Sensing products to boost welding productivity

Weld Select Series

Weld Select Series Weld Select is an industry proven group of Balluff products designed for use in the most inhospitable welding environments.
Poor sensor selection costs welders in every industry increased downtime, unnecessary maintenance, delayed delivery, and lost profits. Now Balluff presents a complete package of welding solutions that extends sensor life and increases productivity in the harshest welding environments. This guide contains two sections. The front section is designed to help all plant levels identify existing issues and offer Balluff-developed solutions to address them. The second section, beginning on page 10, offers an extensive list of products developed by Balluff welding experts from valuable customer input. These products have been tested in the harshest welding environments and provide significant process and part quality improvement.

n Stop Wasting Sensors and destroying connectors n Change the Paradigm of accepted high volume sensor usage n Reduce Downtime due to sensor failure n Slash Consumption of sensors and connectors n Boost Profitability throughout the plant Examples of common weld cell problems that we've solved:
Unprotected and non-bunkered sensors, sensors in damage-prone areas, and/or lighweight brackets. Damage to unprotected sensor faces and cables caused by impact and contact. Slag accumulation and unprotected pigtail sensors cause large amounts of downtime.

Bunker Blocks and SlagMaster coating allow full protection against harsh impact.

Weld Repel Wrap and TPE cables provide flexibility and resistance to weld slag, lubricants, and connector burn-through.

PTFE coated Prox-Mounts and Weld Repel tubing over sacrificial cables improve sensor life and productivity.

n Welding Application Reports n Industry Articles n Sensor Information n Case Studies

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2 www.balluff.com/welding

Welding Environment
Non-contact inductive proximity sensors must perform a wide variety of clamping and nesting indication, and Poka-Yoke functions in harsh welding environments. Hot weld slag accumulation, elevated ambient temperatures, and strong electromagnetic fields emitted by weld guns can cause false triggering and degrade sensor performance.

WELDING CONCERNS
Weld Slag

PROBLEM
Hot welding slag (a.k.a. weld debris, weld spatter, weld berries) sticks to sensor faces and bodies and causes premature failure of sensors in weld cells.

SOLUTION
Balluff SlagMaster coating on sensor faces resists weld debris and provides a thermal barrier, significantly enhancing sensor longevity, and reducing false triggering. PTFE coated sensor bodies resist weld debris accumulation and promote slag removal during regular scheduled maintenance periods.

Electromagnetic Weld Fields

PROBLEM
Strong electromagnetic fields cause conventional sensors to false trigger or chatter.

SOLUTION
Balluff inductive proximity and magnetic field sensors with weld field immunity (WFI) resist electromagnetic fields emitted by weld guns up to 100 kA/m.

Loading Impact
Incidental sensor damage caused by parts loading impact can significantly degrade sensor performance, shorten sensor life, or even destroy a sensor. Balluff SteelFace inductive proximity sensors can withstand multiple heavy impacts and abrasion, and often have the sensing range to be placed out of harms way.

LOADING IMPACT
Damage from Loading Impact

PROBLEM
Severe loading impact and continuous operational impact damages plastic and/or PTFE sensor faces as well as sensor bodies.

SOLUTION
Every precaution should be taken to prevent electronics such as sensors from being hit, but in many cases, loading impact cannot be avoided. By nesting a Balluff SteelFace inductive proximity sensor into a rugged Prox Mount or Bunker Block, the likelihood of premature failure becomes lessened, even with repeated impact over time.

Sensor Face Damaged by Impact

PROBLEM
Standard tubular sensors often fail from damage to the sensor face and coil caused by slag and impact. Over time, small repeated impacts can damage the face and lead to sensor failure.

SOLUTION
Balluff SteelFace inductive proximity sensors with extended range and stainless steel housings resist impact, providing long life in weld cell impact zones. Balluff Bunker Blocks and Prox Mounts provide sensors an extraordinary degree of physical protection, preventing contact damage to the sensor body and face as well as rapid sensor removal and replacement without need for recalibration.

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Cylinder & Clamp Position

Parts welded in a robotic weld cell must be nested and held in place by pneumatically or hydraulically actuated clamps which are often equipped with sensors located in the clamp jaws to indicate clamped or unclamped position. Clamp position can also be determined by magnetic field sensors located on the outer wall of an aluminum or composite pneumatic cylinder. To determine clamping position, a Balluff BMF magnetoresistive sensor tracks the magnetic field emitted by a magnet attached to the cylinders piston. In high-pressure hydraulic cylinders, Balluff StrokeMaster end-of-stroke sensors detect the spud or cushion of a piston shaft to sense clamp position.

CYLINDER & CLAMP

Cylinders & Clamps Need Stroke Detection

PROBLEM
High-pressure hydraulic welding clamps need the right sensors to accurately sense piston extend/retract position and may require electronic weld field immune sensors.

SOLUTION
Balluff StrokeMaster high pressure-rated end-of-stroke sensors accommodate pressures up to 3,000 PSI and fit virtually all common cylinder brands and bore sizes. StrokeMaster heads swivel to direct connector wiring away from weld hostility.

Premature Reed Switch Failure

PROBLEM
When installed on pneumatic clamping cylinders, failure-prone reed switches and drift-prone Hall Effect sensors deteriorate, often providing inaccurate switch points before failing completely.

SOLUTION
Balluff BMF magnetoresistive sensors come with a lifetime warranty and fit virtually all cylinder housing styles and brands. They provide precise switch points and withstand the rigors of the weld process, while providing wear free, non-contact reliability.

Photoelectric Sensors
Photoelectric and fiber optic sensors require special protection and mounting expertise when integrated into welding cells. Balluff has a wide range of photoelectrics with application-specific infrared, red, or laser capability that can reliably sense through smoke, oil and dirt. In addition, Balluff provides a range of accessories that protect photoelectric optics from heat, slag, and lens occlusion in the hostile weld cell environment.

PHOTOELECTRICS
Fiber Optic Limitations

PROBLEM
Fiber optics can become occluded in the weld cell and stop functioning. They can become broken when weld fixtures are removed, causing fibers to vibrate loose. Cables with excess length break when tied back and get damaged by slag.

SOLUTION
Typically, fiber optic solutions are not the best choice in weld cells. Metal-body laser sensors or inductive proximity sensors are almost always a better choice.

Damage by Loading Impact

PROBLEM
Impact-prone photoelectric sensors can easily become physically damaged in welding environments.

SOLUTION
Bunker Blocks and Prox Mounts can be used to protect tubular photoelectric sensors. They provide a thermal barrier, protect against weld slag and impact, and provide rapid sensor change out. Bunker Blocks, available in several sizes and styles, protect block style photoelectric sensors in the weld environment.

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Protecting Connectivity
Weld cells demand the toughest connectivity solutions. Hot debris, cable flex, UV radiation, and high ambient heat can damage peripheral devices. PVC jacketed sensor connectors, fine for clean and dry applications, are generally unsuitable for welding environments. Today, PUR (polyurethane) connector jacketing is being replaced with superior high-flex, chemical-resistant TPE (thermoplastic elastomer) jacket materials that can better withstand well cell punishment. Now, TPE connectivity components teamed with Balluff Weld Repel products can result in reduced weld cell material costs and downtime plus increased system longevity and overall profitability.

S
Sensor Cable Burn-Through

CONNECTIVITY
PROBLEM
Weld slag burns through and destroys conventional cabling. Its weight often pulls the cable away from the connector, exposing it to even more damage.

SOLUTION
Balluff TPE cables provide exceptional burn-through resistance. Especially in conjunction with Balluff Weld Repel tubing, typical problems with insulation burn through disappear. When self-bonding Weld Repel wrap is used to attach Weld Repel tubing to the sensor connector, all gaps allowing debris are eliminated while remaining transparent for viewing LEDs. Use Weld Repel area protection sheets to protect large areas from debris.

Network I/O Blocks Damaged

PROBLEM
Sensor connections often terminate into plastic junction blocks or network blocks which can easily be damaged in welding cells.

SOLUTION
A rugged line of industrial I/O products designed for use in the harshest environments offer a greater degree of strength and durability for applications like robotic welding cells. Most major bus and Ethernet based industrial networks are supported and provide detailed diagnostics on the connections from short circuit protection to network status. In the dark confines of a weld cell, the bright and large LEDs are easy to see.

