Training manual

Inductive Sensors

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Training manual

You will find further information, data sheets, prices etc. at: www.ifm-electronic.com

Training manual Inductive proximity switches (March 2003)

C:\lokal\s100e.doc 10.01.07 11:55

Guarantee note

This manual was written with the utmost care. However, we cannot assume any guarantee for the contents.

Since errors cannot be avoided despite all efforts we appreciate your comments.

We reserve the right to make technical alterations to the products so that the contents of the training manual may
differ in this respect.

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Induticve Sensors

Contents

1 Introduction 5

1.1 Proximity switches in industrial processes 5

1.2 Notation 7
1.3 On the contents 7
2 Basics 9

2.1 Electromagnetic induction 9

3 Features of inductive proximity switches 12

3.1 Comparison 12
3.1.1 Limitation 12
3.1.2 Mechanical and electronic switches 13
3.2 Technology and operating principle 15
3.2.1 Basic inductive sensor 15
3.2.2 Signal generation 19
3.2.3 Evaluation 21
3.3 Practical use 23
3.3.1 Operating distance 23
3.3.2 Hysteresis 28
3.3.3 Correction factors 30
3.3.4 Switching times and switching frequency 34
3.3.5 Notes on practical use 39
3.4 Mounting instructions 41
3.4.1 Flush / Non flush 41
3.4.2 Mutual interference 44
3.4.3 Mechanical stability 46
3.5 Technology and operating principle K1, K0 48
3.5.1 Designations 48
3.5.2 Conventional inductive sensor 48
3.5.3 Sensor with K = 1 51
3.5.4 Sensor with K = 0 54

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4 Inductive proximity switches of ifm 56

4.1 Mechanical properties 56

4.1.1 Structure in general 56
4.1.2 Chronological development 56
4.1.3 Modular technology 60
4.1.4 Application of the efectorm 62
4.1.5 Production of the efectorm 63
4.2 Designs 63
4.3 Electrical data 65
4.3.1 Important parameters 65
4.3.2 Overview 67
4.4 Switches with special features 68
4.4.1 Use in hazardous areas 68
4.4.2 Switch for quarter-turn actuators 69
4.4.3 Units with mounting aid 70
4.4.4 quadronorm units 72
4.4.5 Non polarised units 73
4.4.6 Self-monitoring systems 73
4.4.7 Weld-field immune units 74
4.4.8 Units with increased operating distance 77
4.4.9 Units for overflush mounting 78
4.4.10 Special correction factors, K1, K0 80
4.5 Criteria for practical use 82
5 Application examples 85

Annex 90

Technical glossary 91

Type key 96

Production code 98

Index 99
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Induticve Sensors
1 Introduction

1.1 Proximity switches in industrial processes

What for? Automated production processes require sensors for supplying
information. They provide signals about positions, limits, levels or serve as
pulse pick-ups. Without reliable sensors even the best controller is not
able to control processes.

In general, all these sensors consist of two parts: The first registers the
change in the physical conditions (basic sensor), the second converts the
signals of the basic sensor into electrical output signals (signal
processing).

In general, a distinction is made between binary sensors which provide a

defined high-low signal and analogue sensors which are preferably used
for temperature, distance, pressure, force measurement, etc. The sensor
supplies an analogue signal which is further analysed for measurement
and control.

Figure 1: Structure of a sensor

Sensor The figure shows the general diagram which basically applies to every
sensor. The sensors only differ in some details, e.g. individual
components are not used or cannot be used separately. Sometimes the
basic sensor is also called just sensor. In this case it must be seen from the
context whether the whole unit or the basic sensor is meant. Some units
consist of separate components, e.g. NAMUR sensors or often also
temperature sensors. Here the transducer is connected to a separate
evaluation unit or amplifier.

Intelligent In Figure 1 the characteristic feature of the intelligent sensor is its

communication capability. But this term is also used in a different sense.
A sensor which only supplies the binary information
object detected or
object not detected

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is in general not called intelligent. But a sensor which is able to supply

additional information, e.g.
object reliably detected or
object unreliably detected
is considered to be intelligent.

Binary and digital
In order to avoid misunderstandings the difference is briefly explained.
Binary means "two states" (on/off). An analogue signal which can have
any value within certain limits is often digitized today so that it can be
processed in electronic controllers. This is done using an A/D converter
(analogue to digital). It divides the analogue signal into steps. The
number of steps results from the number of the bits used. Whereas one
bit can only take two values, 8 bits can take 256 and 10 bits 1024. This is
also called resolution. Less than 8 bits are seldom used because the
resolution would then be too coarse. More than 12 bits are also seldom
used because it does not make sense if the resolution is much higher
than the measurement accuracy.
Encoders are an exception. They provide digital signals straight away (see
training manual encoders).

