Sensor Selection Guide

Product overview brochure

 Inductive Sensors
Balluff offers a variety of inductive sensor solutions: standard
designs, block styles, extended range, weld field-immune,
specialized sensing – whatever the need, there’s a Balluff
inductive sensor that will provide optimum service. Balluff
sensors are found in machine tool equipment, the plastics
industry, textile production machines, woodworking, automotive
manufacturing – wherever there is a need to automate. From Mini
to Maxi block style sensors from 5 x 5 mm to 80 x 80 mm, and
tubular housings from 3 mm to 30 mm sizes, Balluff inductive
sensors monitor, control, measure, and automate production
sequences with high reliability and freedom from wear.

Photoelectric Sensors
Balluff photoelectric sensors are designed to provide specific
process tracking, position information, and part quality solutions
in all areas of the automation process. They are especially suited
for applications in robotics, assembly, and material handling.
Along with tubular housings both in plastic and metal sized from
5 mm to 30 mm, Balluff also offers a range of sensors in rigid,
block-shaped plastic housings. From classic diffuse,
retroreflective, and thru-beam types to more specialized versions,
the Balluff photoelectric line will handle the toughest applications.

Cylinder & Valve Sensors

Magnetic field sensors are primarily used for monitoring the piston
position on pneumatic cylinders. The magnetic field of a magnet
embedded in the piston is detected by the sensor through the
cylinder housing wall. Thanks to their non-contact position sen-
sing capability, these electronic magnetic field sensors are reliable,
wear-free, and are finding ever-wider use. Balluff offers perfect
solutions for a variety of typical pneumatic cylinders. Balluff’s
universally compatible range of cylinder sensors with their
engineered mounting bracket kit concept will fit virtually any
cylinder shape or size.

Capacitive Sensors
Capacitive sensors detect the change in capacitance caused by
the approach of an object in their electrical field. These sensors
find broad use in sensing metals, plastics, or liquids and are used
extensively in applications involving packaging, plastics handling,
and liquid level sensing.

Remote Systems
Sensors are often required to rotate or follow the movement of a
machine component or part being manufactured. This often
results in repeated twisting and tangling of wiring, resulting in
cable wear and ultimately failure. Balluff power remote systems
consist of a transmitter and receiver unit that transmits power and
sensor information through an air gap. They eliminate wiring failure
while providing noise and contactless wear-free operation even in
extreme conditions.

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ID Systems

Connectors
Balluff provides a range of RFID systems to track work in progress
and provide feedback on in-process testing. Computer-assisted
manufacturing, modern warehouse systems, flexible assembly
lines, plus logistics and distribution systems benefit from Balluff
BIS RFID systems. BIS components are available in plastic or
metal housings and plug-in versions to meet any application
requirement. Balluff has developed a complete line of easy to use
read-only systems that interface directly into a PLC through
discrete inputs or an RS-232 interface. These systems offer data
reliability and environmental ruggedness not found in bar code
systems. Read-only systems are ideal when product data are
stored centrally in a control system and referenced by a code
contained on RFID tags located on products, parts, or pallets.

Mechanical Switches
Engineered for the most demanding switching requirements and
harsh environmental conditions, Balluff cam switch systems are
still the preferred solution of automatic machinery builders around
the world. Key applications include control of automatic machine
tools, overtravel limiting, and robot dynamic zone control.

Transducers
Balluff Micropulse linear position transducers provide highly
accurate and reliable position control signals. Balluff’s non-
contact magnetostrictive technology means performance does
not degrade over time, as with linear potentiometers.
Micropulse transducers are available with a variety of housing
styles and electrical outputs to fit a wide range of applications and
are very popular in the lumber industry, plastic injection and blow
molding, tire and rubber manufacturing, stamping presses, die
casting, and all types of automated machinery where a
continuous, absolute position signal is required.

Accessories
A compete range of accessories helps save costs and provides
optimum sensor integration in any environment. In addition to
protecting Balluff sensors, our accessory line is designed to permit [Link]
precise, lasting sensor location positioning while permitting quick
sensor change out at any time.