Non-Contact Connectors
Interchangeable weld fixtures and rotating weld tables often require the use of troublesome, expensive, and high-maintenance contact-based rotating assemblies such as slip rings or commutator ring/brush solutions. In many cases wires inevitably fray and break. In contrast, Balluffs unique non-contact connectors provide a wear free connectivity, powering sensors and providing control information across an air gap.

NON-CONTACT
Broken or Worn Out Communicator Rings

PROBLEM
Rotational weld cells, or cells that use interchangeable fixtures, often incur high maintenance and frequent stoppages due to damaged slip rings, tangled, over-flexed, or twisted wiring.

SOLUTION
Non-contact connector systems provide communication between two or more separated weld cell components through an air gap to energize and communicate between the controller and the sensors. Because there is no hard wired connection, weld fixtures can be inserted into a weld cell frame without the need for mechanical connections, facilitating rapid change out, and improved operator safety.

How Non-Contact Connectors Work

Think of this like a mechanical connector without pins or the requirement of physical contact. When connected, power goes out to the devices and signals come back from the devices. Depending on the specific product of interest, different information can be passed. Power only or power plus, discrete inputs and outputs, or analog voltage signals can be transmitted across the air gap. Each base head is mounted on the controller side of the application and as many remote heads as needed are mounted on the sensors/actuators side of the application.

<15mm Multiple Sensors Remote Base PLC

Signal Power

Signal Power

Signal Power

Inductive Coupling
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Robot Zone Limit Systems

Balluff zone limit systems are hardware kits that provide diverse, complementary, and redundant position monitoring for up to three robot axes. Designed to interface with a user-supplied safety monitoring relay or safety PLC, Balluff zone limit systems include all mounting hardware, complementary redundant cams, and the proven Balluff multiple position limit switch, available in either mechanical or non-contact inductive configurations. These robust systems install easily and provide the flexibility to adjust zone angles and zone location, while providing a control-reliable means to mute personnel sensing devices when the robot is safely out of the way.

ROBOT ZONE LIMIT

Increased Productivity and Safety within Robotic Weld Cells

Pre-Engineered Automation System: Fanuc ArcMate Robot with Lincoln Electric Welding Package, featuring the Balluff zone limit system.

PROBLEM
Wherever a human operator must share workspace with a robot, theres no question that safety is the highest priority. When a person enters a robotic work cell, the robot must be safely idled. But this idle time results in a loss of the robots productivity.

SOLUTION
Enter Balluffs robot zone limit systems. These pre-engineered hardware kits let you recapture that lost productivity, while maintaining complete operator safety. Finally, you dont have to sacrifice productivity to keep your floor team safe.

Axis Zone Limit System

Balluff Axis 1 Zone Limit System The Axis 1 position of the robot is directly detected by the Balluff zone limit system. As long as the robot is safely away from the operator-occupied area of the cell, the safety light curtain is muted and the robot remains operational.

Balluff Axis 2 Zone Limit System Some applications may require the robot arm to traverse past an operator to go to another area of the cell. By implementing a zone limit system on Axis 2 (commonly called boom back), the robot can pass in front of the operator with the arm safely retracted without shutting down the robot, even though the operator is present.

Balluff Axis 3 Zone Limit System Axis 3 zone limit systems are sometimes referred to as flip over switches. Some robots have the capability to reach backwards. In these cases, an Axis 1 zone limit system is not sufficient to determine the actual position of the robot arm.

Inductive Sensors SlagMaster coating

SlagMaster coating significantly prolongs sensor life by providing a thermal barrier to protect against heat, retarding build up of 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 14. Order Code Sensing Distance Output Logic Housing Material Wiring Diag. Drawing Dimensions A B C Connection

3-Wire DC, Non-Weld Field Immune, SlagMaster M8 Tubular, Flush, 1030VDC, Non-Weld Field Immune BES02P5 BES02P0 BES02P1 BES02PN BES02PU BES0149 BES0388 BES02PW 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 3 mm PNP, N/O PNP, N/O NPN, N/O NPN, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O Stn. Stl. Stn. Stl. Stn. Stl. Ni CuZn Ni CuZn Stn. Stl. St. Bk Zn Chromate Ch CuZn A A B B A A A A 5 1 1 1 1 1 5 1 30 45 45 65 65 43 20.5 66 30 34.5 34.5 45 45 28.5 20.5 40 M8 M8 M8 M8 M8 M8 M8 M8 M12, 0.3m PUR Pigtail M8 M8 M12 M12 M12 M12, 1.0m PUR Pigtail M12

M8 Tubular, Quasi Flush, 1030VDC, Non-Weld Field Immune M12 Tubular, Flush, 1030VDC, Non-Weld Field Immune BES0450 BES035R BES03UP BES02P3 BES02P4 BES02PM BES02PR BES03ZL BES02PL BES02PT BES0314 BES02KY BES0455 BES0456 4 mm 4 mm 4 mm 8 mm 8 mm 7 mm 7 mm 7 mm 7 mm 7 mm 7 mm 7 mm 20 mm 30 mm PNP, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, Comp PNP, N/O PNP, Comp PNP, Comp CuZn Ni CuZn CuZn Ni CuZn Ni CuZn GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn PBT PBT A A B A B A A A A A D A D D 1 1 1 1 1 2 2 2 2 2 2 2 3 5 45 70 45 44.5 44.5 32 32 32 32 32 32 32 62 62 30 40 30 29.5 29.5 20 20 20 20 20 20 20 40 40 M12 M12 M12 M18 M18 8 8 8 8 8 8 8 40 40 M12 M12 M12 M12 M12 M12, 0.2m TPU Pigtail M8, 0.2m PUR Pigtail M8, 1.5m PUR Pigtail, Irradiated 5m, PUR, Irradiated M12, 0.2m PUR Pigtail M12, 0.2m PUR Pigtail w/WeldRepel Tubing M8, 0.2m PUR Pigtail w/WeldRepel Tubing M12 M12

M18 Tublar, Flush, 1030VDC, Non-Weld Field Immune

20mm x 32mm Block, Flush, 1030VDC, Non-Weld Field Immune

40mm x 40mm Cube, Flush, 1030VDC, Non-Weld Field Immune 40mm x 40mm Cube, Non-Flush, 1030VDC, Non-Weld Field Immune

PNP, N/O

Polarized N/O

Non-Polarized, N/O

NPN, N/O

PNP, Comp

AC/DC, N/O

10

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Order Code

Sensing Distance

Output Logic Housing Material

Wiring Diagram

Drawing

Dimensions A B C

Connection

2-Wire DC, Non-Weld Field Immune, SlagMaster M8 Tubular, Flush, 2-Wire DC, 1030VDC, Polarized, Non-Weld Field Immune BES00C0 BES0324 BES00C1 BES0326 BES0329 BES032A 2 mm 2 mm 3 mm 3 mm 7 mm 15 mm N/O N/O N/O N/O N/O N/O CuZn CuZn CuZn CuZn CuZn CuZn C C C C C C 1 5 1 5 5 5 50 40 50 43 46 42.5 29.5 40 35.5 40.5 40 40 M8 M8 M12 M12 M18 M30 M12 M12, 0.3m PUR Pigtail M12 M12, 0.3m PUR Pigtail M12, 0.3m PUR Pigtail M12, 0.3m PUR Pigtail

M12 Tubular, Flush, 2-Wire DC, 1030VDC, Polarized, Non-Weld Field Immune

M18 Tubular, Flush, 2-Wire DC, 1030VDC, Polarized, Non-Weld Field Immune M30 Tubular, Flush, 2-Wire DC, 1030VDC, Polarized, Non-Weld Field Immune 20mm x 32mm Block, Flush, 1030VDC, Non-Polarized, Non-Weld Field Immune BES03TM 5 mm N/O GD-ZN E 2 32 20 8 M12, 0.2m PUR Pigtail

2-Wire AC/DC, Non-Weld Field Immune, SlagMaster M12 Tubular, Non-Flush, 3-Wire AC/DC, 20250V AC/DC, Non-Weld Field Immune BES044A 4 mm N/O Stn. Stl. F 1 70 40.5 M12 1/2-20 UNF - 2A High Temperature 120 C, Non-Weld Field Immune, SlagMaster M8 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune BES02HY BES02HZ BES032K BES02J3 2 mm 2 mm 5 mm 5 mm PNP, N/O PNP, N/O PNP, Comp PNP, N/O Stn. Stl. Ni CuZn Ni CuZn GOAISi12 A A D A 1 1 1 4 55.5 75 83 50 55.5 40.5 60 25 M8 M12 M18 10 PTFE, 3m Cable Silicon, 3m cable M12 Silicon, 3m cable M12 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune M18 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune M30 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune

Sensing face C

46

4.2 15
30

40

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets. 11

Inductive Sensors Slag resistant housing

PTFE-coating helps prevent hot weld slag from sticking to the metal sensor body. In areas where weld slag is inevitable, the slick PTFE-coating makes it easier to quickly remove the weld slag without damaging the sensor. The parts listed below are non-weld field immune.

