Position Sensing

SOLUTIONS
Linear, Rotary, Spring-Loaded,
Free-Core and Custom
Position Sensors

“Your Sensor
Business Partner”
About Macro Sensors
Macro Sensors Company History
Macro Sensors is "your sensor business partner...," solving
position measurement problems as an extension of the
customer's engineering resource. Macro Sensors designs and
manufactures highly accurate, extremely rugged position
sensors utilized in industrial and aerospace applications
worldwide.

Macro Sensors traces its origins directly to Herman Schaevitz

who founded Schaevitz Engineering in 1945. Mr. Schaevitz is Howard A. Schaevitz
widely recognized as the pioneer developer of LVDT Chairman of the Board
technology. He transformed the LVDT from a hand-made
laboratory device to the mission critical position sensor it is American Sensor Technologies (AST)
today and built Schaevitz Engineering into a successful AST was founded in 1997 by a professional management
enterprise with the LVDT as the core product. Following Mr. team with knowledge and experience in the MEMS-based
Schaevitz' retirement, he was succeeded as CEO by his son, sensor industry, along with the drive to manufacture
Howard, who presided over a decade of extraordinary products in the U.S. Their relationship provides AST both
corporate growth and product expansion. unique and complementary talents in development
engineering, marketing and business administration.
Collectively, the founders bring over 80 years of industry
experience to AST, assuring the company's ability to
manage fast-paced business growth while sustaining the
frequent introductions of new technologies and products.

Common applications of AST's sensor products are

industrial OEM, fluid power, hydraulic systems, fuel cells,
medical gases, HVAC/R, water management, oil & gas
exploration and off-road vehicles. By utilizing AST's
exclusive portfolio of sensor technologies including the
Macro Sensors Corporate Headquarters - Pennsauken, NJ USA proprietary Krystal Bond™ Technology, the specialized
needs of key niche markets can be supported. Many of
After the sale of Schaevitz Engineering to a larger firm,
AST's products offer UL/cUL, CSA and CE approvals in
Howard and several members of the Schaevitz "brain trust"
hazardous environments.
formed Macro Sensors, a division of Howard A. Schaevitz
Technologies, to design, manufacture and market position
sensors and related products. Macro Sensors' personnel
bring a level of knowledge and experience unrivaled in the
position sensor industry with more than 500 years of
cumulative design and manufacturing know-how. The
organization continues to flourish in the manner established
by its predecessors, fueled by an expanded product line and
customer driven design-for-application engineering.

In 2005, American Sensor Technologies (AST), a state-of-the-

art manufacturer of Krystal Bond™ Technology MEMS
pressure sensors, acquired Macro Sensors, thereby creating
a single source offering customers both pressure and
position sensing expertise at the highest level.

AST Corporate Headquarters - Mt. Olive, NJ USA

2 “quality products made in the USA”

 LVDT Basics
What is an LVDT? means that an LVDT features unlimited mechanical life with no
The letters LVDT are an acronym for Linear Variable source of friction.
Differential Transformer, an electromechanical transducer that Infinite Resolution and Repeatability
converts the rectilinear motion of an object to which it is Since an LVDT operates on electromagnetic coupling principles
coupled mechanically to a corresponding electrical signal. in a friction free structure, it can measure infinitesimally small
Structure of a typical LVDT changes in core position. This infinite capability is limited only
by the noise and resolution of the LVDT signal conditioner.
The figure below shows the components of a typical LVDT.
The internal structure consists of a primary winding centered Single Axis Sensitivity
between a pair of secondary windings symmetrically spaced An LVDT responds to motion of the core along the coil's axis,
about the primary. The coils are wound on a coil form, but is generally insensitive to cross axis motion of the core or
surrounded by a magnetic shield, and secured in a cylindrical to its radial position. Thus, an LVDT can usually function
housing. This coil assembly is usually the stationary element without adverse effect in applications involving misaligned or
of the position sensor. floating moving members, and in cases where the core doesn't
travel in a precisely straight line.
Housing and End Caps

Magnetic Shell Coil Form

Separable Coil And Core
Because the only interaction between an LVDT's core and coil
Coil Assembly
is magnetic coupling, the coil assembly can be isolated from
the core by inserting a non magnetic tube between the core
and the bore. By doing so, a pressurized fluid can be contained
Core within the tube, in which the core is free to move, while the
coil assembly does not have to be pressurized.