This text mainly deals with binary sensors as replacement for mechanical
switches. It provides information about the operating principle, features
and criteria for using inductive sensors. Furthermore it presents typical
applications and suitable types to make it easier for the user to select the
right unit for his application. Many names are used for inductive sensors:
Proximity switch, initiator, inductive sensor, non-contact position sensor.
In addition, manufacturer-specific names are also used, e.g. efector
(registered trademark of ifm electronic gmbh). The term proximity switch,
however, is standardised and used in the following text.

In industrial applications mainly one system has been tried and tested:
Inductive proximity switches. These sensors are suitable for the non-
contact detection of a wide range of different conductive materials.

ifm has produced non-contact proximity switches for over 30 years. They
are used in all industrial applications. What makes these units and in
particular the efectors so successful?

The inductive sensor withstands interference best (see training manual

photoelectric sensors). With the experience of the past decades the units
have been improved. For more than 20 years ifm has granted a 5-year
warranty for standard units. Due to its high reliability the inductive
proximity switch has virtually replaced the mechanical switch. Moreover,
new applications come up again and again where a high degree of
automation was inconceivable in the past.

Next generation When the electronic proximity switch was launched it was simply seen as
a replacement for the mechanical switch which has now been replaced.
This means different types were developed, produced and sold to the
user who contacted the manufacturer if the sensor needed additional
features in his application. After many years of experience with the units
another point of view can be taken. The first question now is: What
features does a sensor need for a certain application?

Are there any examples? In the food industry for example the following conditions must be taken
into account:
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Temperature shocks (cooled fruit juice – hot cleaning liquid)
New cleaning agents (are to creep into all crannies to remove build-
up, residues, i.e.: high demands on ingress resistance)
Aggressive media (fruit juice also contains acids!)
e.g. in metalworking
Coolants (surface wetting increasingly improved, i.e. there are also
high demands on ingress resistance, moreover the medium can react
with the sensor materials)

To fulfil such requirements, the efectorm was developed as a new

generation. It is described in section 4.1 how the above-mentioned
conditions (temperature, ingress resistance, materials) are met.

1.2 Notation
For a better understanding a few notations are explained to make
reading the text and finding information easier.

Keywords Keywords which refer to the topic to be dealt with in the following
section are given in the left margin.

What does FAQ mean? This stands for Frequently Asked Questions. This term is also used for
modern electronic media. Almost everybody starting to cope with a new
task asks the same questions. Sometimes FAQs instead of keywords
precede a section. To differentiate them from simple keywords, they are
written in italics.

( 4) A figure in round brackets in the left margin refers to a formula used in

the text, e.g. see (4). Of course these formulas do not need to be learnt
by heart. They are meant to make understanding of the subject easier
because a formula similar to an illustration describes a relation more
briefly and clearly than many words.

1.3 On the contents

Basic information about inductive proximity switches is found in this
manual. Important terms and relations are explained, state-of-the-art
technology and technical data of ifm units are presented. This results in
the following structure.

1. Introduction The introduction is followed by the chapter:

2. Basics Here the physical basics that are useful for a better understanding of the
operating principle and features are briefly presented. A few basic terms
are explained.

3. Features of the inductive proximity switches

Here the limitation to binary sensors is discussed. Other more complex
systems in practical use are presented. Then comes a general overview of
different sensing systems to make the correct classification of inductive
proximity switches and the decision where they can be used and where
not easier. The knowledge of their features, advantages and
disadvantages enables successful use.

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4. ifm units Here the data of ifm sensors are listed and explained. The mechanical
structure, electrical features and use are described. Special units are
presented.

5. Applications A few applications with illustrations are briefly described.

Annex This manual is intended to help you with your self-study. Therefore
important terms are briefly explained again in the technical glossary. The
points which are important for the ifm units are presented in detail in the
chapters preceding the glossary. The index helps to look them up. The
type key and code for the production date are also explained.

Much success! With this basic information everybody should be able to benefit from this
product and to use the efector 100 successfully.

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2 Basics
Do I have to know this? Many operators use inductive sensors successfully without knowing these
basics. In the following chapters several notes on practical applications
are given. The basic knowledge helps to structure such information. This
makes more sense than learning a dozen rules by heart. Understanding
the operating principle also makes the selection of the switches and their
application easier. Some basic knowledge is necessary to be a competent
partner.
The physical basics are outlined in this chapter. This description is not too
long and theoretical. Only essential information is provided.

In the following section a few basic terms are explained which will then
be used without any further explanation in 3.2. Those who are familiar
with these basic terms can skip this chapter or come back to it if needed.

2.1 Electromagnetic induction

Flux If magnetic field lines penetrate a surface, this is referred to as magnetic
flux . Figure 2 is only a simplified representation. It is assumed that the
magnetic field is homogenous (identical over the whole surface) and the
direction is everywhere perpendicular to the surface.