Order Code

Sensing Distance

Output Logic

Housing Material

Wiring Diagram

Drawing

Dimensions A B C

Connection

2-Wire DC, Non-Weld Field Immune, PTFE Coated M8 Tubular, Flush, 2-Wire DC, 1036VDC, Polarized, Non-Weld Field Immune BES039R BES039T BES03H7 BES039U BES039W BES03HL BES03FH BES03FJ BES0398 BES027K BES03KL BES03FR 2 mm 2 mm 2 mm 3 mm 3 mm 3 mm 7 mm 7 mm 7 mm 15 mm 15 mm 15 mm N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O CuZn CuZn CuZn CuZn CuZn CuZn CuZn CuZn CuZn CuZn CuZn CuZn C C E C C E C C E C C E 1 3 1 1 3 1 1 3 1 3 1 1 50 40 50 50 43 50 51 46 51 42.5 51 51 29.5 40 29.5 35.5 40 35.5 35 40 35 40 35 35 M8 M8 M8 M12 M12 M12 M18 M18 M18 M30 M30 M30 M12 M12, .3m PUR Pigtail, Irradiated M12 M12 M12, .3m PUR Pigtail, Irradiated M12 M12 M12, .3m PUR Pigtail, Irradiated M12 M12, .3m PUR Pigtail, Irradiated M12 M12

M8 Tubular, Flush, 2-Wire DC, 1036VDC, Non-Polarized, Non-Weld Field Immune M12 Tubular, Flush, 2-Wire DC, 1036VDC, Polarized, Non-Weld Field Immune

M12 Tubular, Flush, 2-Wire DC, 1036VDC, Non-Polarized, Non-Weld Field Immune M18 Tubular, Flush, 2-Wire DC, 1036VDC, Polarized, Non-Weld Field Immune

M18 Tubular, Flush, 2-Wire DC, 1036VDC, Non-Polarized, Non-Weld Field Immune M30 Tubular, Flush, 2-Wire DC, 1036VDC, Polarized, Non-Weld Field Immune

M30 Tubular, Flush, 2-Wire DC, 1036VDC, Non-Polarized, Non-Weld Field Immune

PNP, N/O

Polarized N/O

Non-Polarized, N/O

+/-

-/+

NPN, N/O

PNP, Comp

AC/DC, N/O

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Inductive Sensors Ultra high temperature-resistant sensors

For applications that require reliable sensor function at high ambient temperature, Balluff offers high temperature-resistant sensors. Capable of operating in temperatures as high as 160 F, Balluff high temperature sensors meet either IP67 or IP69 ratings. The following sensors are non-weld field immune.

Order Code

Sensing Distance

Output Logic

Housing Material

Wiring Diagram

Drawing

Dimensions A B C D

Connection

High Temperature 120 C, Non-Weld Field Immune, SlagMaster M8 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune BES02HY BES02HZ BES032K BES02J3 2 mm 2 mm 5 mm 5 mm PNP, N/O PNP, N/O PNP, Comp PNP, N/O Stn. Stl. Ni CuZn Ni CuZn GOAISi12 A A D A 1 1 1 4 55.5 75 83 50 55.5 40.5 60 25 M8 M12 M18 10 PTFE, 3m Cable Silicon, 3m cable M12 Silicon, 3m cable M12 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune M18 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune M30 Tubular, Flush, High Temperature 120 C, 1030VDC, Non-Weld Field Immune High Temperature 160 C, IP69 Rated, Non-Weld Field Immune, Non-SlagMaster Coated M18 Tubular, Flush, High Temperature 160 C, 1030VDC, Non-Weld Field Immune BES043T BES043U BES043W BES043Y 5 mm 8 mm 10 mm 15 mm PNP, N/O PNP, N/O PNP, N/O PNP, N/O Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. A A A A 1 2 1 2 80 80 85 85 60 60 65 65 M18 M18 M30 M30 10 8 FEP, 2m cable FEP, 2m cable FEP, 2m cable FEP, 2m cable M18 Tubular, Non-Flush, High Temperature 160 C, 1030VDC, Non-Weld Field Immune M30 Tubular, Flush, High Temperature 160 C, 1030VDC, Non-Weld Field Immune M30 Tubular, Non-Flush, High Temperature 160 C, 1030VDC, Non-Weld Field Immune

A
B A

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets. 13

Inductive Sensors Weld Field Immune

Weld field immune inductive sensors are used for work-piece positioning in welding areas where strong magnetic fields influence ordinary sensors oscillator/coil systems. This leads to false switching when no target is present. Balluff weld field immune inductive sensors can be mounted in the direct vicinity of welding tongs or electrodes, since welding currents of up to 100 kA do not affect the switching function of the sensor. Order Code Sensing Distance Output Logic Housing Material SlagMaster Coating Wiring Diagram Drawing Dimensions A 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 2 61 61 61 61 65 65 61 61 50 65 65 83 80 65 65 65 65 65 50 65 65 65 65 65 65 B 40 40 40 40 50 50 35 35 26 40 40 50 59.5 40 50 50 30 30 25.5 40 40 40 50.5 50.5 27 C M12 M12 M12 M12 M12 M12 M12 M12 M12 M18 M18 M18 M18 M18 M18 M18 M18 M18 M18 M30 M30 M30 M30 M30 M30 13 10 10 10 5 5 10 D M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 Connection

M12 Flush Tubular, 1030VDC, Weld Field Immune BES02J4 BES02J5 BES02J6 BES02J8 BES02K1 BES02K2 BES02JM BES02JN BES02JY BES02J9 BES02JA BES02JC BES02JE BES02JF BES02KC BES02KE BES02JP BES02JR BES02K8 BES02JH BES02JJ BES02JL BES02KL BES03F1 BES02JU 2 mm 2 mm 2 mm 2 mm 3 mm 3 mm 4 mm 4 mm 8 mm 5 mm 5 mm 5 mm 5 mm 5 mm 7 mm 7 mm 8 mm 8 mm 12 mm 10 mm 10 mm 10 mm 13 mm 13 mm 15 mm PNP, Comp PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PTFE Stn. Stl. PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE Stn. Stl. PTFE Stn. Stl. PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn n n n n n n n n n B A A A A A A A A A A A A A A A A A A A A A A A A

M12 Non-Flush Tubular, 1030VDC, Weld Field Immune

M18 Flush Tubular, 1030VDC, Weld Field Immune

M18 Non-Flush Tubular, 1030VDC, Weld Field Immune

M30 Flush Tubular, 1030VDC, Weld Field Immune

M30 Non-Flush Tubular, 1030VDC, Weld Field Immune

Balluffs BunkerProx is a rugged, self-bunkering M18 inductive proximity sensor specially designed to survive longer in abusive welding applications without external protection. The strong, massively thick housing has the ability to withstand repeated mechanical impacts and also serves as an intermittent heat sink to shield the sensor electronics from the intense heat of red-hot weld slag. A frontal impact deflection ring helps protect the high-temperature ceramic face from impact damage during part loading and unloading. BUNKERPROX Order Code Sensing Distance Output Logic Housing Material SlagMaster Coating Wiring Diagram Drawing Dimensions A 1 65 B 50 C M18 D M12 Connection

M18 Flush Tubular, 1030VDC, Weld Field Immune BES03MY 4 mm PNP, N/O PTFE CuZn n A

14

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Order Code

Sensing Distance

Output Logic

Housing Material

SlagMaster Coating

Wiring Diag.