Environmentally Robust
Primary Winding
The materials and construction techniques used in assembling
Secondary Windings Encapsulation
an LVDT result in a rugged, durable sensor that is robust to a
variety of environmental conditions. Bonding of the windings is
The moving element of an LVDT is a separate tubular followed by epoxy encapsulation into the case, resulting in
armature of magnetically permeable material called the core. superior moisture and humidity resistance, as well as the
The core is free to move axially within the coil's bore, and is capability to take substantial shock loads and high vibration
mechanically coupled to the object whose position is being levels in all axes. Both the case and core are made of
measured. The bore is large enough to provide radial corrosion resistant metals, with the case also acting as a
clearance between the core and coil with no physical contact. supplemental magnetic shield. And for those applications
where the sensor must withstand exposure to flammable or
In operation, the LVDT's primary winding is energized by corrosive vapors and liquids or operate in pressurized fluid,
alternating current of appropriate amplitude and frequency, the case and coil assembly can be hermetically sealed using a
known as the primary excitation. The LVDT's electrical output variety of welding processes.
signal, which varies with the axial position of the core, is the
secondary winding differential AC voltage. Usually this AC Ordinary LVDTs operate over a very wide temperature range,
output voltage is converted a high level DC voltage or current and, if required, they can be produced to operate down to
that is more convenient to use. cryogenic temperatures, or at the elevated temperatures and
radiation levels found in many nuclear reactors.
Why use an LVDT?
LVDTs have significant features and benefits which derive Absolute Output
from its fundamental physical principles of operation and the An LVDT is an absolute output device, as opposed to an
materials and techniques used in its construction. incremental output device. This means that in the event of loss
of power, the position data being sent from the LVDT will not
Unlimited Mechanical Life and Friction Free Operation be lost. When the measuring system is restarted, the LVDT's
Because there is normally no contact between the LVDT's core output value will be the same as it was before the power
and coil structure, parts do not rub together or wear out. This failure occurred.

www.macrosensors.com 3
Markets
Energy
BENEFITS

High temperatures to 250 ºC

High pressure to 20,000 PSI

Radiation to 3 x 10 7 Rads

APPLICATIONS

Power generation

Hazardous locations

Down-hole pipeline monitoring

Factory Automation
APPLICATIONS

Product gaging

Process control
BENEFITS

Wide selection of measurement ranges

Non-linearity to 0.1%

Hermetically sealed

μm (micro-inch) resolutions

Analog I/O for PLC compatibility

Absolute measurement

Indicators / controllers

4 www.macrosensors.com
 Markets
Aerospace / Military
BENEFITS

COTS compatibility

High temperatures to 250 ºC

Hermetically sealed

APPLICATIONS

Control surface position

Engine control feedback

Thermal control

Submarine hatch

Pilot control inputs

Hydraulics / Pneumatics
APPLICATIONS

Spool valves

Cylinders

Booms
BENEFITS Valve position

Frictionless Actuators

Unlimited cycle life

Embedable

Excellent stroke to length ratio

www.macrosensors.com 5
Markets
Industrial OEM
BENEFITS

Cost effective solutions

Supply chain support

Integral or remote electronics

Custom design solutions

ISO 9001: 2000 certified

APPLICATIONS

Electro-mechanical systems

High volume product

Civil Engineering / R&D

APPLICATIONS

Structural monitoring

Test equipment

BENEFITS

Wide range of products

High vacuum operation

Submersible

Extensive selection of indicators and controllers

6 www.macrosensors.com
 Markets
Subsea / Marine
BENEFITS

High pressure to 20,000 PSI

Inconel / Monel construction

316L stainless steel construction

Long term reliability

20+ years survivability

APPLICATIONS

Control valves

ROV and exploration

Pipeline monitoring

Off-shore drilling and platforms

Transportation
APPLICATIONS

Railroad

Agricultural equipment

Road paving equipment

BENEFITS Off-road construction equipment

Unlimited cycle life

Hermetically sealed (IP-69K)

