Weld Select Series

Page 1:Weld Select SeriesSensing products to boost welding productivityWeld Select SeriesSensing products to boost welding productivity

Page 2:2Weld Select SeriesWeld Select is an industry proven group of Balluff products designed foruse in the most inhospitable welding environments.Poor sensor selection costs welders in every industry increased downtime, unnecessary maintenance, delayed delivery, and lost profits.Balluff presents a complete package of welding solutions that extends sensor life and increases productivity in the harshest weldingenvironments.This guide contains two sections. The front section is designed to help all plant levels identify existing issues and offer Balluff-developedsolutions to address them. The second section, beginning on page 14, offers an extensive list of products developed by Balluff weldingexperts from valuable customer input. These products have been tested in the harshest welding environments and provide significantprocess and part quality improvement.n Stop wasting sensors and destroying connectorsn Change the paradigm of accepted high volume sensor usagen Reduce downtime due to sensor failuren Slash consumption of sensors and connectorsn Boost profitability throughout the plantExamples of common weld cell problems that we have solved:Weld Repel®Wrap and TPE cables provideflexibility and resistance to weld slag, lubricants,and connector burn-through.Unprotected and non-bunkered sensors,sensors in damage-prone areas, and/orlight weight brackets.Bunker Blocks™ and SpatterGuard coating allowfull protection against harsh impact.Damage to unprotected sensor faces and cablescaused by impact and contact.

Page 3:www.balluff.com 3Slag accumulation and unprotected pigtailsensors cause large amounts of downtime.PTFE coated Prox-Mounts and Weld Repel®tubing over sacrificial cables improve sensor lifeand productivity.Standard sensors can accumulate slag,damage the sensing face and cause falsetripping of the sensor.Steelface®sensors with W51 ceramic coatingresist the slag and the sensor can be brushedclean with no damage or issues.Weld Select Series 1Sensing products to boost welding productivity 1Contents3Problems and SolutionsWelding Environment 4Loading Impact 5Cylinder & Clamp Position 6Photoelectric Sensors 7Protecting Connectivity 8Non-Contact Coupling 9Weld Sensing Best Practices 10Communication from Start to FinishIO-Link increases efficiency 12Network Components 14Inductive Couplers15Cables 16Inductive Sensors 18Cylinder and Clamp Sensors 30Photoelectric Sensors 32Pressure Sensors 34Accessories 36Balluff GmbH 40Contents

Page 4:4Welding EnvironmentNon-contact inductive proximity sensors must perform a wide variety of clamping and nesting indication, and Poka-Yoke functions in harshwelding environments. Hot weld slag accumulation, elevated ambient temperatures, and strong electromagnetic fields emitted by weld gunscan cause false triggering and degrade sensor performance.PROBLEMStrong electromagnetic fields cause conventional sensors to falsetrigger or “chatter.”SOLUTIONBalluff inductive proximity and magnetic field sensors with weld fieldimmunity (WFI) resist electromagnetic fields emitted by weld guns upto 100 kA/m.Electromagnetic Weld FieldsWeld SlagPROBLEMHot welding slag (a.k.a. weld debris, weld spatter, weld berries)sticks to sensor faces and bodies and causes premature failure ofsensors in weld cells.SOLUTIONBalluff SpatterGuard coating on sensor faces resists weld debris andprovides a thermal barrier, significantly enhancing sensor longevity,and reducing false triggering. PTFE coated sensor bodies resist welddebris accumulation and promote slag removal during regularscheduled maintenance periods.See page 20 to find your solution See page 22 or 25 to find your solutionWelding Environment

Page 5:www.balluff.com 5Loading ImpactIncidental sensor damage caused by parts loading impact can significantly degrade sensor performance, shorten sensor life, or even destroya sensor. Balluff SteelFace®inductive proximity sensors can withstand multiple heavy impacts and abrasion, and often have the sensingrange to be placed out of harm’s way.PROBLEMSevere loading impact and continuous operational impact damagesplastic and/or PTFE sensor faces as well as sensor bodies.SOLUTIONEvery precaution should be taken to prevent electronics such assensors from being hit, but in many cases, loading impact cannotbe avoided. By nesting a Balluff SteelFace®inductive proximitysensor into a rugged Prox Mount or Bunker Block™, the likelihoodof premature failure becomes lessened, even with repeated impactover time.Damage from Loading Impact Sensor Face Damaged by ImpactPROBLEMStandard tubular sensors often fail from damage to the sensor faceand coil caused by slag and impact. Over time, small repeatedimpacts can damage the face and lead to sensor failure.SOLUTIONBalluff SteelFace®inductive proximity sensors with extended rangeand stainless steel housings resist impact, providing long life in weldcell impact zones. Balluff Bunker Prox™ and PlungerProx™ providesensors an extraordinary degree of physical protection, resisting oreliminating contact damage to the sensor body and face as well asrapid sensor removal and replacement without need for recalibration.See page 36 or 38 to find your solution See page 18 or 28 to find your solutionLoading Impact