Drawing

Dimensions A B 20 20 20 20 20 20 20 20 20 C 8 8 8 8 8 8 8 8 8 D

Connection

Block 20 x 32, Flush 1030VDC, Weld Field Immune BES02KR BES0313 BES02KT BES02KU BES01W7 BES01W8 BES01W9 BES01WC BES02KW 5 mm 5 mm 5 mm 5 mm 5 mm 5 mm 5 mm 5 mm 5 mm PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn GD-Zn n n n n n A A A A A A A A A 3 3 3 3 3 3 3 3 3 32 32 32 32 32 32 32 32 32 M12 PUR .2m Pigtail M12 PUR .2m (Irradiated) Pigtail w/WeldRepel Tubing M12 PUR .2m Pigtail M12 PUR .2m Pigtail w/ WeldRepel Tubing M8 PUR .2m Pigtail M12 PUR .5m Pigtail M8 PUR .5m Pigtail 3m PUR (Irradiated) Cable M12 5m PUR (Irradiated) Pigtail M20 x 1.5 Conduit M12 1/2-20 UNF - 2A 1/2-20 UNF - 2A 1/2-20 UNF - 2A 1/2-20 UNF - 2A 44 44 1/2-20 UNF - 2A 1/2-20 UNF - 2A M12 M12 M12 M12 M12 M12

Block 20 x 32, Flush 1030VDC, Weld Field Immune BES0230 BES0231 BES02KZ BES02L0 BES02L3 BES02L4 BES02L1 BES02L2 BES022L BES0215 BES021C BES021J BES021L BES021M 15 mm 15 mm 5 mm 5 mm 5 mm 5 mm 5 mm 5 mm 15 mm 15 mm 25 mm 35 mm 35 mm 40 mm PNP, N/O PNP, N/O N/O N/O N/O N/O N/O N/O PNP, Comp PNP, Comp PNP, Comp PNP, Comp PNP, Comp PNP, Comp PBT PBT PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PBT PBT PBT PBT PBT PBT n n n n A A C C C C C C B B B B B B 4 4 1 1 1 1 5 5 6 6 6 6 6 6 120 132.5 80 80 80 80 67 67 62 62 62 62 62 62 40 40 46 46 46 46 35.5 35.5 40 40 40 40 40 40 40 40 M18 M18 M18 M18 M18 M18 40 40 40 40 40 40

M18 Flush Tubular, 20250V AC/DC, Weld Field Immune

M18 Flush Tubular, 20250V AC/DC, Weld Field Immune

40mm x 40mm Cube, Flush, 1030VDC, Weld Field Immune

40mm x 40mm Cube, Non-Flush, 1030VDC, Weld Field Immune

PNP, N/O

PNP, Comp

AC/DC, N/O

C
D

B
46 7.3 B

46

60

5.3

6.5

7.3

30

30 40

D
C
40

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets. 15

Inductive Sensors Factor 1 - Weld Field Immune

Balluff Factor 1 sensors have special dual coil electronic circuitry whose function is unaffected by strong magnetic fields found in processes such as induction hardening and welding environments. They also come equipped with PTFE-coated housings resistant to weld splatter. Factor 1 sensors detect all metals at the same distance. There is no need to de-rate the sensing distance based on target material. Factor 1+ sensors provide greater switching distances for increased performance. Order Code Factor 1 M8 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1 BES02YT BES02YR BES02JZ BES02K0 BES02K3 BES02K4 BES02JW BES02K5 BES02K6 BES02K9 BES02KA BES02KJ BES02KK BES02K7 BES02KF BES02KH BES02KM BES02KN BES02KP BES03MZ 1.5 mm 1.5 mm 3 mm 3 mm 3 mm 3 mm 8 mm 8 mm 8 mm 5 mm 5 mm 5 mm 5 mm 12 mm 12 mm 12 mm 10 mm 10 mm 20 mm 20 mm PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PTFE Stn. Stl. PTFE Stn. Stl. PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn n n n n n n n n A A A A A A A A A A A A A A A A A A A A 1 1 1 1 1 1 3 3 3 1 1 1 1 3 3 3 1 1 3 3 57 49 50 50 65 65 50 65 65 50 50 65 65 50 65 65 65 65 65 65 40 40 36 36 50 50 26 40 40 35 35 50 50 25.5 40.5 40.5 50.5 50.5 37.5 37.5 M8 M8 M12 M12 M12 M12 M12 M12 M12 M18 M18 M18 M18 M18 M18 M18 M30 M30 M30 M30 13 13 10 10 10 10 10 10 M12 M8 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 Sensing Distance Output Logic Housing Material SlagMaster Coating Wiring Diagram Drawing Dimensions A B C D Connection

M12 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1

M12 Non-Flush Tubular, 1030VDC, Weld Field Immune - Factor 1

M18 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1

M18 Non-Flush Tubular, 1030VDC, Weld Field Immune - Factor 1

M30 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1

M30 Non-Flush Tubular, 1030VDC, Weld Field Immune - Factor 1

PNP, N/O

PNP, Comp

PNP, Monitor

16

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Order Code

Sensing Distance

Output Logic

Housing Material

SlagMaster Coating

Wiring Diagram

Drawing

Dimensions A B 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 C 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40

Connection

40mm x 40mm Cube, Flush, 1030VDC, Weld Field Immune BES022K BES0214 BES0216 BES0457 BES021P BES021R BES021T BES021U BES021A BES021H BES021K BES0220 BES0221 BES0305 BES0307 BES0304 Factor 1+ M8 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1+ BES03YP BES0452 BES03YW BES03YT BES0453 BES0454 2 mm 4 mm 12 mm 8 mm 8 mm 15 mm PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn PTFE CuZn A A A A A A 1 1 1 1 1 1 65 56 56 56 66 66.5 37 39 40 40 50 50.5 M8 M12 M18 M18 M18 M30 M12 M12 M12 M12 M12 M12 M12 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1+ M18 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1+ 15 mm 15 mm 20 mm 20 mm 15 mm 15 mm 15 mm 20 mm 25 mm 35 mm 35 mm 35 mm 35 mm 20 mm 35 mm 40 mm PNP, Comp PNP, Comp PNP, Comp PNP, Comp PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, Comp PNP, Comp PNP, Comp PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PTFE PA PTFE PA PTFE PA n n n n n B B B B A C A A B B B A A A A A 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 62 62 62 62 62 62 62 62 62 62 62 62 62 66 66 66 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12

40mm x 40mm Cube, Non-Flush, 1030VDC, Weld Field Immune

40mm x 40mm Cube with Corner LED's, Flush, 1030VDC, Weld Field Immune 40mm x 40mm Cube with Corner LED's, Non-Flush, 1030VDC, Weld Field Immune

M30 Flush Tubular, 1030VDC, Weld Field Immune - Factor 1+

B
D

46 54 A

30

5.5
40

M121
30

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets. 17

40

46

Inductive Sensors SteelFace

Balluff SteelFace sensors are the go-to sensors for physicaly abusive environments. Their one-piece gun-drilled stainless steel housings stand up to major incidental impacts, their long range characteristics combined with optional PTFE coatings give them long-term survivability in tough weld cell applications, and their price/performance ratio is the best in the market.

Up to 1.0 mm thick impact and abrasion resistant face

One-piece solid stainless steel construction

Order Code

Sensing Distance

Output Logic

Housing Material

Wiring Diagram

Drawing

Dimensions A B 44.5 44.5 49.5 49.5 49 49 44.5 44.5 49.5 49.5 49 49 41 41 36 36 42 42 35 35 42 42 32 32 C M8 M8 M12 M12 M18 M18 M8 M8 M12 M12 M18 M18 M12 M12 M12 M12 M18 M18 M18 M18 M30 M30 M30 M30 10 10 7 7 5 5 D

Connection

M8 Tubular, Flush, 1030VDC, 2X Extended Range BES02N5 BES02N3 BES02NA BES02N8 BES02NJ BES02NF BES02N6 BES02N4 BES02NC BES02N9 BES02NJ BES02NH BES02WH BES02WF BES02WE BES02WC BES02Y3 BES02Y2 BES02Y1 BES02Y0 BES02YF BES02YE BES02YC BES02YA 2 mm 2 mm 4 mm 4 mm 7.2 mm 7.2 mm 2 mm 2 mm 4 mm 4 mm 7.2 mm 7.2 mm 6 mm 6 mm 10 mm 10 mm 10 mm 10 mm 20 mm 20 mm 20 mm 20 mm 40 mm 40 mm PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O PNP, N/O NPN, N/O Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. PTFE Stn. Stl. PTFE Stn. Stl. PTFE Stn. Stl. PTFE Stn. Stl. PTFE Stn. Stl. PTFE Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. A B A B A B A B A B A B A B A B A B A B A B A B 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 1 2 2 65 65 65 65 65 65 65 65 65 65 65 65 60 60 60 60 63.5 63.5 63.5 63.5 63.5 63.5 63.5 63.5 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12

