Feeling, Watching and Listening ...

ABB Position Sensors

The Focus

ABBs focus is on the requirements of our customer. They determine our products and services which means that our systems are based both on ABBs extensive knowledge, and on in-depth feedback from users regarding their system needs. Our customers are backed by ABBs many years of experience in

the field of switchgear and control system needs. ABBs worldwide organisation provides competent specialists, consultants and qualified service technicians.

Efficient Systems The switchgear and control product line is very comprehensive and offer economical and technical solutions for equipping modern plants and machinery. The product line offers a range of differentiated systems for the process environment from position detection to

electrical switching. ABB is the answer to all of our manufacturing solutions. Delivery of the entire range of sensor, automation and switching systems from one supplier simplifies the ordering procedure. Our goal is to save you time and make ordering easier by consolidating your efforts into one source.

The Focus

Sensors - an Overview Sensors Sensors are one building block in the broad range of ABB products. These sensors are being used more and more in todays high tech world of rapidly changing factory automation. They can meet the challenge of higher speed processes along with the required greater accuracy. ABB offers a broad range of powerful and efficient sensors for a wide variety of applications.

Inductive Sensors

Capacitive Sensors

Photoelectric Sensors

Ultrasonic Sensors

Various Housings

Output Signals

Connections and Interfacing

Type Codes for ABB Position Sensors

Example Fields of Application

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Approvals

Sensors - an Overview

Position sensors are used for the electronic detection of objects in a wide variety of industrial applications from machine tools to packaging lines to process level detection. The output signal from the sensor is then sent to another device, such as a programmable con-

troller, for the purposes of control or monitoring. The sensor operates without physical contact. An electronic switching signal is issued as soon as an object approaches the sensor. ABB sensors provide enclosure IP67 protection and operate precisely. Because

Inductive Sensors

Capacitive Sensors

Inductive sensors detect metallic objects at an operating distance of up to 50 mm. They are insentive to external influences and are durable for all applications. They offer high speed, no contact sensing at an extremely long life.

Capacitive sensors detect virtually any material (paper, cardboard, plastic, etc.) at an operating distance of up to 20 mm. They are also suitable for detection of metallic or fluid objects. They offer high speed, no contact sensing at an extremely long life.

Metallic objects Operating distance up to 50 mm Switching frequency up to 5 kHz

Non - metallic objects Fluids Metallic objects Operating distance up to 20 mm Switching frequency up to 10 Hz

there are no mechanical parts or contacts, the sensor achieve a contact-free operation, free of bounce or wear. The range of ABB sensors cover virtually all fields of application occurring in the sector of machine and factory operation.

Photoelectric Sensors

Ultrasonic Sensors

Photoelectric sensors see light-reflecting or opaque objects at an operating distance of up to 20 m. They can also be used with fiberoptic cable for detection of extremely small objects.

Ultrasonic sensors detect the position of objects with a sound-reflecting surface. They may be used at an operating distance of up to 6 m. They are resistant to dust and operate independently of the colour of the object to be detected.

Light reflecting and opaque objects Small objects Operating distance up to 20 m and more

Sound-reflecting objects Operating distance up to 6 m Self-cleaning

Inductive Sensors ...

... are standardized owing to their clearly defined characteristics and operating conditions and can thus be used easily: they detect only metallic objects, they feature a precisely outlined sensing range,

they operate reliably and are not impaired by light, noise, non-conductive dust or fluids, such as oil, they detect precisely and without the need for adjustment and they offer largely standardized parameters.

Basic Mode of Operation The essential component of the inductive sensor is its oscillator with open coil. When a metallic object approaches the sensor, the oscillation is initially attenuated and ultimately interrupted. This effect is detected by a trigger circuit and is forwarded as an output signal.

Operating Distance The distance between the sensor and the object plays a crucial role for achieving reliable results. The operating distance is differentiated as follows in order to allow for various operating conditions:

Object Open coil

Su=1.21 x Sn Sr=1.1 x Sn Sn Sr=0.9 x Sn Su=0.81 x Sn Operating range Sa with frontal approach

Nominal Operating Distance Sn: Typical operating distance under the measurement conditions defined in the Standard. This involves a defined target made of steel ST37 with a minimum thickness of 1 mm and a minimum size approaching the sensor. The following apply: Diameter of target = diameter of sensor front face or Diameter of target = three times nominal operating distance. The higher value counts.