Page 6:6PROBLEMHigh-pressure hydraulic welding clamps need the right sensors toaccurately sense piston extend/retract position and may requireelectronic weld field immune sensors.SOLUTIONBalluff StrokeMaster®high pressure-rated end-of-stroke sensorsaccommodate pressures up to 3,000 PSI and fit virtually all commoncylinder brands and bore sizes. StrokeMaster heads swivel to directconnector wiring away from weld hostility.Cylinders & Clamps Need Stroke Detection Premature Reed Switch FailurePROBLEMWhen installed on pneumatic clamping cylinders, failure-prone reedswitches and drift-prone Hall Effect sensors deteriorate, often provid-ing inaccurate switch points before failing completely.SOLUTIONBalluff BMF magnetoresistive sensors come with a lifetime warrantyand fit virtually all cylinder housing styles and brands. They provideprecise switch points and withstand the rigors of the weld process,while providing wear free, non-contact reliability.More information on our website or on request See page 30 to find your solutionCylinder & Clamp PositionParts welded in a robotic weld cell must be nested and held in place by pneumatically or hydraulically actuated clamps, which are oftenequipped with sensors located in the clamp jaws to indicate “clamped” or “unclamped” position. Clamp position can also be determined bymagnetic field sensors located on the outer wall of an aluminum or composite pneumatic cylinder. To determine clamping position, a BalluffBMF magnetoresistive sensor tracks the magnetic field emitted by a magnet attached to the cylinder’s piston. In high-pressure hydrauliccylinders, Balluff StrokeMaster®end-of-stroke sensors detect the “spud” or cushion of a piston shaft to sense clamp position.Cylinder & Clamp Position

Page 7:www.balluff.com 7Photoelectric SensorsPhotoelectric and fiber optic sensors require special protection and mounting expertise when integrated into welding cells. Balluff has a widerange of photoelectrics with application-specific infrared, red light, or laser capability that can reliably sense through smoke, oil and dirt. Inaddition, Balluff provides a range of accessories that protect photoelectric optics from heat, slag, and lens occlusion in the hostile weld cellenvironment.PROBLEMFiber optics can become occluded in the weld cell and stopfunctioning. They can become broken when weld fixtures areremoved, causing fibers to vibrate loose. Cables with excesslength break when tied back and get damaged by slag.SOLUTIONTypically, fiber optic solutions are not the best choice in weld cells.Metal-body laser sensors or inductive proximity sensors are almostalways a better choice.Fiber Optic Limitations Damage by Loading ImpactPROBLEMImpact-prone photoelectric sensors can easily become physicallydamaged in welding environments.SOLUTIONBunker Blocks™ and Prox Mounts can be used to protect tubularphotoelectric sensors. They provide a thermal barrier, protect againstweld slag and impact, and provide rapid sensor change out. BunkerBlocks™, available in several sizes and styles, protect block stylephotoelectric sensors in the weld environment.See page 32 to find your solution See page 36 to find your solutionPhotoelectric Sensors