M12 Tubular, Flush, 1030VDC, 2X Extended Range

M18 Tubular, Flush, 1030VDC, 2X Extended Range

M8 Tubular, Flush, 1030VDC, 2X Extended Range with PTFE Coating

M12 Tubular, Flush, 1030VDC, 2X Extended Range with PTFE Coating

M18 Tubular, Flush, 1030VDC, 2X Extended Range with PTFE Coating

M12 Tubular, Quasi Flush, 1030VDC, 3X Extended Range

M12 Tubular, Non-Flush, 1030VDC, 3X Extended Range

M18 Tubular, Quasi Flush, 1030VDC, 3X Extended Range

M18 Tubular, Non-Flush, 1030VDC, 3X Extended Range

M30 Tubular, Quasi Flush, 1030VDC, 3X Extended Range

M30 Tubular, Non-Flush, 1030VDC, 3X Extended Range

18

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Order Code

Sensing Distance

Output Logic

Housing Material

Wiring Diagram

Drawing

Dimensions A B 42 42 42 39.5 39.5 39.5 37.5 37.5 42 39.5 37.5 67 66.5 67 66.5 C M12 M12 M12 M18 M18 M18 M30 M30 M12 M18 M30 M12 M18 M12 M18 D 2 2 2 2.5 2.5 2.5 2.5 2.5 2 2.5 2.5 2 2.5 2 2.5

Connection

M12 Tubular, Flush, 1030VDC, Ferrous Only BES02Z3 BES02Z1 BES02Z0 BES02Z9 BES02Z7 BES02Z6 BES02ZJ BES02ZF BES02Z2 BES02Z8 BES02ZH BES02Z5 BES02ZC BES02Z4 BES02ZA 2 mm 2 mm 2 mm 5 mm 5 mm 5 mm 8 mm 8 mm 2 mm 5 mm 8 mm 2 mm 5 mm 2 mm 5 mm PNP, N/O PNP, N/C NPN, N/O PNP, N/O PNP, N/C NPN, N/O PNP, N/O NPN, N/O PNP, N/O PNP, N/O PNP, N/O N/O N/O N/O N/O Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. Stn. Stl. A C B A C B A B A A A D D D D 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 65 65 65 66 66 66 66 66 65 66 66 85 90 85 90 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 1/2" x 20 1/2" x 20 1/2" x 20 1/2" x 20

M18 Tubular, Flush, 1030VDC, Ferrous Only

M30 Tubular, Flush, 1030VDC, Ferrous Only

M12 Tubular, Flush, 1030VDC, Non-Ferrous Only M18 Tubular, Flush, 1030VDC, Non-Ferrous Only M30 Tubular, Flush, 1030VDC, Non-Ferrous Only M12 Tubular, Flush, 20250VAC/300VDCVDC, Ferrous Only M18 Tubular, Flush, 20250VAC/300VDCVDC, Ferrous Only M12 Tubular, Flush, 20250VAC/300VDCVDC, Non-Ferrous Only M18 Tubular, Flush, 20250VAC/300VDCVDC, Non-Ferrous Only

PNP, N/O

PNP, N/C
B

NPN, N/O

AC/DC

1 2 3

GRN RD/BLK RD/WH

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets. 19

Cylinder and Clamp StrokeMaster sensors

Balluff high-pressure cylinder sensors are designed to sense the spud or cushion of a high pressure pneumatic or hydraulic cylinders piston to indicate clamped or unclamped cylinder gripping jaw positions. Rated to 3000 psi, these embedded inductive, WFI sensors are commonly found in heavy duty welding applications such as automotive and Tier supplier welding environments. StrokeMaster sensors are available to accommodate many cylinder bore diameters in both AC/DC and in DC formats to meet many welding electrical requirements. Order Code Length Sensing Distance 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm Output Logic Housing Material Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Wiring Diagram B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B Drawing Connection Order Code Length

Cylinder sensor, Flush, 20250 VAC / VDC, 3000 PSI, 304 rotation, Weld Field Immune BHS0004 BHS0006 BHS0007 BHS0009 BHS000C BHS000F BHS000J BHS000K BHS000L BHS000N BHS000R BHS000U BHS000Y BHS0010 BHS0012 BHS0014 BHS0015 BHS0017 BHS0019 BHS001A BHS0003 BHS0005 BHS0008 BHS000A BHS000E BHS000H BHS000M BHS000P BHS000T BHS000W BHS000Z BHS0011 BHS0013 BHS0016 BHS0018
PNP, N/O

Spacer Kit (refer to drawing 3) 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A 1/2" UNF-20-2A BAM0165 BAM0166 BAM0167 BAM0168 BAM0169 BAM016A BAM016C BAM016E BAM016F BAM016H BAM016J BAM016K BAM016L BAM016M BAM016N BAM016P BAM016R BAM016T BAM016U BAM016W BAM016Y BAM016Z BAM0170 BAM0171 BAM0172 BAM0173 BAM0174 BAM0175 0.150 0.158 0.180 0.188 0.198 0.225 0.250 0.291 0.307 0.315 0.337 0.362 0.372 0.375 0.380 0.400 0.440 0.500 0.562 0.600 0.650 0.684 0.712 0.742 0.810 0.850 0.875 0.937

0.912" 1.025" 1.225" 1.250" 1.300" 1.350" 1.500" 1.592" 1.725" 1.750" 1.875" 2.062" 2.275" 2.375" 2.775" 2.875" 3.750" 3.775" 4.560" 4.990" 0.912" 1.025" 1.250" 1.300" 1.350" 1.500" 1.750" 1.875" 2.062" 2.275" 2.375" 2.775" 2.875" 3.775" 4.560"

AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O
Polarized N/O

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Cylinder sensor, Flush, 20250 VAC / VDC, 3000 PSI, 304 rotation, Weld Field Immune

Note: Spacer may be required to elevate cylinder sensor to position sensing face in optimal position. Balluff recommends the following guidelines when mounting our Strokemaster sensors: A - Recommended to allow for mechanical wear (0.025" to 0.047") B - This dimension must be large enough to allow the sensor to turn off when the rod is present (0.110" to 0.118")

20

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Order Code BHS003H BHS003J BHS003L BHS003M BHS003P BHS003R BHS003T BHS003W BHS003Y BHS0040 BHS0041 BHS0043 BHS0044 BHS0045 BHS0047 BHS0048 BHS003K BHS003N BHS003U BHS003Z BHS0042 BHS003F BHS0046

Length 0.912" 1.025" 1.225" 1.250" 1.300" 1.350" 1.500" 1.592" 1.750" 1.875" 2.062" 2.775" 2.875" 3.775" 4.560" 4.990" 1.025" 1.250" 1.500" 1.750" 2.062" 2.875" 3.775"

Sensing Distance 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm 2 mm

Output Logic PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O AC/DC, N/O

Housing Material Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al Stn. Stl. / Al

Wiring Diagram A A A A A A A A A A A A A A A A B B B B B B B

Drawing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2

Connection M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN 7/8" -16 UN

Cylinder sensor, Flush, 1030 VDC, 3000 PSI, 304 rotation, Weld Field Immune

Cylinder sensor, Flush, 20250 VAC / VDC, 3000 PSI, 304 rotation, Weld Field Immune

Z/Spacers (inches) 0.18 0.912 1.025 1.25 Probe Length (inches) 1.35 1.5 1.75 1.875 2.062 2.375 2.775 2.875 3.775 4.56 0.732 0.845 1.070 1.170 1.320 1.570 1.695 1.882 2.195 2.595 2.695 3.595 4.380 0.188 0.724 0.837 1.062 1.162 1.312 1.562 1.687 1.874 2.187 2.587 2.687 3.587 4.372 0.225 0.687 0.800 1.025 1.125 1.275 1.525 1.650 1.837 2.150 2.550 2.650 3.550 4.335 0.307 0.605 0.718 0.943 1.043 1.193 1.443 1.568 1.755 2.068 2.468 2.568 3.468 4.253 0.372 0.540 0.653 0.878 0.978 1.128 1.378 1.503 1.690 2.003 2.403 2.503 3.403 4.188 0.375 0.537 0.650 0.875 0.975 1.125 1.375 1.500 1.687 2.000 2.400 2.500 3.400 4.185 0.5 0.412 0.525 0.750 0.850 1.000 1.250 1.375 1.562 1.875 2.275 2.375 3.275 4.060 0.544 0.368 0.481 0.706 0.806 0.956 1.206 1.331 1.518 1.831 2.231 2.331 3.231 4.016 0.562 0.350 0.463 0.688 0.788 0.938 1.188 1.313 1.500 1.813 2.213 2.313 3.213 3.998 0.6 0.312 0.425 0.650 0.750 0.900 1.150 1.275 1.462 1.775 2.175 2.275 3.175 3.960 0.684 0.228 0.341 0.566 0.666 0.816 1.066 1.191 1.378 1.691 2.091 2.191 3.091 3.876 0.712 0.200 0.313 0.538 0.638 0.788 1.038 1.163 1.350 1.663 2.063 2.163 3.063 3.848 0.81 0.102 0.215 0.440 0.540 0.690 0.940 1.065 1.252 1.565 1.965 2.065 2.965 3.750 0.937 0.088 0.313 0.413 0.563 0.813 0.938 1.125 1.438 1.838 1.938 2.838 3.623 Example: Need probe length of 1.125" combine sensor BES-516-200-S2-1.35-S21 with a 0.225" spacer (1.35" tube length - 0.225" spacer = 1.125 adjusted length). Note: A difference of 0.005" will still have to be carefully considered when sizing a spacer and sensor to the cylinder. Spacer kits include a spacer, O ring, and appropriate mounting screws. Other spacer kits may be available; consult factory. To order a spacer kit: Use part number BESA-516-20-KIT-* (X.XXX) measured in inches. (For both DC and AD/DC devices, there is no difference in flange dimensions.)