Figure 2: Magnetic flux

( 1) =BA

[ ] = 1 Wb = 1 Weber =1 Vs, magnetic flux

[B] = 1 T = 1 Tesla = 1 Vsm -2 magnetic flux density, magnetic induction
[A] = 1 m3 , area

It may be confusing that the quantity B itself is sometimes referred to as

magnetic induction. This should not be mixed up with the phenomenon
of induction.

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Faraday The following relation was first discovered and described by the English
physicist Faraday. It is therefore called Faraday's law. It is one of the
basics in electrical engineering. Important applications are for example
generators, transformers and eddy current brakes. However, the sensor
does not brake objects, but its operating principle is also based on eddy
currents.

Figure 3: Eddy currents

( 2) U=- / t

[U] = 1 V, electrical voltage

[ ] = 1 Wb = 1 Weber =1 Vs, magnetic flux
[t] = 1 s, time

The rate of change of the magnetic flux is essential. This also explains the
importance of the alternating current. A transformer for example can
only be used with alternating current. The greater the change of the flux
within a time interval, i.e. the faster it changes, the greater is the induced
voltage. It is always present even in vacuum but can of course only
generate a current if there are mobile charge carriers. So an eddy current
can be created in the surface of Figure 3 if it is imagined as a thin plate of
conductive material. From this important conclusions can be drawn for
practical use:

Conductivity is decisive
Magnetizability can be another effect

Energy If electric current flows through a conductor, heat is generated (apart

from superconductors). Where does it come from? This can for example
be explained with the generator. Work must be performed permanently
if energy is to be supplied permanently. If much energy is taken from a
transformer on its secondary side, e.g. in case of a short circuit, it must
be supplied by the primary side. If on the primary side the current is
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Induticve Sensors
also used for the inductive sensor (see 3.2) even if the energy volume is
so small that the heat generated by the eddy currents is virtually not
measurable.

Lenz This name refers to a definition of the negative sign in ( 2) and is known
as Lenz's Law. It states that the effect of induction is always opposite to
its cause. With this in mind it is easy to understand the next section.

Skin effect The skin effect occurs for example for eddy currents generated in a
conductive plate (see Figure 3). If the surface and directions remain
constant, the voltage can only be induced by the change in the magnetic
flux density B according to ( 2). Eddy currents are then generated in the
conductor. But current-carrying conductors also have a magnetic field.
This means a magnetic flux density is part of eddy currents. How is this
"induced" B related to the one generated? The answer is given by Lenz's
Law: It is opposite. So the magnetic field is weakened, i.e. prevented
from penetrating the conductor. It remains at the surface, i.e. in the skin.
This also explains that high-frequency currents do not flow within
conductors but at their surface. This has also an effect on the detection
of thin foils by means of inductive proximity switches (see 3.2).

Where are the fluids? It is easy to understand what is the flux of water flowing through a tube.
It is for instance the amount of volume per time. But what means the flux
of a magnetic field and what is flowing there? In a magnetic field there is
no real flow. But for electromagnetic (and also for gravitational) fields
apply the same relations, rules, equations etc. as for real fluids. Because it
is easier to understand real fluids , they can be used as a model also for
magnetic fields. This is the reason why the same expressions, for instance
flux, are used. The advantage is, that you have to understand only once
the basic concepts. Then you may apply this knowlwdge to many
different cases, as fluids or magnetic fields etc.

Is this all? These basics are sufficient to understand inductive proximity switches.
The rest "only" refers to technical matters. Again it's the little things that
cause big problems! Much know-how acquired during decades is needed
to build a sensor operating on this principle which withstands
interference best (see training manual photoelectric sensors).

Knowledge of the basics is no end in itself but facilitates understanding

of the sensor characteristics which are important for practical use. This
for example concerns the detection of thin foils, small or irregularly
shaped objects, detection of objects with different conductivity, etc.

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3 Features of inductive proximity switches

3.1 Comparison

3.1.1 Limitation

Position sensor This sensor belongs to the group of position sensors. Photoelectric or
capacitive sensors also belong to this group. Criteria to select the suitable
position sensor are given in the training manual photoelectric sensors,
criteria to select an inductive proximity switch in the following sections
(e.g. 3.3.5). Another group are the fluid sensors. There is no clear
distinction between these groups, they overlap. Capacitive sensors with
binary output for example are often used for level monitoring of fluids.
But as a position is detected after all they can still be considered to be
position sensors.

Alternatives The criteria to select a position sensor for a certain application are
described in the above-mentioned documentation. Measuring systems for
lengths and distances are no real alternative to inductive proximity
switches because the task to be performed is different. The only
alternative to the inductive sensor as binary sensor (this point is treated
farther below) is the mechanical position switch. This is detailed in 3.1.2.

Binary In general, the inductive proximity switch is used as a binary position

sensor (see 1.1). The external evaluation of the analogue signal of the
transducer only makes sense in special cases. To be able to use this signal
for distance measurement, very restrictive conditions must be taken into
account. It must for example be ensured that the detected objects are
very similar. Furthermore the object must approach the sensor in always
the same way, i.e. mechanical guidance must be accurate (see 3.3.2 and
Figure 21). ifm supplies no inductive proximity switch with an analogue
output as standard unit.