Examples of target size: Sensor SIF5-M18N-V2-PO Nominal operating distance: 5 mm Sensor diameter: 18 mm Target diameter: 18 mm (= Sensor diameter) Sensor SIN6-M12N-V2-PO Nominal operating distance: 6 mm Sensor diameter: 12 mm Target diameter: 18 mm (= 3 x nominal operating distance) Effective Operating Distance Sr : This allows for manufacturing tolerances of the individual sensors and may be up to 10 % above or below the nominal operating distance Usable Operating Distance Su : This includes influences resulting from operating voltage tolerances and temperature range and lies a further 10 % above or below the effective operating distance, i.e. at 81 ... 121 % of the nominal operating distance. Recommended Actuation Distance Sa : This is less than 81 % of the nominal operating distance in the case of frontal approach to the object.The distance should be around 40 % of the nominal operating distance in the case of lateral approach.

Sensor Distances with Various Materials If materials other than steel are used, the operating distances are almost always less. For instance:

Steel:

100% Sn

Stainless steel: 80% Brass: Aluminium: Copper: 40% 40% 30%

Metal foils and special target versions require test measurements.

Hysteresis A hysteresis is required for all switching-type sensors in order to avoid chattering of the outputs. In the case of inductive proximity switches, the hysteresis results from the difference between the operating distances when the target is approaching and when the target is moving away and is approx. 5 % of the nominal operating distance.

Actuation distance Sa=0.4 x Sn with lateral approach Operating distance when the target moves away from the sensor

Hysteresis Operating distance when the target approaches the sensor

Installation Options Either flush or non-flush inductive sensors may be fitted, depending on local conditions.

Sensors fitted too close together have a mutual influence on each other. Consequently, minimum clearances must be observed, in particular in the case of the non-flush sensor types.

Flush Sensors are shielded and can thus be fitted easily with no major requirements. Flush installation also protects the sensor against mechanical damage.

Flush installation

3d

Flush installation

Flush installation

Non-flush installation

Non-flush Sensors offer maximum possible operating distance. A minimum recess is required in the surrounding material. The following applies: Lateral clearance = sensor diameter Depth = twice nominal operating distance

The high switching frequency is one of the most important advantages of position sensors by comparison with mechanical limit switches. Certain lug sizes and clearances must be observed in order to achieve the values specified in the ABB catalogue.

2 Sn

2d

Non-flush installation

Capacitive Sensors ...

... detect an extremely wide variety of materials, primarily non-metallic materials, at close range: they detect metallic and non-metallic objects, they detect fluids in non-metallic containers, they operate reliably in clean environments, they can be adapted to a wide variety of conditions of the various object materials by adjustment and they achieve maximum functionality at low switching frequency.

Basic Mode of Operation The heart of the capacitive sensor is an oscillator with open capacitor which generates an electrostatic field. The oscillator does not oscillate if there is no object in the vicinity. If the metallic or non-metallic object to be detected approaches, the capacitance increases and oscillation starts. A trigger circuit detects this change and trips the output signal. Since different materials influence the electrostatic field differently, the capacitive sensors should be adjusted accordingly during installa-

tion in order to achieve optimum operability. One typical application of capacitive sensors is detection of fluids in non-metallic containers, e.g. in plastic tanks. Sensor adjustment suppresses any influences resulting from the tank wall.

Object Open capacitor

Photoelectric Sensors ...

... cover a broad range of application owing to three operating principles: 1. Diffuse reflective sensors detect lightreflecting objects. 2. Retroreflective sensors with reflector detect transparent objects as the result of an obstruction in the light beam. 3. Through beam photoelectric sensors detect transparent objects, in precisely the same way as reflex photoelectric sensors.

Accessories extend the scope of possible applications: Fiber-optic waveguides as an add-on detect extremely small objects and operate at high ambient temperatures or under cramped installation conditions. Depending on design, they operate as diffuse reflective sensors or as through beam photoelectric sensors. A dust-free, clean environment ensures reliable operation of the sensors.

Basic Modes of Operation Diffuse Reflective Sensors These receive the light reflected back from the object. If a defined quantity of light is detected, the output signal is tripped. The nominal operating distances extend up to 800 mm, depending on type. The achievable sensing distance depends on the size of the object to be detected, its color and its condition, such as surface roughness.