304 48 35 25 O-ring 17.13 X 2.62 UNC 1/4-20X3/4 12.9 37

304 48 35 25 O-ring 17.13 X 2.62 UNC 1/4-20X3/4 12.9

37

12.7

64.2

UNF-20-2A or M12 7/8-16 UN L 8

64.2

LED 1 LED 2

51

12.7

30

30

LED 1 LED 2

UNF-20-2A or M12 7/8-16 UN 8

2
21

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets.

51

Cylinder and Clamp Magnetoresistive sensors

Poor-performing, low-cost reed or Hall Effect switches, often fail to provide reliable clamped or unclamped position information for pneumatic cylinders used in weld cells. An upgrade to Balluff BMF magnetoresistive sensors will provide highly dependable position information over time. BMF sensors are available for virtually every cylinder configuration. They increase machine uptime, lower stocking requirements, and carry a lifetime warranty.

Order Code

Max Temp . 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 85 C 70 C 85 C 85 C 85 C 105 C 85 C 105 C 105 C 105 C 85 C 85 C 85 C 85 C 85 C 85 C

Weld Field Immune

V-Twin

Output Logic

Housing Material PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT PBT LCP Al Al Al Al Al Al Al Al Al Al Al Al Al Al

Wiring Diagram A A A A A A A A A A A A A A A A A A A B A A A A A A A A A A A A A

Drawing

Connection

BMF 204 C-slot for Festo (3.8mm), Slide-In, 1030VDC, 3-wire BMF0001 BMF00A6 BMF0002 BMF0003 BMF0005 BMF0006 BMF00A1 BMF00E3 BMF00A2 BMF00A3 BMF00A4 BMF00A5 BMF00AR BMF00CH BMF00C5 BMF00C4 BMF00C9 BMF00CA BMF0061 BMF008C BMF008E BMF008F BMF0066 BMF0067 BMF007W BMF007Y BMF00A0 BMF0080 BMF0081 BMF0082 BMF0083 BMF0084 BMF008A PNP, N/O PNP, N/O PNP, N/O PNP, N/O n n PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O n n PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O n n n PNP, N/O PNP, N/O PNP, N/O NPN, N/O PNP, N/O PNP, N/O PNP, N/O n PNP, N/O PNP, N/O PNP, N/O PNP, N/O n n n n n n n PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O PNP, N/O 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 5 5 6 2m Cable .3m M12 Pigtail .3m M8 Pigtail .5m M8 Pigtail .3m M12 Pigtail .3m M8 Pigtail 2m Cable 5m Cable .3m M8 Pigtail .5m M8 Pigtail .3m M12 Pigtail .3m M8 Pigtail 2m Cable 5m Cable .3m M12 Pigtail .3m M8 Pigtail .3m M12 Pigtail .3m M8 Pigtail .3m M12 Pigtail M8 M12 M8 M8 M12 5m Cable .3m M8 Pigtail .3m M8 Pigtail w/WeldRepelTubing 5m Cable .3m M12 Pigtail .3m M12 Pigtail .3m M12 Pigtail .3m M12 Pigtail M12

BMF 214 C-slot for SMC (4mm), Slide-In, 1030VDC, 3-wire

BMF 235 T-slot, Drop In, 1030VDC, 3-wire

BMF 305 Unversal, Bracket Required, 1030VDC, 3-wire

BMF 315 T-slot, Drop In, 1030VDC, 3-wire

BMF 32 Unversal, Bracket Required, 1030VDC, 3-wire

22

www.balluff.com/welding

M8 or M12

M8 or M12

Festo slot

SMC slot

6
Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets.
PNP, N/O NPN, N/O

Balluffs V-Twin magnetic field sensors provide two sensors with a single connector in either an M8 or M12 configuration. The BMF V-Twin is available in several sizes and form factors to cover applications from grippers and short stroke cylinders to C-Slot, T-Slot, round, and tie rod cylindersin some cases without requiring additional mounting brackets. Realize sensor and connection savings of 30% or more!

23

Photoelectric Sensors BOS and BOD sensors

When a photoelectric sensor has to be used in a weld cell, it must be protected to survive in this extreme sensing environment. Success requires a degree of application expertise. Mechanical protection and bunkering must be applied to achieve acceptable sensor survivability. In addition, ambient weld smoke, weld debris, oil, and mist, as well as sensing distance, excess gain requirements, and precision parameters must be taken into account in the choice of a photoelectric sensor. However, with the appropriate sensor choice, mounting hardware, and connectivity, it is possible to apply a photoelectric in the weld cell environment.

Order Code

Sensing Distance

Light Source

Output Logic

Housing/Lens Material

Bunker Block Available n n n

Wiring Diag.

Drawing

Dimensions A B 48 48 48 45 82 48 48 48 48 48 48 45 43.5 43.5 43.5 50 50 50 50 50 50 50 50 50 50 60.2 60.2 60.2 60.2 60.2 60.2 60.2 C M18 M18 M18 M18 20 M18 M18 M18 M18 M18 M18 M18 M18 M18 M18 17 17 17 17 17 17 17 17 17 17 28.5 28.5 28.5 28.5 28.5 28.5 28.5 23 D

Connection

Background Suppression - M18 Tubular, 1030VDC BOS014W BOS019P BOS019N BOS010J BOS0081 BOS01CA BOS01E7 BOS01E8 BOS01CF BOS01C1 BOS01E3 BOS010K BOS0047 BOS001A BOS001C BOS0089 BOS0082 BOS008A BOS0083 BOS008C BOS0084 BOS008E BOS0085 BOS008F BOS0086 BOS018N BOS0156 BOS018U BOS018P BOS018T BOS018W BOS018R 30300 mm 30300 mm 30300 mm 10120 mm 40120 mm 300 mm 300 mm 300 mm 600 mm 600 mm 600 mm 400 mm 100 mm 200 mm 400 mm 30300 mm 30300 mm 150600 mm 150600 mm 2560 mm 2560 mm 30150 mm 30150 mm 50300 mm 50300 mm 2002000 mm 2002000 mm 2002000 mm 2002000 mm 2002000 mm 2002000 mm 2002000 mm Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Infrared Infrared Class II Laser Class II Laser Class II Laser Class II Laser Class II Laser Class II Laser Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red Visible Red PNP, Comp PNP, NO PNP, NO / Error output PNP, NO PNP, Comp PNP, Comp PNP, NO PNP, NC PNP, Comp PNP, NO PNP, NC PNP, NO PNP, NO PNP, NO PNP, NO PNP, Comp NPN, Comp PNP, Comp NPN, Comp PNP, Comp NPN, Comp PNP, Comp NPN, Comp PNP, Comp NPN, Comp PNP, NO PNP, NO/Error output PNP, NC PNP, Comp NPN, NO/Error output NPN, NC/Error output NPN, Comp Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Ni CuZn / Glass Stn. Stl. / Glass Stn. Stl. / Glass Stn. Stl. / Glass ABS / PMMA ABS / PMMA ABS / PMMA ABS / PMMA ABS / PMMA ABS / PMMA ABS / PMMA ABS / PMMA ABS / PMMA ABS / PMMA ABS / Glass ABS / Glass ABS / Glass ABS / Glass ABS / Glass ABS / Glass ABS / Glass n n n n n n n n n n n n n n n n n n n B A A A B B A G B A G A A A A B C B C B C B C B C A D M B H J C 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 75 75 75 75 82 75 75 75 75 75 75 75 70 70 70 50 50 50 50 50 50 50 50 50 50 80.5 80.5 80.5 80.5 80.5 80.5 80.5 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12

Diffuse - M18 Tubular, 1030VDC

Background Suppression - Block, 1030VDC

Background Suppression - Block, 1030VDC

24

www.balluff.com/welding

Order Code

Sensing Distance

Light Source

Output Logic

Housing/Lens Material

Bunker Block Available

Wiring Diag.