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3.1.2 Mechanical and electronic switches

Figure 4: Schematic representation of a mechanical switch

The following figure shows an example of a mechanical limit switch.

Figure 5: Mechanical limit switch

If an inductive sensor is compared with a mechanical limit switch, the

mechanical limit switch has the following features:

For actuation a switching force is required, mechanical contact is

necessary
Only low switching frequencies can be achieved
Calculation of angle of approach and travel (switch-on graph)
necessary
Wear of the mechanically moved parts
Change of the switch points due to wear
Transfer resistance of the contacts changes
Life is limited due to the number of switching cycles
Contact bouncing leads to undefined signals
Due to the contact resistance a certain minimum current is required

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High susceptibility to dirt and moisture

Even slight dirt leads to corrosion
Completely different designs or sensing elements (rolls, plungers,
levers, etc.) are necessary for different applications (e. g. approach
from front or side)

The proximity switch which converts without contact the approach of

objects into switching signals has the following features:

The movement of the objects to be sensed is not impeded

Short response and switching times
High switching frequencies
No wear, no change of the switch points
Life not limited due to the number of switching cycles
No failure due to dirty or corroded contacts
No contact bouncing due to the electronic, i.e. non-contact output
(transistor, thyristor, triac)
Signals are suitable for further processing in electronic circuits
No need to calculate the travel (switch-on graph)
Only one design for different movements

Figure 6: Replacement for different designs

Very small designs feasible

Insensitive to moisture, dust, oil, etc..

The following figures show the difference in the switching response:

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Ideal switch Proximity switch Mechanical switch

no delay switches in the µs range high delay
switches in the ms range
also contact bouncing

Figure 7: Switching delays

It is obvious which of the two types comes closest to the ideal switching
response (i.e. low-high change without delay). The non-contact proximity
switch (efector) performs this task almost perfectly and provides the
signal which can be evaluated more easily and more reliably.

When comparing all features it can be clearly seen that the inductive
switch only has advantages over the mechanical limit switch. So using
non-contact sensors is a benefit for the user, which increases the
operational reliability of his installation and reduces the operating cost
thus improving competitiveness.

3.2 Technology and operating principle

3.2.1 Basic inductive sensor

Electromagnetic field / Resonant circuit An LC oscillator generates an alternating electromagnetic field with a
frequency between 100 kHz and 1 MHz. Here the magnetic field is
important, any air-core inductor can be used to generate it.

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ï î í ì
1 Ferrite core
2 Coil
3 Housing
4 Magnetic field

Figure 8: Field of an inductive sensor

Below the sensor is built up step by step: from the coil to the sensor.
î

1 Coil
2 Electromagnetic field

Figure 9: Field of a coil

Coil with core It can be seen that the field is generated symmetrically to the coil without
any preferred direction. In practice, however, no air-core inductor is used
but attempts are made to give the magnetic field a preferred direction by
means of a highly permeable ferrite material. By integrating the coil into
a ferrite core the magnetic field of the coil concentrates on the area in
front of the sensor, i.e. in this area the sensor becomes particularly
sensitive. The field distribution is similar to that of a lifting magnet with
the only difference that for a lifting magnet a static field is generated.

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1 Coil
2 Ferrite core
Figure 10: Coil with core

Screen If coil and ferrite core are additionally surrounded by a metal screen, the
magnetic field is exclusively limited to the area in front of the sensor.
Thus such a sensor can be completely surrounded by metal on its sides
which does not affect its switching response. These sensors are suitable
for flush installation (see 3.4.1).

1 Coil
2 Ferrite core with outer metal ring
3 Housing
Figure 11: Coil with screen

If an electrically conductive material passes through this alternating

magnetic field, eddy currents are induced in the material in accordance
with the law of inductance which draw energy from the LC oscillator of
the sensor.

This system can be compared with a transformer. The primary winding is

represented by the coil, the secondary winding and the load by the
electrically conductive object. Primary coil and secondary coil are coupled
via the field, i.e. in principle this is an air-core transformer.

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Figure 12: Block diagram

The amount of the eddy current losses depends on several factors:

Distance and position of the object in front of the proximity switch

Dimensions of the object and its outer shape
Electrical conductivity and permeability.

This means: For the binary sensor the distance where it changes its
switching state depends on all these factors (cf. 3.4.1). Therefore
proximity switches are normally designed as binary sensors. An analogue
output signal is less suitable, for example, for distance measurement.