Connectivity Products
A comprehensive line of cables, cordsets, and connection blocks
complement our product line, facilitating sensor use in every area
of automation. Balluff offers custom application expertise on
request.

[Link] · 1-800-543-8390 1
 Balluff Means
Industry Expertise

Automotive Automated Assembly

From stamping, to powertrain, Machines are getting smaller, faster,
to final assembly, Balluff's and smarter. Fortunately, so are
rugged products have proven Balluff's sensing and ID products.
themselves up to the task.

Rugged, long-range The industry standard Miniature, long-range A new level of reliability
inductive proximity multiple mechanical inductive proximity and performance from
sensors switches sensors pneumatic cylinder
position sensors

Accurate and reliable Ultra-reliable RFID Specialized Ultra-reliable RFID

photoelectric systems photoelectric systems with the latest
sensors sensors in connection options

Manual Assembly Welding

Here, error proofing is the name Monitoring the position of parts and
of the game. It takes a sensor clamps in welding environments
company with the products and requires specialized products for
the know-how to solve real-world sensor longevity. Our products and
issues. accessories enable maximum uptime.

Rugged, long-range Ultra-reliable RFID Special coatings Dynamic zone

inductive proximity systems with the latest in provide weld-field restriction using
sensors connection options immunity with Balluff multiple
Balluff's weld-specific mechanical switches
proximity sensors

All types of lasers, A new level of Eliminate troublesome

true color, and UV reliability and weld- connection problems
sensors field immunity with with Balluff's power
pneumatic clamp remotes
sensors
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 Intro
Metal Forming Machine Tool
Balluff has the in-die sensing Balluff has the rugged, reliable
critical to protect dies from sensors and ID solutions to meet the
damage, allow more strokes, requirements of this industry. Tool ID
and provide error proofing has proven itself as an effective
during the forming process. method for error proofing setup.

Miniature tubular and Steel face and long-range

block style sensors are easily inductive proximity
bunkered within the die sensors

Long range lasers and self- Ultra reliable RFID systems

contained thru-beams for track tool data such as tool
slug-out and part-out type, presetter offsets and
detection usage history

Tire and Rubber Wood

Given the amount of motion You need heavy duty sensors to
involved, Balluff position meet the position and handling
feedback products are equirements of this rugged
preferred worldwide. industry.

Rugged, long-range Reliable position Rugged, long-range Reliable position feedback

inductive proximity feedback on hydraulic inductive proximity of saw blades with
sensors for machine sensors with sensors for machine Micropulse®
feedback Micropulse® feedback magnetoresistive linear
magnetoresistive transducers
linear transducers
Long-range lasers for Long-range lasers for
error proofing and positioning and UV
position feedback sensors for wood
grading

Plastics
Balluff's line of feedback devices
[Link]
effectively handle the position
feedback requirements of injection
and blow molding equipment.

Reliable detection of Reliable position feedback

plastic parts and pellets with Micropulse®
with Balluff's capacitive magnetoresistive linear
sensors transducers

Rugged, long-range
inductive proximity
sensors for machine
feedback

[Link] · 1-800-543-8390 7
Tubular Inductive Sensors

Tubular
Inductive
Sensors
3 mm 4 mm 5 mm 6.5 mm
Housing Size Smooth Smooth Threaded Smooth
Sensing distance 2X STD, 2X STD, 2X STD, 2X, 3X, 4X
Flush 1.0 mm 0.8 mm, 1.5 mm 0.8 mm, 1.5 mm 1.5 mm, 2 mm
Non-flush 3.0 mm 5.0 mm 5.0 mm 2.5 mm, 3 mm, 4 mm
1.12 1.12 1.14 1.15
DC 3/4 Wire Metal

AC 2-Wire Metal

AC/DC 2-Wire Metal

DC 2-Wire Metal

Cable Cable Cable

Connection Options Cable
Connector Connector Connector
Cable w/connector Cable w/connector Cable w/connector

Web Address: [Link]/inductives

Pigtail-style tubular
inductive sensors
Balluff now offers a variety of standard
inductive sensors with pigtail connectors.
These sensors are available with PUR
cable in 0.2 meter or 0.5 meter lengths.