Page 8:8PROBLEMWeld slag burns through and destroys conventional cabling. It’sweight often pulls the cable away from the connector, exposing it toeven more damage.SOLUTIONBalluff engineered a new line of high durability cables encompassingevery part of the cable to withstand a welding environment. This lineof cables has a PTFE coated nut to prevent accumulation of debris,as well as a weld spark immune connector body to withstand suddenburst in temperature. Balluff tested different kinds of cable jackets inweld cells until finding our most durable cables: silicone tube,silicone cable, and PTFE cable. These different options keepproduction moving and reduce the number of cable replacements.Sensor Cable Burn-Through Network I/O Blocks DamagedPROBLEMSensor connections often terminate into plastic junction blocks ornetwork blocks which can easily be damaged in welding cells.SOLUTIONA rugged line of industrial I/O products designed for use in theharshest environments offer a greater degree of strength anddurability for applications like robotic welding cells. Most major busand Ethernet based industrial networks are supported and providedetailed diagnostics on the connections from short circuit protectionto network status. In the dark confines of a weld cell, the bright andlarge LEDs are easy to see.More information on our website or on requestProtecting ConnectivityWeld cells demand the toughest connectivity solutions. Weld debris shortens the life of a cable in different fashions. Slag can build up onthe jacket, pulling the cable out of the connector. Weld sparks burn through the cable causing shorts in the connection, and the extremeenvironment temperatures can cook components. Balluff’s family of high durability cables were designed and tested with weld environmentsin mind. The bodies of the connectors are weld spark immune with PTFE coated nuts to prevent slag from sticking or burning theconnectors. This family has multiple cable jackets selected to endure different environmental challanges.See page 16 to find your solutionProtecting Connectivity

Page 9:www.balluff.com 9Non-Contact CouplingInterchangeable weld fixtures and rotating weld tables often require the use of troublesome, expensive, and high-maintenancecontact-based rotating assemblies such as slip rings or commutator ring/brush solutions. In many cases, wires inevitably fray and break.In contrast, Balluff’s unique non-contact connectors provide a wear free connectivity, powering sensors and providing control informationacross an air gap.PROBLEMRotational weld cells, or cells that use interchangeable fixtures, oftenincur high maintenance and frequent stoppages due to damagedslip rings, tangled, over-flexed, or twisted wiring.SOLUTIONNon-contact connector systems provide communication betweentwo or more separated weld cell components through an air gap toenergize and communicate between the controller and thesensors. Since there is no hard-wired connection, weld fixtures canbe inserted into a weld cell frame without the need for mechanicalconnections, facilitating rapid change out.Broken or Worn Out Communicator RingsHow Non-Contact Couplers WorkThink of this like a mechanical connector without pins or therequirement of physical contact. When connected, power goes outto the devices and signals come back from the devices. Dependingon the specific product of interest, different information can bepassed. Power only or power plus, discrete inputs and outputs, oranalog voltage signals can be transmitted across the air gap. Eachbase head is mounted on the controller side of the application andas many remote heads as needed are mounted on the sensors/actuators side of the application.More information on our website or on requestAny application with an A-side/B-side or 360º rotating table needsconnections across an axis of rotation. The non-contact couplerfrom Balluff provides transparant connection between the sensorsand controller. Since it is non-contact, it is completely wear-free andhas dramatically reduced repair and downtime versus manytraditional connection methods.Inductive CouplingMultiple Sensors PLC<15mmRemote BaseSignalPowerSignalPowerSignalPowerNon-Contact Coupling

Page 10:101. Select the Right SensorWhen selecting the right sensor, you have to take into account multiple aspects of the application:how the sensor is being used, what environment is it being exposed to, and why the current installationhas continuously failed. Common questions to consider are: Environmental n Will the sensor signal be affected by the weld noise? n Is the sensor failing due to heat from the environment? n Is there excessive weld slag accumulation on the sensor? Application n Does a different sensor technology make more sense? n Can I detect this part from a different angle or location? n Is there a better mounting solution for the sensor?Balluff offers many combinations of sensor technologies for use in the welding environment, and the besttechnology may require some testing before it can be determined.Weld Sensing Best PracticesSelecting Components for SurvivabilityWhen working in harsh environments and in heavy duty applications like welding, it is important to take a multi-angle approach to designingthe application. When you are working with existing sensor installations, it is important to consider all the reasons for the sensor’s failurebefore determining a winning solution. While blind trial and error will eventually lead to improvements in sensor life, Balluff has developed,with our customers, a strong best-practice approach for applying sensors in automated welding.Select ProtectLearnConnectWeldingBestPracticesSelect ProtectLearnConnectWeldingBestPracticesAuswählen SchutzLernenAnschlussSchweißenbesteAnwendungenSelect ProtectLearnConnectWeldingBestPracticesSelect ProtectLearnConnectWeldingBestPracticesSelect ProtectLearnConnectWeldingBestPracticesWeld Sensing Best Practices