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3.2.2 Signal generation

Figure 13: Schematic representation oscillator circuit

Oscillator circuit As can be seen on the diagram the eddy current losses can be taken into
account by changing the resistance R2 in the oscillator circuit. If the
object is brought so close that the equation

R1 R3
( 3)
R2 R4

is no longer valid, the operational amplifier can no longer supply the

energy required to maintain the oscillation, so the oscillation is
attenuated (damped) or breaks down. So the circuit represents a
functional inductive sensor which converts the two states
object outside the critical distance = oscillator oscillates with a large
amplitude and
object within the critical distance = oscillator oscillates with a small
amplitude or not at all
into an easily evaluable electrical signal.

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Ë Ë

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ï
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î
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1 Proximity switch not damped

2 Proximity switch damped
Figure 14: Damping (trigger stage)

What does "damped" mean? You often hear: "The sensor is damped". This is easier to understand
with the information given above.

Other evaluation methods are also possible. So the change in inductance

or the quality factor of the oscillator circuit can be measured in a
different manner. But so far the method described above has proven to
be the best choice. But to obtain special features, other methods are also
applied, see 3.5.

Resistance characteristics
In the following figure the energy consumption of the detected object is
represented as an apparent change in resistance in the oscillator.
As can be easily seen, this relation is clearly non linear. This confirms that
an inductive proximity switch is of only limited use for providing a signal
which is proportional to distance. It is therefore mainly used as a binary
switch.

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Operating principle
Signal processing / output stage
Figure 15: Resistance characteristics
As the energy loss caused by the object is determined using an oscillator,
the operating principle can be described as follows: Inductive proximity
switches take advantage of the physical effect of the change in the
quality factor in a resonant circuit caused by eddy current losses in
materials of good electrical conductivity.
3.2.3 Evaluation
First, the information contained in the oscillation amplitude must be
converted into a switching signal. This is done by rectifying and
smoothing the oscillation (demodulation). This signal is transferred to a
Schmitt-Trigger stage. So only one of the two possible switching states
"current flows" or "current does not flow" can be taken.
The basic sensor which belongs to the oscillator circuit is followed by
further stages which evaluate the signal. They are shown in the following
block diagram. A comparison with the training manual capacitive
proximity switches clearly shows that inductive and capacitive sensors
have a similar electronic structure. The differences are as follows: type of
basic sensor, type of oscillation and setting option for capacitive units.
Only for a few special inductive sensors (large designs) the sensitivity is
adjustable. The new generation of capacitive sensors operates on another
principle, and so sensitivity is adjustable as standard.
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Figure 16: Block diagram

Clear condition If an object is exactly located at this switch point or if it approaches this
point slowly ("creepingly"), the switching output may constantly change
between the two states, which would result in output chattering. This is
prevented by a clearly defined hysteresis which is generated electronically
(see 3.3.2).

Time response Furthermore it must be ensured by a corresponding circuit that at power

on no wrong switching signal is produced, a power-on pulse suppression
must be available. The time which elapses between power on and sensor
readiness for operation is called power-on delay time and lies in the
millisecond range. Occasionally, this leads to confusion. The power-on
delay time is not the same as the switching time (see 3.3.4 or Figure 24).
The latter is much shorter. Another quantity is the response time, i.e. the
time which elapses between presence of the object and switching of the
output. It depends on the switching frequency (see 3.3.4) and is also
shorter.

Figure 17: Power-on delay time

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Switching function
Output
What does this mean?
Rated operating distance (sn)
What does "rated" mean?
For many units the switching function normally open or normally closed
can be selected. For former units this was also called programming even
if just a wire link had to be cut open.
To switch the output, solid-state switches like transistors and thyristors
are now widely accepted in the market. They have clear advantages over
mechanical switches as regards lifetime, number of reliable switching
operations, switching frequency, and bounce-free switching.
The few disadvantages, i.e. leakage current in the switched-off state,
voltage drop in the switched state and higher sensitivity as regards
overvoltage and overcurrents (see training manual connection
technology) can normally be tolerated or more or less avoided by means
of suitable protective measures.
The block diagrams represent the general principle. Some types have
special features, e.g. a second LED as mounting aid or setting option via a
potentiometer.
3.3 Practical use
3.3.1 Operating distance
At first sight the answer seems quite easy. But on closer examination it
becomes obvious that this term is of prime importance for correct
understanding. Inductive proximity switches operate without contact. The
object to be detected only has to come close to the sensor. But what
does close mean? The distance where a proximity switch can reliably
detect an object is called operating distance. It depends on
the type and design of the sensor
the specific characteristics of the individual switch
external conditions
shape, dimensions and material characteristics of the objects to be
detected.
A characteristic distance, i.e. the rated operating distance, is allocated to
each type and indicated on the type label. For inductive sensors it
depends on the coil, shape and dimensions of the ferrite core and the
structure of the sensing head, i.e. the basic sensor. As a rule of thumb, it
can be said that the longer the operating distance, the larger are the
external dimensions of the sensor. The values are between 1 and 60 mm.
For special types this can also be 100 mm. Instead of this designation
which is laid down in the standard (IEC 60947-5-2) ifm uses the term
nominal sensing range sn.
This means that this quantity cannot be considered to be an absolute
value but must be interpreted. How is the effective operating distance
related to the rated operating distance? In other words: What does the
operating distance depend on? There are several influences.
Different units of one and the same type cannot be completely identical.
This means there are individual variations. Moreover, the sensor is
exposed to changing environmental conditions, e.g. temperature
variations, fluctuations of the operating voltage, etc. Objects near the
sensor but which are not detected, e.g. stationary machine parts, can
23
Training manual

also influence the operating distance (cf. 3.4.1). Finally, the characteristics
of the objects must be taken into account. The effect of these influences
is explained below.