Retroreflective Sensors These are used for larger distances to be monitored. The emitted light beam is reflected by a reflector positioned on the other side of the object. If the light path is interrupted, the signal is tripped. The design of the reflector ensures reliable operation even if the object is imprecisely aligned. The sensor distances extend up to 5000 mm, depending on type.

Object Object
T R T R

Diffuse reflective sensor Retroreflective sensor

Examples of reflection factors on level, aligned surfaces Standard white test card Standard gray test card White paper Wooden boards Beer froth Transparent plastic bottles Car tires Aluminum, bare Aluminum, black anodized 90.0 % 18.0 % 80.0 % 20.0 % 70.0 % 40.0 % 1.5 % 140.0 % 115.0 %

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Through Beam Photoelectric Sensors These have a separate light source and receiver. One disadvantage aspect is the greater cabling effort by comparison with retroreflective sensors. The operating distance can reach up to 20 m, depending on the type used.
Object

Pulse Prolongation This allows even very quickly moving objects to be detected and, e.g. an adequately long signal to be sent to a downstream control.

Object in sensor area Prolonged output signal

Through beam photoelectric sensors

Fiber-optic Waveguides These extend the range of possible applications of photoelectric sensors with important additional fields of application. The upstream fiber-optic waveguide defines whether the sensor is to operate as a through beam photoelectric sensor or as a diffuse reflective photoelectric sensor. Sensors with fiber-optic waveguide are used, primarily, to detect small objects, even under cramped conditions. Depending on design of the fiber-optic waveguide and fiber head, it is also possible to use these systems at high temperatures. Plastic fiber-optic waveguides can be shortened by the user to appropriate length with the supplied tools.
Diffuse reflective sensor

Safety Reserve and Optical Failure Warning Indicator These are used primarily to ensure long-term, trouble-free operation of the sensor and to detect measurement failures at an early point. Owing to the environments in which photoelectric sensors are used, contamination of the lenses may occur over the course of time so that the light detected by the receiver is reduced. The optical failure warning indicator allows the user to set the receive level with an adequate safety reserve during installation. If the light receive level drops to the optical failure warning range, the sensor does, admittedly, still operate reliably but the user is informed that reliable operation is no longer guaranteed in the long term.

T R

Object

Fiber-optic waveguide Optical failure warning range

Retroreflective sensor

Object

Switch point

Switching output Fiber-optic waveguide head for direct detection mode Green LED Red LED Green LED Red LED Green LED

Optical failure warning indicator

Optical failure warning output M6

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Ultrasonic Sensors ...

... open up new possible applications in the field of position detection with their special characteristics: they detect objects independently of their colour, in particular if these objects are aligned perpendicularly with respect to the sensor axis or have a rough surface, they clean themselves if deposits occur on the sensor measuring head,

they operate with temperature compensation in order to compensate for the differing speed of sound at varying temperature and they can also be used to detect objects in aggressive environments or objects not easily accessible because the ultrasonic signal can be deflected accordingly with a mirror.

Basic Mode of Operation

Dead band

Operating range

Object

Ultrasonic sensors operate in reflex mode. An ultrasonic transducer emits and receives the ultrasonic signals. Within a stipulated distance range, the incoming echo is checked, the time taken for the sound to travel the distance is determined and a corresponding output signal is emitted. If the distance between sensor and object is too small, the echo arrives before the ultrasonic transducer has reached steady state and is ready to receive. Objects in this dead band cannot be detected reliably.

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Sound Cone and Response Curve Objects may be moved towards the ultrasonic sensor either frontally or from the side. If it has a smooth surface, the object must enter the sensor's range perpendicularly with respect to the sensor axis. If its position deviates from this axis, the object must be brought nearer. This results in a so-called sound cone as a function of response distance to angle. The minimum size of the object also determines its nature and surface. This means that different sound cones result for different objects and sensors with a longer range require larger objects.

Deflection and Beaming One special aspect of the ultrasonic technique is the capability of deflecting sound with smooth reflectors. This allows the level of an aggressive fluid to be measured for instance. By contrast, measuring errors occur if the sound is to be beamed or deflected with smooth tubes for instance.