Drawing

Dimensions A B C

Connection

Analog - Block, 1030VDC BOD0002 BOD0004 BOD0007 BOD0008 45...85 mm 45...85 mm 30100 mm 80...300 mm Class II Laser Class II Laser Class II Laser Class II Laser 0 - 10 VDC 0 - 10 VDC 4 - 20 mA / PNP, NO 4 - 20 mA / PNP, NO 0 - 10 VDC / (3) PNP, NO 0 - 10 VDC / (3) NPN, NO 0 - 10 VDC / (3) PNP, NO 0 - 10 VDC / (3) NPN, NO 4 - 20 mA / (3) PNP, NO 4 - 20 mA / (3) NPN, NO 4 - 20 mA / (3) PNP, NO 4 - 20 mA / (3) NPN, NO 1- 10 VDC / PNP, NO 4 - 20 mA / PNP, NO ABS/PMMA ABS/PMMA ABS/PMMA ABS/PMMA n n n n K K L L 2 2 2 2 50 50 50 50 50 50 50 50 17 17 17 17 M12 M12 M12 M12

Analog - Block, 1030VDC BOD000U BOD0017 BOD000W BOD000Y BOD0010 BOD0018 BOD0011 BOD0019 2002000 mm 2002000 mm 2006000 mm 2006000 mm 2002000 mm 2002000 mm 2006000 mm 2006000 mm Class II Laser Class II Laser Class II Laser Class II Laser Class II Laser Class II Laser Class II Laser Class II Laser Ana. Al./Glass Ana. Al./Glass Ana. Al /Glass Ana. Al./Glass Ana. Al./Glass Ana. Al./Glass Ana. Al./Glass Ana. Al./Glass E N E N E N E N 4 4 4 4 4 4 4 4 90 90 90 90 90 90 90 90 70 70 70 70 70 70 70 70 35 35 35 35 35 35 35 35 M12 M12 M12 M12 M12 M12 M12 M12

Analog - Block, 1030VDC BOD0015 BOD0016 BOD0013 BOD0014 100600 mm 100600 mm 2002000 mm 2002000 mm Visible Red Visible Red Class II Laser Class II Laser Ana. Al./Glass Ana. Al./Glass F F F F 5 5 5 5 90 90 90 90 73.2 73.2 73.2 73.2 30 30 30 30 M12 M12 M12 M12

1 - 10 VDC / PNP, Ana. Al./Glass NO 4 - 20 mA / PNP, NO PNP, NO PNP, NO PNP, NO PNP, NO PNP, NO PNP, NO Ana. Al./Glass

Thru-Beam, One Piece, "L" shaped, 1030VDC BWL001F BWL001H BWL001J BWL001K BWL001L BWL001M 22 x 22 22 x 22 42 x 41 42 x 41 42 x 60 42 x 60 Infrared Infrared Infrared Infrared Infrared Infrared Stn. Stl./PMMA Stn. Stl./PMMA Stn. Stl./PMMA Stn. Stl./PMMA Stn. Stl./PMMA Stn. Stl./PMMA A A A A A A 6 6 6 6 6 6 96 83.5 110 110 106 106 45.4 45.4 66 66 90 90 10.7 10.7 10.7 10.7 10.7 10.7 M12 M12 M12 M8 M12 M8

For wiring diagrams and drawings, see next page 26.

25

Photoelectric Sensors BOS and BOD sensors Wiring diagrams and drawings
C
B 38

B
4.3 C

B
A 41

A
4.3

1
A

2
A

3
C

or

21.5

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets.
PNP, N/O

F
0114A001

1 2 5 4 3

BN WH GY BK BU

+ Teach Input Analog Output Digital Output -

PNP, Comp

B
PNP, N/C

PNP, N/C, Error Output

G
NPN, N/O & N/C

C
NPN, N/O, Error Output

H
PNP, N/O, Error Output

UB 2 4 Error

1 2 4 3

BN WH BK BU

0V

+ Error Out -

NPN, N/C, Error Output

J E
or A

UB 4 2 0V Error

K
Shield

26

www.balluff.com/welding

Pressure Sensors Fluid detection sensors

Balluff pressure sensors offer an impressive price/performance ratio and are suitable for a wide variety of applications and pressure ranges in factory automation. A large display and simple operating concept save time when configuring parameters. Balluff pressure sensors are versatile and space-saving, with display and connector that can be rotated independently of the flange. Other features include compact housing design, local pressure indicator, digital switching outputs, and available analog output. Order Code BSP005C BSP005H BSP005J BSP000J BSP000W BSP0016 BSP005E BSP0010 BSP0019 BSP005F BSP0011 BSP001A Switching function
4-wire pressure sensors with switching output 4-wire pressure sensors with analog output

Pressure Range -14.5145 -14.5145 -14.5145 0145 0145 0145 01,450 01,450 01,450 03,626 03,626 03,626

Process Connection 1/4 NPT 1/4 NPT 1/4 NPT G1/4 G1/4 G1/4 1/4 NPT G1/4 G1/4 1/4 NPT G1/4 G1/4

Output Logic (2) PNP, NO or NC 010 VDC & PNP NO or NC 420 mA & PNP NO or NC (2) PNP, NO or NC 010 VDC & PNP NO or NC 420 mA & PNP NO or NC (2) PNP, NO or NC 010 VDC & PNP NO or NC 420 mA & PNP NO or NC (2) PNP, NO or NC 010 VDC & PNP NO or NC 420 mA & PNP NO or NC

Electrical Connection M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12

Display and control panel Display and connection housing rotates 320

Adapter NPT 1/4" BAM01KT Stainless steel G 1/4" NPT 1/4"

Process connection

Design Pressure sensors 1...2 bar Pressure sensors 1...10 bar Pressure sensors 0...2 bar Pressure sensors 0...5 bar Pressure sensors 0...10 bar Pressure sensors 0...20 bar Pressure sensors 0...50 bar Pressure sensors 0...100 bar Pressure sensors 0...250 bar Pressure sensors 0...400 bar Pressure sensors 0...600 bar

Relative nominal pressure Overload pressure 29 psi 145 psi 29 psi 73 psi 145 psi 290 psi 725 psi 1450 psi 3626 psi 5802 psi 8702 psi 2 bar 10 bar 2 bar 5 bar 10 bar 20 bar 50 bar 100 bar 250 bar 400 bar 600 bar 58 psi 290 psi 58 psi 145 psi 290 psi 580 psi 1450 psi 2900 psi 5802 psi 9428 psi 10878 psi 4 bar 20 bar 4 bar 10 bar 20 bar 40 bar 100 bar 200 bar 400 bar 650 bar 750 bar

Burst pressure 145 psi 508 psi 145 psi 218 psi 508 psi 1088 psi 2176 psi 3626 psi 6527 psi 10153 psi 11603 psi 10 bar 35 bar 10 bar 15 bar 35 bar 75 bar 150 bar 250 bar 450 bar 700 bar 800 bar

Permitted vacuum

Drawings for reference only. Visit www.balluff.com for the most up-to-date specifications and data sheets. 27

vacuum proof

Accessories Sensor protection

Balluffs sensor protection solution provides total protection not only for the sensor, but for the connector and cable as well. This complete protection package will yield the weld cell a significant increase in productivity because the sensor and its associated connectivity will last far longer than a similar unprotected or poorly protected sensor and cable. Follow these three simple steps to find the right combination for your application:

STEP 1

From the previous pages, select your sensor. a. Form factor (tubular, flatpack, cube, etc.) b. Control logic requirements (DC 3-wire PNP, NPN or DC 2-wire, etc.) c. Identify special characteristics (SlagMaster, Steelface, F1, WFI, etc.)

STEP 2 STEP 3

Select your mechanical protection system (BunkerBlock, ProxMount, Plunger, etc.) The Weld Select Series from Balluff is the ultimate solution for increasing productivity and decreasing sensor failure.