High shock to 1000 g

Vibration to 20 g (RMS)

www.macrosensors.com 7
Free-Core AC LVDTs
PR Series
Our Free-Core AC powered LVDT's are available The PR Series of AC LVDTs features excellent linearity and
high sensitivity and is a reliable and cost effective solution
in a wide varitey of sizes, measuring ranges for many position measurements. Available in either 0.750
and packages. Their robust construction allows inch or 0.812 inch diameters, these units are nominally
interchangeable with legacy units from other manufacturers.
them to be used for general purpose, harsh
environments or hazardous locations.

Scale approx. 1:2

Available in standard 0.750 inch [19 mm] or

0.812 inch [20.6 mm] diameter
Ranges of ±0.05 inches to ±10 inches
[±1.25 mm to ±250 mm]
0.031 [0.8 mm] or 0.062 [1.6 mm] radial core to
bore clearance
±0.25% maximum linearity error

CD Series MD Series
The CD Series of AC LVDTs features a compact The MD Series of sub-miniature AC LVDTs are designed to
package design for applications with size constraints. operate over millions of cycles without wear or degradation of
The low mass core also makes them well suited for signal quality in tight spaces. Ultra-low-mass cores allow
dynamic applications. them to be used for high response dynamic measurements.

Scale approx. 1:1

Scale approx. 1:1

GENERAL PURPOSE

Miniature 0.375 inch [9.5 mm] body diameter Miniature 0.188 inch [4.8 mm] body diameter
Low core mass Low core mass
Ranges of ±0.025 inches to ±2 inches Ranges of ±0.020 inches to ±0.100 inches
[±0.63 mm to ±50 mm] [±0.50 mm to ±2.5 mm]
±0.25% maximum linearity error ±0.5% maximum linearity error

8 www.macrosensors.com
 Free-Core AC LVDTs
HSA Series HSAR Series
The HSA Series AC LVDTs feature a welded stainless The HSAR Series offers all the benefits of the HSA with the
steel connector with glass sealed pins and are designed additional advantage of a radial connector for reduced
for use in harsh environments. installed length. Ranges of ±1 inch and above are rated to
300°F [150°C].

Scale approx. 1:2 Scale approx. 1:2

Available in standard 0.750 inch [19 mm] diameter Available in standard 0.750 inch [19 mm] diameter
Hermetically sealed against hostile environments Hermetically sealed against hostile environments
Ranges of ±0.05 inches to ±10 inches Ranges of ±0.05 inches to ±10 inches

HARSH ENVIRONMENTS & HAZARDOUS LOCATIONS

[±1.25 mm to ±250 mm] [±1.25 mm to ±250 mm]
±0.25% maximum linearity error ±0.25% maximum linearity error
Mating plug for connector included Through-bore design
Mating plug for connector included

SQ Series HLR Series

The SQ Series of AC LVDTs has been developed for use HLR Series AC LVDTs are UL listed for Class 1, Div 2,
in extremely harsh environments. They are epoxy Groups A, B, C, and D, and Class 1, Zone 2, Group IIC
encapsulated in heavy duty aluminum housings and are hazardous locations.
double shielded to enhance their immunity to noise and
external magnetic fields.

Scale approx. 1:4

Scale approx. 1:3

Heavyduty industrial design Available in standard 0.750 inch [19 mm] diameter
Ranges of ±0.50 inches to ±10 inches Stainless steel throughbore construction
[±12.5 mm to ±250 mm] Ranges of ±1 inch to ±10 inches
Splashproof design to IEC IP64* [±25 mm to ±250 mm]
300°F (150°C) operating temperature 1/2 inch conduit outlet for lead wires

*within temperature rating

300°F (150°C) operating temperature

www.macrosensors.com 9
Spring-Loaded AC LVDTs
GHSA Series
Macro Sensors offers a wide variety of spring- These heavy duty units use sleeve bearings to provide good
repeatability and extended service life in shop floor
loaded AC-powered LVDTs designed for applications. Three different configurations are available:
precision dimensional gaging and other factory the GHSA, with an axial connector for close mounting; the
GHSAR, with a radial connector for shorter installed length;
automation applications. and the GHSAR-A, an air extend/spring retract version with
a radial connector.