90 80

70

60

50

40

Angle 30 [degrees]

20

10

0.0 0.5 D 1.0 1.5 2.0 2.5 3.0 3.5 -20 C B A

-10

Mutual Interaction Neighbouring ultrasonic sensors influence each other mutually, and the extent of this influence can generally be determined only experimentally. The Sync. input with which the measurement operation can be disabled alternately offers one advantageous solution. The disable times must be selected depending on the times taken for the sound to travel the distance.
Enable for A A Enable for B B Enable for A

-30 4.0 Distance[m]

Response curves of the sensor SU-D2000-M30N-C1-POS for A: Level target, 700 x 700 mm B: Level target, 100 x 100 mm C: Felt tube 16 mm D: Round bar smooth 25 mm

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Various Housings

ABB offers various housings and sizes for all four sensor types depending on installation situation and local conditions.

Inductive Sensors Smooth cylindrical housings with diameters of 4 and 6.5 mm, normal length and short length

Block housings of size (L x W x H) 28 x 16 x 9 mm

Square block housings of sizes (L x W x H) 80 x 80 x 40 mm, 40 x 40 x 120 mm and 30 x 30 x 90 mm

Capacitive Sensors Threaded housings of normal length with standard diameter 30 mm (M30)

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Photoelectric Sensors Threaded housings of normal length with diameter 18 mm (M18)

Ultrasonic Sensors Threaded housings of normal length with standard diameter 30 mm (M30)

Block housings of sizes 26 x 24 x 12 mm, 40 x 40 x 15 mm, 45 x 50 x 18 mm, 75 x 65 x 25 mm and 50 x 40 x 12 mm

Plastic fiber-optic waveguides for block housings with main size 50 mm

Tightening Torques of the Nuts The following maximum values apply to the threaded versions: Tightening torque Thread diameter M8 M12 M18 M 30 Brass 3 Nm 10 Nm 20 Nm 40 Nm Stainless steel 10 Nm 15 Nm 30 Nm 60 Nm

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Output Signals

The various types of sensor offer different output signals in order to achieve flexible and rapid processing of the information detected by the sensors.

The inductive sensors also offer further DC output types: 4-wire PNP normally open / normally closed combination, PK 3-wire NPN normally open, 4-wire NPN normally open / normally closed combination, 2-wire normally open.

The "3-wire PNP normally open" DC output with designation "-PO" is used preferably for all types of sensor since it allows optimum drive of the inputs of programmable logic controllers. The output signals switched by PNP transistors were originally referred to as "PNP". Today, these outputs are protected against short circuit and reversal polarity.

1/BN DC 4-wire PNP NO/NC combination 2/WH 4/BK 3/BU output

1/BN DC 3-wire NPN NO 4/BK 3/BU

output

1/BN DC 3-wire PNP NO 2/BK 3/BU

output

3/BU DC 4-wire NPN NO/NC combination 4/BK 2/WH 1/BN output

1/BN PNP Transistor 4/BK 3/BU

3/BN DC 2-wire NO 4/BU

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Outputs up to 250 V AC are available for looping into AC circuits. The flexibility required for use in various applications is achieved by the following output types: AC, normally open, AC, normally closed, AC, normally open / normally closed combination.

Photoelectric sensors and ultrasonic sensors feature special outputs with additional terminals which can be used, for instance, for adjusting the function and for synchronization of measurement operations. Induktive and ultrasonic sensors with analog output allow direct measurement of the distance and supply a 4 ... 20 mA and a 0 ... 10 V signal for this purpose.

1 3/BN AC 2-wire NO 4/BU L1 Analog output N 3 4 4-20 mA 2 0-10 V

L+

L-

AC 2-wire NC

3/BN 4/BU

L1 N

3 AC 4-wire NO/NC combination 1 2 4

L1

NO = normally open NC = normally closed

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Connections and ...

Connection via Cable All ABB sensors feature a permanent connection cable as standard and at low cost. The length of the cable is 2 m. You can opt between versions PVC and PUR. A terminal connection offering maximum possible flexibility as regards cable length and cable type is available for large sensors.

The range of ABB sensors also includes M8 and M12 connectors as accessories. These connection types offer the advantage of rapid exchange and maintenance work, in particular in cases in which the sensors are subject to greater risk of damage owing to extreme ambient conditions.

Wireless Connection For use at moving machine parts ABB is offering a wireless connection concept for inductive proximity switches. Here, both the power supply of the sensor as well as the communication with the I/O-device are carried out without a wire connection.