Standard To obtain comparable measurement results for the operating distance a

standard measurement method is prescribed for inductive proximity
switches. This measurement method is defined in IEC 60947-5-2,
formerly in the European standard EN 50010. It defines a standard square
target which is 1 mm thick. The side length a of the target must at least
correspond to the diameter of the sensing face or be three times the
rated operating distance of the sensor, if this value is higher The material
prescribed for the target plate is mild steel.

sn Rated operating distance

sr Effective operating distance
su Usable operating distance
sa Assured operating distance (switched on reliably!)
A Sensing face
a = d Diameter of the sensing face or
a = 3 x sn if this value is higher
Target material: mild steel 1 mm thick
Figure 18: Standard measurement method for the operating distance

This measurement, however, only results in the operating distance of a

typical individual switch under defined environmental conditions.
Therefore fixed limit values are prescribed in the standard which all units
of the manufacturer must meet in case of changing environmental
conditions and individual variations.

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24
Induticve Sensors
Individual variations
Environmental influences
Usable operating distance s u
Maximum value
Temperature variations
The rated operating distance s n which is indicated in the data sheet and
on the type label is a reference value which does not consider
manufacturing tolerances or variations due to temperature influences and
voltage fluctuations. The effective operating distance s r is more useful. It
takes the component and manufacturing tolerances into account. The
effective operating distance is determined at the rated operating voltage
and an operating temperature of 23°C. It can deviate from the rated
operating distance up to 10%. This covers the typical individual
variations. For high quality sensors this is not fully utilised. For the
production of the efectors the component tolerances are kept to a
minimum by precisely adapting every finished circuit to the operating
distance. In practice, it is an advantage if s r is slightly below sn. For an
efector with sn of 10 mm s r is approx. 9.8 mm.
In case of voltage and temperature variations the operating distance of
every proximity switch may vary max. 10% from its effective operating
distance over its whole guaranteed temperature and voltage range
specified in the data sheet. This also applies when the mounting
instructions are adhered to. If this is not possible, the tolerance range of
10% can shift upward or downward. As every electronic component
changes its characteristics with temperature, it is difficult to meet this
requirement. The flush mountable type (see 3.4.1) has the highest
requirements. To fulfil these requirements, thorough selection of the
components and optimisation of the circuit design are required.
The operating distance thus obtained is called usable operating distance
su. It is between 0.9 and 1.1 of the effective operating distance. When
considering all individual switches and operating conditions the usable
operating distance is 0.81 to 1.21 of the rated operating distance. The
minimum value of 0.81 of s n is important and interesting for the user. A
rated operating distance of e.g. 10 mm would lead to an operating
distance of 8.1 mm under extremely poor conditions. This is the
minimum achievable operating distance sa. (assured operating distance).
At this distance every proximity switch must operate reliably (referred to
the standard target).
The maximum value of 1.21 of the rated operating distance is important
to avoid interference caused by remote objects. An object which is
farther away damps the oscillation a little, see the point "predamping"
below. It can be clearly seen that such an object can influence the
operating distance by taking the hysteresis of max. 0.2 of the effective
operating distance into account (see 3.3.2). So every proximity switch
must switch off reliably at 1.43 of the rated operating distance.
How is the operating distance changed by external influences, e.g.
temperature variations? No general rule can be given. The influence
depends on the design, rating of the circuit, characteristics of the
components, etc. In most cases the operating distance increases. This can
lead to problems if as a result of this remote objects are detected which
are not within the range according to the standard. The output can then
switch and stay in this state. Even if the sensor is operated outside the
specified range, e.g. at -40°C or at 100°C, it is not destroyed straight
away. But the switch point will shift. Frequent sharp temperature
variations have a more negative effect on the sensor life. Due to the
different thermal expansion this can lead to mechanical tensions between
the different materials used for the circuit. The new efector m switches
25
Training manual

(see 4.1.3) withstand even sharp temperature shocks much better. The
test method for this feature is described in 4.1.4.