Page 11:www.balluff.com 112. Protect the SensorWhen determining how much protection is needed for the sensor, you still have to consider these typicalquestions: what is the sensor being exposed to and why is the current installation failing. Other commonquestions to consider are: n What available space do I have? n Is there physical contact damage to the existing sensor? n Can I change the tooling in any way?Balluff offers one of the widest varieties of accessories specifically designed for applying sensors in thewelding environment. The best accessory for your specific application may require adaption of thetooling for implementation.3. Connect with ProtectionProtecting the connection between the controller and the sensor can be as much of a pain point askeeping the sensor alive. Whether the sensor cable fails from weld slag buildup or from physicaldamage from contact with a part, the cable can be the lynchpin to a successful weld-sensingapplication. Questions to consider when looking at connectivity options: n Is the cable collecting slag or melting from contact with slag? n Is the connector not meeting the proper bend radius and being damaged? n What temperatures and environments will the cable be exposed to?Balluff offers the strongest options of sensor connectors for your welding applications. These productshave been tested in real-world customer applications and extended the life of an application more than50 times in some instances.4. Learn with Continuous ImprovementThere are some things worth doing over and over, but replacing a proximity sensor every shift is not oneof them. By learning from our failures and analyzing them we can increase our productivity, improve ourquality, and reduce headaches for operators, technicians, and managers. So when a sensor fails, it isbest to document the failure and then begin to make a plan to improve the application. Somequestions to consider at a failed sensor application include the following: n What caused the eventual end of the sensor? Heat? Slag? Impact? n What else is damaging the sensor? Is the cable failing? n Where else do we have a similar installation or application?While we understand that time is tight and downtime costs money, there isn’t always the luxury toanalyze for yourself what is going on in the facility: you are just trying to keep it running. Balluff offersmany opportunities for training or service where we can help you improve the skill set of the techniciansor bring in extra labor to implement improvements.Select ProtectLearnConnectWeldingBestPracticesSelect ProtectLearnConnectWeldingBestPracticesSelect ProtectLearnConnectWeldingBestPracticesSelect ProtectLearnConnectWeldingBestPractices

Page 12:12Communicationfrom Start to FinishIO-Link increases efficiencyCommunicationfrom Start to FinishIO-Link increases efficiencyWhat is IO-Link?IO-Link is the first worldwide standardized IO technology(IEC 61131-9) for communicating from the controller to the lowestlevel of automation. The interface can be used universally and is afieldbus-independent point-to-point connection that operates usingan unshielded industrial cable.What does IO-Link provide?IO-Link transmits all sensor signals to the controller and, conversely,relays control data to the sensor/actuator level. With revolutionaryresults.This is how IO-Link integrates every sensor into the fieldbus level.And IO-Link enables comprehensive ongoing diagnostics andautomated configuration of parameters for IO-Link devices via thecontroller. Even with all these capabilities, IO-Link is quite easy toinstall: one unshielded three-core cable is enough for integratingsensors and actuators. This cable can be up to 20 m long.The connection has been standardized with M5, M8 and M12 plugs.IO-Link simplifies the entire network topology. An IO-Link masteris used with any fieldbus connection to connect IO-Link sensors/actuators or IO-Link sensor hubs. This master has multiple IO-Linkports so that it can bundle data from various devices and reducethe number of devices. This stems from the fact that IO-Link sensorhubs are capable of incorporating and relaying switch signals fromup to 16 binary sensors. If these hubs are connected to an 8-foldIO-Link master, then data from up to 136 sensors is transmitted.Each port on the IO-Link master can optionally be operated inswitching mode (SIO mode for processing binary signals) or inIO communication mode, thus processing information from all ofthe sensors.The IO-Link master transmits large volumes of data in almost notime in the process. By default, up to 32 bytes of process data areavailable per cycle. It takes just 400 μs to exchange 2 bytes of pro-cess data and 1 byte of demand data between the IO-Link masterand the device at a speed of 230 kbaud.Simplification of installation■■ Faster, simpler connection to an unshielded, three-wirestandard cable■■ Standard sensors can also be integrated into the fieldbus level■■ 8-fold IO-Link master for eight different IO-Link devices or eighthubs, each with up to 16 binary sensors■■ Cost-saving due to fewer mechanical installations■■ High security against interference thanks to digital communicationRequirements-based maintenance■■ Continuous diagnostics■■ Automatic readjustment via the controller■■ Predictive error detection■■ Longer maintenance intervalsMore efficient operation■■ Positioning of the sensors right where the action is■■ Process monitoring, configuration and error analysisof the IO-Link devices via the controller■■ Fast, high-performance data transmission■■ Time-optimized machine processes■■ High security against interference by means of digitalcommunication■■ A selection of sensors that is highly suited to the particularapplication because of the simultaneous use of binary,analog, and IO-Link sensorsHighest machine availability■■ Faster, error-free sensor replacement and prompt commissioning■■ Automatic configuration of an IO-Link sensor■■ Prompt format changes and recipe changes centrallyvia the controller■■ Additional security from clearly identifiable IO-Link devices