M5Sensors-
Small
With the smallest
connectors on
the market!
Ideal for
– Currently available on ∅4 mm applications requiring
and M5 models small sensors with
– 4-pin version, pin configuration small connectors:
per IEC 60947-5-2
– IP 67 rated - Automation/handling
– Molded-on PUR cable with - In-die sensing
3 × 26 AWG
– Supply voltage 10...30 V

10 [Link] · 1-800-543-8390
 Tubular Inductive Sensors

Inductive
8 mm 12 mm 18 mm 30 mm
Smooth & Threaded Threaded Threaded Threaded
STD, 2X, 3X, 4X STD, 2X, 3X, 4X STD, 2X, 3X STD, 2X, 3X
1.5, 2 mm 2, 3, 4 mm 5, 8 mm 10, 15 mm
2.5, 3, 4, 6 mm 4, 6, 7, 8, 10 mm 8, 12, 16, 20 mm 15, 22,30,40 mm

Tubular
Style

Block
Style
Special
Duty

Cable Cable Cable Cable

Connector Connector Connector Connector
Cable w/connector Cable w/connector Cable w/connector Cable w/connector

[Link]/inductives

General Purpose Proximity Sensors

Balluff manufactures over 2,000 inductive proximity
sensor designs, many with specific applications in
mind. With so many choices, it can be difficult to
select the appropriate sensor solution.

Balluff’s GlobalProx sensors were designed to meet the

needs of general-purpose applications found in North
America as well as the rest of the world. This makes it
possible for Balluff to ensure global availability and
increased global standardization.

The GlobalProx family consists of a full series of 2-wire DC [Link]

and 3-wire DC sensors.

[Link] · 1-800-543-8390 11
Block Style Inductive Sensors

Block Style
Inductive
Sensors
5 x 5 mm 8x8,8x16 mm 8x16,10x30, 16.5 x 30 mm
Housing Size 20x30 mm Minisensor
Sensing distance STD STD, 2X, 3X STD STD
Flush 0.8 mm 1.5, 2, 3 mm 1.5, 2, 3 mm 2 mm
Non-flush 2.5, 3 mm
Pages:
DC 3/4 Wire

AC/DC 2-Wire

Cable Cable Cable

Cable
Connection Options Connector Connector
Connector
Cable w/connector

Web Address: [Link]/inductives

R03 & R04

New mini
plastic block Sensors
− 8x16x4, 1.5 mm Sn
− 10x30x6, 3 mm Sn
−
−
−
–
Commonly used in automation/handling
Fits in tight areas
Easy top mounting
PNP and NPN available on most units
R03
10x30x6
– Shielded version with 3 mm sensing distance
– Unshielded version with 3 mm sensing distance
– PNP and PNP units available

R04
8x16x4
– Long range in extremely small package
– Shielded version with 1.5 mm sensing distance
– Unshielded version with 2.5 mm sensing distance
– PNP and NPN units available
– Highly visible LED

12 [Link] · 1-800-543-8390
 Block Style Inductive Sensors

Inductive
26 x 40 mm 18x30,17.5x28 mm 25 x 50 mm 20 x 32 mm 42 x 48 mm
Midisensors
STD STD STD STD STD
2, 4 mm 5 mm 5, 7 mm 5 mm
5 mm

Tubular Style

Block
Style
Cable Cable Cable Cable Screw terminals Special
Connector Connector Cable w/connector Connector Duty
Cable w/connector

[Link]/inductives

R05 New midi-sensor

with corner cut-off
– 26 x 40 x 12 mm
− PNP NO and NC with S49 connector and cable
– NPN NO and NC with S49 connector and cable
– AC/DC 20...250 V, 130 mA short circuit protected,
cable versions NO/NC
– All Types available with 2 mm or 4 mm sensing distance
(2X Extended sensing range)

R01 Miniblock Sensors

[Link]

Mini size – Maximum performance

– Compact size with superior sensing range
– Rugged metal housing
– Narrow package can be used in applications where
standard tubular sensors are too large
– Fully embeddable in steel
– SlagMaster version available

[Link] · 1-800-543-8390 13