How precise is the sensor?
The wide range of the allowed tolerances of
0,81 sn < s < 1,21 sn
does not mean that the inductive proximity switch is inaccurate because
the operating distance varies much.
First, no individual sensor can cover the whole tolerance range. For
temperature variations in the specified range for example a change of the
operating distance of 10% as defined in the standard occurs. Only if the
sensor is replaced by another unit of the same type, individual variations
must be taken into account. This means that if high accuracy is important
the sensor may have to be readjusted. But in practice, such problems
seldom occur because the achievable accuracy is limited by other
influences, e.g. mechanical deformation, vibrations, etc.

Example For a better understanding a switch with a rated operating distance of 10

mm is to be looked at. sr has been determined to be 9 mm. This means
due to external influences, e.g. temperature or voltage fluctuations in the
permissible range the switch point may vary between 8.1 and 9.9 mm. If
this sensor is replaced by another unit of the same type, e.g. sr = 11 mm,
the switch point can then vary between 9.9 and 12.1 mm. If the object
(assumed to be of an easily detectable material with sufficient area
surface) is typically at a distance of 5 mm, no problems are expected due
to individual variations. This is an example of a general rule.

Rule of thumb As a rule of thumb the distance of the object (assumed to be of an easily
detectable material with sufficient area surface) is roughly half the rated
operating distance. This distance is for example used when the switching
frequency is determined (see 3.3.3).

Rules Here is a summary of the points which are of special importance for
practical use:
The sensor should be placed so that the object to be detected is
within the assured operating distance, i.e. 0...0.81 of s n. ifm provides
units with an additional set-up LED which signals that the object is
within this range.
If the sensor directly controls the movement of the object (e.g.
switching off the motor), lateral approach must be preferred as due
to the switch-on/switch-off graph (see 3.3.2) the tolerance range is
smaller (the risk of mechanical damage is also lower, see 3.4.3).
Damping from the front is mainly used to detect presence of the
object, e.g. workpiece in a device or closed chuck, etc. With
mechanical devices like limit stops the assured operating distance can
be set.

Repeatability R This term and the measurement method are also defined in the standard.
In accordance with IEC 60947-5-2 s r is measured for a voltage in the
rated voltage range for a period of 8 h. The operating temperature is 23
±5°C. With this test the effect of intrinsic heating is determined.

What does this mean? In practice, it is interesting to know how the switch point varies if the
sensor is approached several times by one and the same object in the
same way. It is not quite correct to call this repeatability because the
meaning of this term is defined in the standard (see above). Nevertheless,
the term is used in this sense, sometimes the term reproducibility is used.
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26
Induticve Sensors
Predamping
Clear space
„Reliably off“
Increased operating distance
Operating distance reduction
What does it mean?
It is important that the value is much better if the conditions only change
slightly, e.g. in case of directly successive measurements. Under ideal
conditions in the laboratory a very high repeatability in the µm range can
be achieved.
What are the effects if other detectable objects, e.g. the metal wall of a
stationary enclosure or build-up of metal swarf, are close to the sensor?
In such a case the efector is predamped. This means that the oscillation
amplitude has already been slightly reduced by these objects but is still
above the switching threshold. As a result of this only a little additional
influence is necessary, e.g. a remote or small object so that the output
switches. Thus the sensor has become more "sensitive", the operating
distance has increased. If possible, this should be avoided because there
will be a higher risk of malfunction (cf. 3.4). In some cases a new type
can be used which "selectively" only reacts to ferromagnetic materials
and is immune to aluminium chips (see 3.3.3).
To avoid predamping it is important to know how far an object may be
away, e.g. from an opposite wall of an enclosure so that the sensor
function is not affected. In Figure 38 it can be seen that a distance of 3 x
sn is recommended.
What has already been discussed under "maximum value" above is
pointed out again because of its importance for applications. Especially in
connection with predamping switching off may pose a problem.
Switching on is not critical here. If the above rule of thumb (half the rated
operating distance) is applied, the sensor reliably switches on if it is
predamped. In adverse cases, however, switching off may then no longer
be ensured. Here the hysteresis, see 3.3.2, must also be considered. The
sensor must only switch off at 1.43 of the rated operating distance. If
sensitivity has been increased due to predamping, it can happen that it
does not switch off at all.
It can be clearly seen with predamping that a greater sensitivity of the
sensor is not always an advantage. It can become more susceptible to
interference. In practice this means that the permissible temperature
range would have to be limited because otherwise the temperature
would inadmissibly influence the operating distance. In the standard IEC
60947-5-2 certain designs are allocated certain (minimum) operating
distances. With many years of experience it is now possible to make
reliable inductive proximity switches which achieve much better operating
distance values than stated in the standard without any restriction of the
temperature range (see 4.4.8). They are called units with increased
operating distance.
This term is closely related to the increased operating distance. As the
operating distance increases the operating distance reduction also
increases. The unit may then no longer operate reliably. One requirement
for the development of units with increased operating distance is to
minimise the operating distance reduction. These units are described in
4.4.8. The term is explained in the following section.
To answer this question some mounting information is necessary (see
3.4).
For non-flush mountable units there must be a defined clear space in the
surrounding area. The influence of predamping thus avoided is the
reason for the longer operating distance compared to flush mountable
units of the same design.
27
Training manual

Flush mountable units can be mounted flush, e.g. with a metal surface.
They are shielded as much as possible from their environment. For the
same design the flush mountable unit has approx. half the rated
operating distance of the non-flush mountable unit. In this operating
distance predamping by the environment has already been taken into
account.
If a flush mountable sensor is not mounted flush, it is not predamped. Its
operating distance is normally reduced compared to flush mounting. This
effect is called operating distance reduction.