Page 13:PLCFieldbuswith IO-Link interfaceStandardsensors/actuatorswww.balluff.com 13IO-Link devices

Page 14:14Special featuresM8,3-pinM8,3-pinM8,3-pinM8,3-pinM8,4-pinM8,4-pinM12,metalM12,metalM12,metalM12,metalM12,metalM12,metalM12,metalM12,metalM12,metalM12,metalM12,metalSensor hubsBNI000PBNIIOL-101-000-K018BNI001WBNIIOL-101-S01-K018BNI000RBNIIOL-102-000-K019BNI001YBNIIOL-102-S01-K019BNI0021BNIIOL-104-000-K021BNI0022BNIIOL-104-S01-K021BNI0032BNIIOL-104-000-Z012BNI003UBNIIOL-302-000-Z012BNI0039BNIIOL-104-S01-Z012BNI003TBNIIOL-104-S01-Z012-C01BNI003CBNIIOL-302-S01-Z012BNI005PBNIIOL-104-S01-Z012-C02BNI003ABNIIOL-302-S01-Z013BNI0048BNIIOL-302-S01-Z013-C01BNI0035BNIIOL-302-000-Z013BNI0033BNIIOL-252-000-Z013BNI0034BNIIOL-256-000-Z013No. of Ports 4 4 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8Max. Inputs 4 4 8 8 16 16 16 16 16 16 16 16 16 16 16 8 16Max. Outputs 16 16 16 16 16Configurable Max. Inputs/Outputs 16 16 16 16 16IO-Link Version 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0Network ComponentsSensor hubs and networking modulesSpecial features8ports4×IO-Link8ports8ports8ports8ports4×P111interface8ports4×P111interface8ports4×RFIDinterface4ports4×IO-Link4ports4×IO-LinkSensor hubsBNI005RBNIPBS-502-101-Z001BNI0047BNIPBS-302-101-Z001BNI005CBNIPBS-104-101-Z001BNI0057BNIPBS-202-101-Z001BNI0064BNIPBS-551-001-Z001BNI0065BNIPBS-552-001-Z001BIS00T3BISV-6102-019-C001BNI004NBNIPBS-507-002-Z001BNI004PBNIPBS-504-002-K008No. of Ports 8 8 8 8 8 8 4 4Max. Inputs 16 16 16 8 8 8 4Max. Outputs 16 16 8 4Configurable Max. Inputs/Outputs 16 16Analog Input U/I 4IO-Link Ports, Max. 4 1 4 4IO-Link Version 1.1 1.1 1.1 1.1Network Components

