluff.de

www.balluff.comDoc. no. 896001/Mat. no. 231434 EN E13; Subject to modification.

Object Detection

Linear Position Sensing and Measurement

Condition Monitoring and Fluid Sensors

Industrial Identification

Industrial Networking and Connectivity

Accessories

Systems and Service