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... Interfacing

ABB sensors are integrated in the switchgear and control engineering range so that they fit in well and are compatible with other devices in order to ensure optimum further processing of the information detected by the position sensors. This means that the position sensors

not only communicate smoothly with the controls of the distributed, intelligent ABB Advant Controller 31 automation system for instance but also allow other switchgear devices, such as contactors or illuminated pushbutton switches, to be controlled easily.

Interfacing to Controls

Power supply unit +24V DC 0V DC

Interfacing to Switchgear Devices

+24V DC

L1

Power supply unit

0V DC

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Type codes for ABB Position Sensors

The characteristic features of the sensors have been coded in 5 steps in the type designation in order to render the essential characteristics of the ABB sensors transparent and thus make it easier to choose the device you need. The coding, comprising combinations of letters and numbers, ensures clear and uncomplicated identification of the individual sensors.

Sensor Types: SI = Inductive SC = Capacitive SO = Photoelectric SU = Ultrasonic WS = Wireless Installation Method and Detection Range: Inductive Capacitive F0.8 ... F40 = flush installation, operating distances: 0.8 to 40 mm (Capacitive sensors can be adjusted up to 10 mm) N2 ... N50 = non-flush installation, operating distance: 2 to 50 mm Photoelectric R2000 ... R5000 = Retroreflective, operating distances: 2000 to 5000 mm D200 ... D800 = Diffuse reflective, operating distances: 200 to 800 mm L15 ... L150 = Fiber-optic waveguide basic unit, operating distances: 15 to 150 mm as through beam photoelectric sensor LT or as diffuse reflective sensor LD Ultrasonic D500 ... D6000 = Ultrasonic reflection principle, operating distances: 500 to 6000 mm

Types of Housing: Inductive Z4 = Smooth cylindrical, 4 mm Z6 = Smooth cylindrical, 6.5 mm M8 = Thread M8 x 1 M12 = Thread M12 x 1 M18 = Thread M18 x 1 M30 = Thread M30 x 1.5

Q30 = Block with square front face 30 x 30 mm Q40 = Block with 40 x 40 mm Q80 = Block with 80 x 80 mm B28 = Block 28 x 30 x 12 mm B45 = Block 45 x 30 x 12 mm

Connections: V2 = PVC cable, 2 m in length U2 = PUR cable, 2 m in length C1 = M12 connector C3 = M12 connector (Brad Harrison)

SI F2 M12N V2 PO
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Capacitive M30 = Thread M30 x 1.5 Photoelectric M18 = Thread M18 x 1 B26 = Block 26 x 24 x 12 mm B40 = Block 40 x 40 x 13 mm B75 = Block 75 x 64 x 25 mm

Ultrasonic M30 = Thread M30 x 1.5 Version: N = Normal type of construction / length S = Short type of construction T = Other short type of construction U = US type (conduit thread NPT)

C8 = M8 connector with 3 pins C9 = M8 connector with 4 pins T = Terminal connection (larger sensors)

Output Signals: PO = DC 3-wire PNP PC = DC 3-wire PNP PK = DC 4-wire PNP NO = DC 3-wire NPN NK = DC 3-wire NPN DO = DC 2-wire AO = AC 2-wire AC = AC 2-wire AK = AC 4-wire

Normally open ( NO) Normally closed (NC) NO/NC combination Normally open ( NO) NO/NC combination Normally open ( NO) Normally open ( NO) Normally closed (NC) NO/NC combination

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Example Fields of Application

Mbelherstellung

Furniture Manufacture

Bottling and Canning Foodstuffs

Conveyor Systems

Printing Presses

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Robotics Mixing Systems

Cranes

Production Engineering

Plastics Machines

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Approvals

The extensive range of ABB sensor equipment offers diverse possible applications for various operating conditions.

The ABB position sensors have been granted a whole number of national and international approvals, such as the following, in order to allow this broad field of application to also be used internationally:

CE mark

Bureau veritas (BV) France

Germanischer Lloyd (GL) Germany

UL USA

CSA Canada
Brochure No. 2CDC140001 B0201 Printed in the Federal Republic of Germany (03/02 3 GKD)

ABB Schalt- und Steuerungstechnik GmbH P.O. Box 10 50 09 D-69040 Heidelberg Telephone ++49 62 21 / 7 77-0 Telefax ++49 62 21 / 7 77-115 http://www.abb-sst.de

Mit freundlicher Empfehlung With the complements of Avec nos meilleurs compliments