Page 15:www.balluff.com 15flexible Freizone für Letter-FormatBaseRemoteBaseRemoteTogether withsensor hubInductive CouplersBIC M30 and BIC Q40 bidirectionalRemote BaseTogether withanalog hubinterface 16 IN interface 4×, analogType M30×107.5mmM30×100mmM30×107.5mmM30×100mm40×40×63mm40×40×63mmOrder codePart numberBIC000EBIC2I0-I2A50-M30MI3-SM4A5ABIC000CBIC1I0-I2A50-M30MI3-SM4A4ABIC0054BIC2I0-IAA50-M30MI3-SM4A5ABIC0053BIC1I0-IAA50-M30MI3-SM4A4ABIC0070BIC1B0-ITA50-Q40KFU-SM4A4ABIC0071BIC2B0-ITA50-Q40KFU-SM4A5AWorking Range 0...5 mm 0...5 mm 0...5 mm 0...5 mm 1...5 mm 1...5 mmInstallation Non-flush Non-flush Non-flush Non-flushReliable Offset ±4 mm ±4 mm ±4 mm ±4 mm ±5 mm ±5 mmTransfer Voltage 24 V 24 V 24 V 24 V 24 V 24 VContinuous OutputCurrent Remote500 mA 500 mA 500 mATransferable Output 12 W 12 W 12 W 12 W 12 W 12 WDegree of Protection asper IEC 60529IP 67 IP 67 IP 67 IP 67Housing Material CuZn Coated CuZn Coated CuZn Coated CuZn Coated PBTP PBTPConnection M12 Connector,Female, 5-pinM12 Connector,Male, 4-pinM12 Connector,Female, 5-pinM12 Connector,Male, 4-pinM12 Connector,Male, 4-pin,A-codedM12 Connector,Female, 5-pin,A-codedIO-LinkTransfer rate 38.4 kbaud 38.4 kbaud 38.4 kbaud 38.4 kbaud COM 2 COM 2Cycle Time min. 3 ms 3 ms 3 ms 3 ms Depends onIO-Link deviceDepends onIO-Link deviceProcess Data Cycle 12 ms 12 ms 33 ms 33 msIO-Link ProcessData Length3 input bytes 3 input bytes 11 input bytes 11 input bytes 1...32 byte 1...32 byteFrame Type 1 1 1 1SIO Mode no noBaseEnergyDataRemotePrinciple of operationBase – connects the system to the controller: transmits power tothe remote, receives the status information from the sensor andrelays it to the controller.Remote – connects the sensors and actuators with the inductivecoupling system. The remote is mounted on the mobile side of theapplication.Inductive Couplers

Page 16:16CablesCables for harsh environmentsHot weld sparks burn, melt and destroy cable and connector.Buildup of damage over time can cause shorts and failures.Double-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 m050 = 5 mSingle-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 m050 = 5 mSplitterStandard Lengths Available:003 = 0.3 m006 = 0.6 mMolded silicone-free cabeln Weld-resistant, flame-resistant, highly flexibleSilicone cablen Abrasion and mechanical resistantn Thermal shock resistantTypeM12Single-endedM8Double-endedM8toM12Double-endedM12Double-endedM12SplittersPart numberBCCW415-0000-1A-003-SW0434-___BCCW425-0000-1A-003-SW0434-___BCCW314-W314-30-304-SW0434-___BCCW313-W413-3E-300-SW0334-___BCCW314-W414-3E-304-SW0434-___BCCW415-W414-3A-304-SW0434-___BCCW425-W415-3A-304-SW0434-___BCCW414-W415-W415-U2046-___BCCW414-W425-W425-U2046-___Female, Straight n n n n n nFemale, Right Angle n n nMale, Straight n n n n n n nMale, Right Angle3-wire n4-wire n n n n n nJacket TemperatureOperational Temperature Fixed –40...200 ºCOperational Temperature Moving –25...200 ºCVoltage Rating 250 VAmperage 4ADouble-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 mSingle-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 mSplitterStandard Lengths Available:003 = 0.3 m006 = 0.6 mTypeM12Silicone-freeCablePart numberBCCW415-W414-3A-304-BW8434-003BCCW415-W414-3A-304-BW8434-006BCCW415-W414-3A-304-BW8434-010BCCW415-W414-3A-304-BW8434-020Fermale, Straight n n n nMale, Straight n n n nJacket TemperatureOperational Temperature Fixed –50… 130 °COperational Temperature Moving –40… 125 °CMaximum Temperature atOuter JacketShort-time 800 °CSpecial Properties For high welding loads,flame-resistantVoltage Rating 250 VAmperage 4ACables