Select your connectivity system a. TPE Cable b. Weld Repel tubing, sheeting & wrap

TPE Cables BCC05F9 BCC05T7 BCC05FR BCC05TU BCC050M BCC0556 BCC01YW BCC01ZN M12 Straight female, 4-wire, 5 m M12 Right angle female, 4-wire, 5 m M12 Straight female, 3-wire, PNP LED, 5 m M12 Right angle female, 3-wire, PNP LED, 5 m M8 Straight female, 3-wire, 5 m M8 Right angle female, 3-wire, 5 m 1/2 X 20 UNF Straight female, 3-pin dual keyway, 15 ft 1/2 X 20 UNF Right angle female, 3-pin dual keyway, 15 ft

P TE

STEP 2

Prox Mounts PTFE (White) Coated Brass Short Proxes (30mm) BAM00AK BAM00E1 BAM00FW BAM00J7 PTFE (White) Coated Brass Long Proxes (40mm) BAM00AF BAM00CZ BAM00FP BAM00J5 PTFE (Black) Coated Steel Proxes (30mm) BAM00AC BAM00CW BAM00FM Outter Diameter M12x1 M16x1 M24x1.5 M36x1.5 Inner Diameter 8 mm 12 mm 18 mm 30 mm

28

www.balluff.com/welding

Weld Repel Wrap BAM0183 BAM0182 1" wide x 12 ft Clear wrap 2" wide x 36 ft Clear wrap

Weld Repel Area Protection BAM0179 BAM017A 3 ft x custom length in ft 3 ft x 3 ft sheet

P TE

Weld Repel Jacket BAM017E BAM017H BAM017L PTFE recommended. See pages 12-13. BAM017N BAM017R BAM017U BAM017Z SlagMaster recommended. See pages 10-11. Clear tubing, 1/4" dia. x 50 ft (15 m) Clear tubing, 3/8" dia. x 50 ft (15 m) Clear tubing, 1/2" dia. x 50 ft (15 m), * Clear tubing, 5/8" dia. x 50 ft (15 m)** Clear tubing, 3/4" dia. x 50 ft (15 m) Clear tubing, 1.5" dia. x 25 ft (15 m) Clear tubing, 2" dia. x 25 ft (15 m)

M8 SE DE

M12

SE DE

* Recommended for use with M12 (micro) single ended cables ** Recommended for use with M12 (micro) double ended cables Recommended for use with M8 (nano) single ended cables Recommended for use with M8 (nano) single ended cables

Bunker Block Machined AL BAM00EJ BAM00EU BAM00HE BAM00JP BAM00EK BAM00EW BAM00HF BAM00JR Prox Mount Required BAM00AF BAM00CZ BAM00FP BAM00J5 BAM00AK BAM00E1 BAM00FW BAM00J7 Description M8 sensors (40 mm+) M12 sensors (40 mm+) M18 sensors (40 mm+) M30 sensors (40 mm+) M8 sensors (short) M12 sensors (short) M18 sensors (short) M30 sensors (short)

Bunker Block II without positive stop for direct sensor mounting Copper Plated Steel BAM00A4 BAM00C6 BAM00F5 BAM00HR Description M8 sensors M12 sensors M18 sensors M30 sensors

29

Accessories Sensor protection

Balluff offers many accessories designed to survive in the welding environment. These offerings are very effective at protecting and increasing sensor and connectivity life. Covers, caps, plungers, and clamps are all designed to help protect the sensor from damage. Metal connectivity accessories allow for heavy duty applications in the harshest environments, while Weld Jacket is another option in the fight to protect cables from damage. All of the products listed below will help reduce sensor failure and increase sensor life expectancy.

Aluminum Clamp with Positive Stop BAM00A7 BAM00CF BAM00FC BAM00HW AL clamp for M8 sensors AL clamp for M12 sensors AL clamp for M18 sensors AL clamp for M30 sensors

Q40 & 26K Sensor Accessories BAM00JY BAM00K0 BAM00K1 BAM0155 Q40 Metal mounting bracket Q40 AL protection cover w/PTFE face cover Q40 PA6 protection cover BOS 26K Bunker Block

R01 Flatpack Sensor Accessories BAM00NK BAM00NL BES02YW Over-the-top, retro-fit bunker block Socket style bunker block (for new installations) PTFE protective cover

Air Blow-off Accessories & Air Knife BAM00PY BAM00R9 BAM0041 Air blow-off for M12 sensors Air blow-off for M18 sensors Air knife assembly

Heavy Duty Prox Actuator Plunger BAM015K Prox plunger for M12 sensors

Protective Caps BAM0156 BAM0157 BES 30-CERAMIC-CAP-1 BAM00C3 BAM00ER BAM00HC BAM00JM BAM0123 Ceramic for M12 sensors Ceramic for M18 sensors Ceramic for M30 sensors PTFE caps for Prox Mounts (M12) PTFE caps for Prox Mounts (M16) PTFE caps for Prox Mounts (M24) PTFE caps for Prox Mounts (M36) Protective glass lens cap (M18)

WELD Jacket WELD-JACKET-1/2" WELD-JACKET-3/4" Silicone & fiberglass 1/2" diameter (by the foot) Silicone & fiberglass 3/4" diameter (by the foot)

30

www.balluff.com/welding

Industrial Networks and Connectivity Products

In welding, equipment is required to survive in rugged and harsh environments, and control components are not excluded. Short circuits, weld slag and impact damage inevitably happen to products installed on equipment. The ability to hold up to these problems, provide easy to troubleshoot diagnostics and easy to see indication can reduce downtime and make issues easier to troubleshoot over traditional I/O devices and architectures.

Multiple Protocols

IP67 Addressing n Push buttons or rotary dials n Quick changeout, no PCs or devices required to address

Powerful and Safe Outputs n Up to 2 Amps n Easy overload troubleshooting

Clearly visible status LEDs n Speedup troubleshooting n Short circuit indication Detailed Level of Diagnostics n Port level diagnostics n Shorts, voltage, overload, etc.

Innovative housing design n Extreme durability n Low-profile

Description Input Only Output Only Input / Output Configurable

Inputs 16 0 8 16 max

Outputs 0 8 8 16 max BNI004M BNI0015 BNI0017 BNI004F BNI0001 BNI0002 BNI0004 BNI0003 For full product offering, download the latest catalog at www.balluff.com/connectivity

31

Sensing, Networking, and Identification for Industrial Automation

Object Detection
Inductive sensors, cylinder sensors, magnetic field sensors capacitive sensors, ultrasonic sensors, photoelectric sensors, fiber optic devices, fiber optics, angle sensors, through-beam fork sensors, optical window sensors, light grids, contrast sensors, luminescence sensors, color sensors, mechanical and inductive single and multiple position switches

Linear Position and Measurement

Micropulse transducers, magnetic linear encoder system, inductive displacement system, inductive distance sensors, magnetoinductive distance sensors, capacitive distance sensors, photoelectric distance sensors, ultrasonic sensors

Fluid Detection
Pressure sensors, capacitive sensors for level detection

Industrial Identification
Industrial RFID systems, vision sensors

Networking and Connectivity

Connectors and connection cables, valve connectors, passive splitter boxes, active splitter boxes, IO-Link, bus systems (Profibus, Profinet, CC-Link, DeviceNet, EtherNet), inductive couplers, power supplies, electrical devices

www.balluff.com
Connect with us online! Scan the QR Code to visit our social media page at: www.balluff.com/socialmedia

Accessories
Brackets and mountings, assembly system BMS

USA Balluff Inc. 8125 Holton Drive Florence, KY 41042 Phone: (859) 727-2200 Toll-free: 1-800-543-8390 Fax: (859) 727-4823 E-Mail: [email protected]

Canada Balluff Canada, Inc. 2840 Argentia Road, Unit #2 Mississauga, Ontario L5N 8G4 Phone: (905) 816-1494 Toll-free: 1-800-927-9654 Fax: (905) 816-1411 E-Mail: [email protected]

Mexico Balluff de Mexico S.A. de C.V Prol. Av. Luis M. Vega #109 Col. Ampliacion Cimatario Queretaro, QRO 76030 Phone: (++52 442) 212-4882, 224-3583, 224-3171 Fax: (++52 442) 214-0536 E-Mail: [email protected]

Doc. No. 886764/Mat. No. 219837 E Edition 2011-11 Product specifications, availability, and pricing are subject to change without notice.