Scale approx. 1:2

Available in standard 0.750 inch [19 mm] diameter

Ranges of ±0.05 inches to ±2 inches
[±1.25 mm to ±50 mm]
Repeatability of 0.000025 inches or better
Mating plug for connector included

BBP/BBT Series GSA Series

These AC LVDTs utilize linear ball bearings to provide The GSA Series of short range spring loaded
exceptional repeatability and long service life. They position sensors were developed for cost sensitive
are available in 0.315 inch [8 mm] diameter plain body applications requiring LVDT reliability and performance.
and 0.375 inch [9.5 mm] diameter, either plain or
GENERAL PURPOSE GAGING

threaded body.

Scale approx. 1:2

Scale approx. 1:2

Ranges of ±0.04 inches to ±0.20 inches

[±1 mm to ±5 mm]
Repeatability of 0.000006 inches Ranges of ±0.10 inches to ±0.30 inches
(0.15 ìm) or better [±2.5 mm to ±7.5 mm]

Life exceeds 2 x 108 cycles ±0.5% maximum linearity error

Sealed to IEC IP65 Economical 3/4 inch size

Also available in air extend/spring retract versions

10 www.macrosensors.com
 Support Electronics
LVC 2500 Series
The LVC 2500 is a rugged, compact, din rail mount, Macro Sensors provides support electronics
single-channel signal conditioner for AC LVDTs that
operates on 10-30 V DC. Designed expressly for use in solutions for users, system integrators and
24 V systems with PLCs, it offers the user a choice of OEMS. These include AC/DC operated single-
three analog outputs.
channel and dual channel microprocessor-
based controllers and indicators with digital
readout and setpoint control for both AC and
DC LVDT's.

Scale approx. 1:3

10-30 V DC operation
Outputs of 0 to 10 V DC, 0 to ±10 V DC, or 4-20 mA
DIN rail mounting
Adjustable span and zero
User selectable gain and excitation frequencies
Synchronizable oscillator

DMC Series DMI Series

The DMC Series is an accurate, high performance, The DMI Series is an accurate, high performance,
programmable dual-channel controller. programmable single-channel indicator.

115/230 V AC power line operation; 12/24 V DC (optional) 115/230 V AC power line operation F o r A C & D C LV D Ts
0-10 V DC single analog output; 4-20 mA (optional) Supports all standard AC LVDTs (DMI-A1)
RS232C serial communications or 24 V powered DC LVDTs (DMI-D1)

Four independently programmable set points 12/24 V DC powered operation (optional)

to control four 5 A Form A relays 0-10 V DC single analog output (optional)
Supports all standard AC LVDTs (DMC-A2) RS232C serial communications (optional)
or 24 V powered DC LVDTs (DMC-D2) Four independently programmable set points
PC-software configurable to control four 5 A Form A relays (optional)
Scrolling prompts for easy meter setup

www.macrosensors.com 11
Free-Core and Spring-Loaded DC LVDTs
HSD Series
Macro Sensors pre-calibrated DC-powered LVDTs The HSD Series of precalibrated DC LVDTs is designed for
operation in hostile environments. The standard HSD
are designed for a wide range of industrial includes an in-line, hermetically-sealed, stainless steel
applications. Free-core and spring-loaded models connector, while a radial version (HSDR) with a through-
bore design allows easy cleaning and reduced installed
are offered in a variety of mechanical length. A mating plug is also included.
configurations and include built-in electronics for
the following standard I/O configurations:

• 24 V DC input, true 0-10 V DC output, Scale approx. 1:2

3-wire, single-ended electronics

• ±15 V DC input, 0 to ±10 V DC output Available in standard 0.750 inch [19 mm] diameter
Precalibrated ranges of 0.10 inches to 20 inches
• 4-20 mA loop powered or ±0.05 inches to ±10 inches
[2.5 mm to 500 mm or ±1.25 mm to ±250 mm]
±0.25% maximum linearity error, ±0.1% optional
Operate in hostile environments

S Series GHSD Series

The S Series consists of general purpose, free- core The heavy duty GHSD includes an axial connector for close
DC LVDTs that utilize built-in electronics to provide the mounting. It is also available with a radial connector for
desirable features of an AC LVDT, while offering the shorter installed length (GHSDR) or in an air extend/spring
convenience of DC input and pre-calibrated DC output. retract version with a radial connector (GHSDR-A).

Scale approx. 1:2

Scale approx. 1:2

Available in standard 0.750 inch [19 mm] diameter Available in standard 0.750 inch [19 mm] diameter
Precalibrated ranges of 0.10 inches to 20 inches Ranges of 0.10 inches to 4 inches
or ±0.05 inches to ±10 inches or ±0.05 inches to ±2 inches
[2.5 mm to 500 mm or ±1.25 mm to ±250 mm] [2.5 mm to 100 mm or ±1.25 mm to ±50 mm]
±0.25% maximum linearity error, ±0.1% optional ±0.1% or ±0.25% maximum linearity error
Economical, general purpose DC LVDTs Low pressure air extend/spring retract version

12 www.macrosensors.com
 Long Stroke and Rotary Position Sensors
LP Series
LP Series infinite life position sensors offer frictionless operation, enhanced
stroke to length ratios, high resolution, excellent repeatability, and low hysteresis.
They are particularly suited for use where installation space is limited. These
rugged sensors are contructed of stainless steel, and are hermetically sealed
against hostile environments to IEC standard IP-68.

Scale approx. 1:3

Potentiometer replacement; unlimited cycle life

Available in standard 0.750 inch [19 mm] diameter
Ranges of 4.0 inches to 40.0 inches [100 mm to 1000 mm]
±0.25% maximum linearity error, ±0.1% optional
Available with the following standard I/O configurations:
24 V DC input, true 0-10 V DC output, 3-wire, single-ended
5 V DC input, 0.5 to 4.5 V DC output
4-20 mA loop powered

RSE 1500 Series

The Macro Sensors RSE 1500 series of
contactless, fractional turn rotary position sensors
Scale approx. 1:1
provide an output proportional to shaft rotation
with a true zero to 10 V DC output. RSE 1500
series rotary sensors are enclosed in a 1-1/2 inch
diameter anodized aluminum shell, and have a
0.250 inch stainless steel shaft running in high
performance ball bearings.

0° to 30°, 60°, 90°, or 120° rotational ranges

Full 360° rotation contactless technology
Non-linearity less than ±0.1% of FRO
DC voltage absolute analog outputs
Environmentally sealed to IEC IP-66
Integral DC-in / DC-out electronics

www.macrosensors.com 13
Custom OEM Designs

Macro Sensors has a library of over 800 custom

High Pressure
designs. Our engineering team will work closely
with your company to offer the most cost-effective
solution to your measurement challenges.

Flange mount

Spring loaded

Up to 5000 psi

Monel / Inconel High Temperature

High pressure up to 5000 psi Up to 200 °C

Submersible Ruggedized design

Subsea Rod-eye end connections

14 www.macrosensors.com
 Custom OEM Designs
Hazardous Locations Remote Electronics

Explosion-proof Hostile environments

Weather-proof UL approved

Wide range of operating temperatures High level outputs

(0-10 V, 4-20 mA, 0.5 - 4.5 V, etc.)

Military / Aerospace In-Cylinder Mounting

Flight qualified Frictionless

High reliability High pressure hydraulics

COTS High stroke to length ratio

www.macrosensors.com 15
Some of our business partners are...

7300 US Route 130 North, Bldg. 22

Pennsauken, NJ 08110-1541 USA
tel: 856-662-8000
fax: 856-317-1005
www.macrosensors.com
[email protected]

All specifications subject to change without notice.

© 2008 Macro Sensors 08/08