Page 17:www.balluff.com 17PTFE (FEP)n Low friction, high temperaturen Resistant to caustic agentsTypeM12Single-endedM8-M12Double-endedM12Double-endedM12SplittersPart numberBCCW415-0000-1A-003-TW0434-___BCCW425-0000-1A-003-TW0434-___BCCW313-W413-3E-300-TW0334-___BCCW415-W414-3A-304-TW0434-___BCCW425-W414-3A-304-TW0434-___BCCW414-W415-W415-U2048-___BCCW414-W425-W425-U2048-___Female, Straight n n n nFemale, Right Angle n n nMale, Straight n n n n nMale, Right Angle3-wire n4-wire n n n nJacket TemperatureOperational Temperature Fixed –65...200 ºCOperational Temperature Moving –65...200 ºCVoltage Rating 250 VAmperage 4ATypeM12FiberglassClothCablePart numberBCCW415-W414-3A-304-FW9434-003BCCW415-W414-3A-304-FW9434-006BCCW415-W414-3A-304-FW9434-010BCCW415-W414-3A-304-FW9434-020Fermale, Straight n n n nMale, Straight n n n nJacket TemperatureOperational Temperature Fixed –40… 130 °COperational Temperature Moving –25… 180 °CMaximum Temperatureat Outer JacketShort-time 800 °CSpecial Properties Weld-resistant, flame-resistant,highly flexibleVoltage Rating 250 VAmperage 4ADouble-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 m050 = 5 mSingle-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 m050 = 5 mSplitterStandard Lengths Available:003 = 0.3 m006 = 0.6 mFiberglass cloth cablen Weld-resistant, flame-resistant, highly flexibleDouble-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 m050 = 5 mSingle-endedStandard Lengths Available:003 = 0.3 m006 = 0.6 m010 = 1 m015 = 1.5 m020 = 2 m050 = 5 mSplitterStandard Lengths Available:003 = 0.3 m006 = 0.6 mSelect ProtectLearnConnectWeldingBestPractices

Page 18:18Inductive SensorsBunkerProx®Balluff’s BunkerProx®is a rugged “self-bunkering” M18 inductive sensor specially designed to survive longer in abusive welding applicationswithout external protection. The strong, massive thick housing has the ability to withstand repeated mechanical impacts and also serves asan intermittent heat sink to shield the sensor electronics from the intense heat of the red-hot weld slag. A frontal impact deflection ring helpsprotect the high-temperature ceramic face from impact damage during part loading and unloading.n Repels weld slag and makes manual removal of slag easiern Eliminates sensor output flicker due to weld fieldsn Resists damage of electronics and sensing face due toheat and hot slagn Survives repeated impacts at the sensor face and bodyThick, strongone-piececonnectorbodyWide-radiuscorners forstress relief atcritical junctionof connectorbody to housing“Green” foamsealant handlestemperaturefluctuations,without loss ofsealing properties4 mm sensingrange, weldfield immuneelectronicsShock-dampingmaterialprotects criticalboard-coiljunctionNon-brittle,ferrite-free coilcarrier can’t faildue to impactfracturessmall-diameter coilis less vulnerableto heavy cornerimpactsImpactdeflection ringprotects againstcontinuous partloading contactCeramicface resistsweld spatterburn-throughup to 2200ºF(1200ºC)Weld spatter-resistant coatingresists melting upto 300ºF (150ºC)Tough plasticcoil cap ensurespositively sealedfront housingMassively thickbrass housingforms protectiveintermittent heat sinkBunkerProx®TubularInductiveSensorsTypeM18Tubular,10…30VDCOrder codePart numberBES03MYBESM18MI-PSC40B-S04G-W03Sn (mm) / Mounting 4 FOutput Logic PNP NOSpecial Properties WFICoatings PTFEConnector M12Benefits of BunkerProx®:WARNINGRead, understand, and follow warnings and manual. Failure to do so could result in serious injury or death.Never use as a sensing device forpersonnel protectionDoes NOT include self-checking redundancy circuitry required for use in personnel safety applicationsDoes NOT meet OSHA and ANSI standards for point-of-operation devicesInductive Sensors

Page 19:www.balluff.com 19Inductive SensorsPlungerProx™Balluff’s all new PlungerProx™is a high durably assembly intended for direct contact applications. The heavy dutydesign allows the sensor to come in constant contact with the machine or part to verify presence or position,making it ideal for welding fixtures, stamp and die, and ejection control applications. Mated with Balluff M8sensors and multipule tip selections, the PlungerProx™offers the maximum in application flexibility.InductiveSensorsTypeRoundTipChiselTipFlatTipM6ThreadedTipPaddleTip(ø50mm)AccessorytoThreadedTipOrder codePart numberSET015ABAVBP-PH-00093-01SET015FBAVBP-PH-00093-02SET0167BAVBP-PH-00100-01SET0168BAVBP-PH-00100-02SET0169BAVBP-PH-00101-01SET016ABAVBP-PH-00101-02SET016CBAVBP-PH-00102-01SET016EBAVBP-PH-00102-02BAM025TBAMTG-AM-015-001Output Logic PNP, NO n n n n n n n n nTip Round Round Chisel Chisel Flat Flat Threaded Threaded PaddleTip Actuator Material Steel/ChromePlatedSteel/ChromePlatedSteel/ChromePlatedSteel/ChromePlatedSteel/ChromePlatedSteel/ChromePlatedSteel/ChromePlatedSteel/ChromePlatedSteel/ChromePlatedHousing Material BrassM18BrassM18BrassM18BrassM18BrassM18BrassM18BrassM18BrassM18Connection M8 M12 M8 M12 M8 M12 M8 M12Three spring tensions:LowMediumHighFour Plunger Tips:RoundFlatChiselThreaded M4Two Piece Housingfor Maintenancen High reliability and long service life even in contaminated environmentsn Disassemble easily for cleaning and repairn Control the switch point with precision and allow for plunger over traveln Specialize the application for a variety of sizes, approaches, and requirementsBenifits of PlungerProx™:Select ProtectLearnConnectWeldingBestPractices

Page 20:SpatterGuard coating significantly prolongs sensor life by providing a thermal barrier to protect against heat, retarding build upof weld spatter and slag, and easing removal of surrounding deposits of weld debris during scheduled maintenance periods.The parts listed below are non-weld field immune sensors and without PTFE-coating.For PTFE-coated, weld field immune sensors, see page 22.20TubularInductiveSensors3-Wire DC, Non-Weld Field Immune, SpatterGuardTypeM8tubular10…30VDCM12tubular10…30VDCM18tubular10…30VDCOrder codePart numberBES02P5BES516-324-SA96-G-E4-C-S4-00.3BES02P0BES516-324-SA96-G-E5-C-S49BES02P1BES516-343-SA96-G-E5-C-S49BES02PNBESM08MH1-NSC20B-S04G-101BES02PUBESM08MH1-PSC20B-S04G-101BES0149BESM08EE-PSC20B-S04G-101BES0388BESG08EC-PSC20B-EP01-GS04-516BES02PWBESM08MH1-PSC30B-S04G-101BES0450BES516-325-SA96-G-E5-C-S4BES035RBES516-325-SA96-G-S4-CBES03UPBES516-329-SA96-G-E5-C-S4BES02P3BES516-326-SA96-G-E5-Y-S4BES02P4BES516-355-SA96-G-E5-Y-S4Sn (mm) / Mounting 2 F 2 F 2 F 2 F 2 F 2 F 2 F 3 QF 4 F 4 F 4 F 8 F 8 FOutput Logic PNP NO PNP NO NPN NO NPN NO PNP NO PNP NO PNP NO PNP NO PNP NO PNP NO NPN NO PNP NO NPN NOCoatings SG SG SG SG SG SG SG SG SG SG SG SG SGConnector M120.3 m PURM8 M8 M12 M12 M12 M12 1 PUR M12 M12 M12 M12 M12 M12Inductive SensorsSpatterGuard coatingBlockInductiveSensors3-Wire DC, Non-Weld Field Immune, SpatterGuardType20x32mmBlock,10...30VDC40x40mmCube,10...30VDCOrder codePart numberBES048YBESR01ZC-PSC70B-BZ00,2-GS04-108BES0492BESR01ZC-PSC70B-BZ00,2-GS49-108BES0484BESR01ZC-PSC70B-BZ05-108BES02PTBESR01ZC-PSC70B-BP00.2-GS04-101BES0314BESR01ZC-PAC70B-BP00.2-GS04-107BES02KYBESR01ZC-PSC70B-BX00.2-GS49-105BES0455BESQ40KFU-PAC20B-S04G-101BES0456BESQ40KFU-PAC30F-S04G-101Sn (mm) / Mounting 7 F 7 F 7 F 7 F 7 F 7 F 20 F 30 FOutput Logic PNP NO PNP NO PNP NO PNP NO PNP NO PNP NO PNP Comp PNP CompCoatings SG SG SG SG SG SG SG Face SG FaceConnector M120.2 m TPUM80.2 m TPU5 m TPU M120.2 m PURM120.2 m PURM80.2 m PURM12 M12