3.3.2 Hysteresis

Context This subject is often treated in combination with the operating distance.
But for the sake of clarity it is described separately in this section.

Is a hysteresis requested?
The hysteresis is the difference between the distance at which the output
switches when the object approaches and the distance at which the
output switches back again when the object moves away. If an object is
located precisely at the switch point, the switching output may constantly
change between the two states ON and OFF. This is prevented by a
clearly defined hysteresis which is generated electronically. The difference
between switch-on point and switch-off point integrated into the circuit
results in a range of 1 – 20% of the operating distance in which the
object to be detected must move so that the proximity switch switches
on and off reliably.

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28
Induticve Sensors

Figure 19: Hysteresis

The hysteresis is also important for other sensors, e.g. pressure and
temperature sensors. Here a freely adjustable hysteresis is an advantage
because easy control functions can thus be implemented.

Lateral approach If the object does not approach the proximity switch axially but radially,
i.e. from the side, the exact switch-on and switch-off points depend on
the shape of the electromagnetic field. The manufacturers indicate
switch-on graphs in their data sheets which normally correspond to the
following figure. As can be easily seen, the required deviation between
switch-on and switch-off points is reduced considerably if the object
approaches radially. As repeatability is also improved, this should be the
preferred direction of actuation, e.g. for positioning tasks. Moreover,
mechanical damage of the sensor is avoided (see 3.4.3).

This switch-on graph, also called hysteresis graph, supplies further

information about accuracy. In areas where the switch-on graph is farther
away from the switch-off graph, i.e. in the limit area where the object is
just still detected, accuracy is lower. Finally it also depends on the design.
The smaller the design, i.e. the shorter the operating distance, the higher
is the achievable (absolute) repeatability.

29
Training manual

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î ï
³³
íî

Í®
¿
ïê

ð
êð ìð îð ð óîð ³³ óêð
¿
Figure 20: Hysteresis graph

Half the rated operating distance This is also confirmed by the above-mentioned rule of thumb (see 3.3.1).
This distance is a good compromise between the extreme cases too close
(low hysteresis, i.e. possible output chattering and risk of mechanical
damage) and too far away (low accuracy).

3.3.3 Correction factors

Do you have to know more?
In practice, the object is of course seldom a standard target (see 3.3.1).
The objects can be larger, smaller, irregularly shaped and consist of
different materials. The rated operating distance must then be multiplied
with correction factors to determine the actual operating distance. This
virtually is a change in scale. The tolerances of the standard, e.g. ± 10%
for temperature variations are maintained. For the hysteresis graph as
well (see Figure 20) the values change accordingly. How these factors are
determined is described below.

In practice, the type of approach does not always correspond to that

defined in the standard. But it has an effect on the operating distance.
This can hardly be considered by means of a correction factor. In case of
doubt the user should always carry out a test in his application. Figure 21
shows what happens if there is no precise mechanical guiding which
ensures that the object always approaches in the same way. This example
confirms that the inductive sensor is normally not suitable for distance
measurement (see 3.1.1).

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30
Induticve Sensors

Figure 21: Approach of an object

Side length If a smaller or non-square target is used instead of the standard target
(see Figure 18) to IEC 60947-5-2, the operating distance must be
corrected by a factor. For square targets which differ from the standard
dimensions this factor is shown in the figure below. The typical graph of
this correction factor is indicated which shows the shorter operating
distance for much smaller targets and the virtually constant operating
distance for longer sides.

Figure 22: Correction factor side length

Rule of thumb Another rule of thumb says that the operating distance corresponds to
the rated operating distance if the object is not smaller than the sensing
face of the sensor (see 3.2.1). Only if the dimensions are much smaller,
objects are no longer detected.

Shape factor For other shapes, e.g. if metal balls are detected, the factor can no longer
be specified in general. With the ball the operating distance is reduced a
little. The value, however, depends on the radius of the ball. For objects
which are shaped even more irregularly the operating distance can only
be estimated from experience and should be determined by carrying out
tests on site.

31
Training manual

Material If instead of the material defined in the standard (mild steel) another
material is used for the target, the operating distance must also be
corrected. For inductive proximity switches this correction factor directly
depends on the electrical conductivity of the material as this determines
the level of the eddy current losses (exception: ferromagnetic materials,
see below).

Is good conductivity an advantage?
It can be seen from the following figure that the correction factor for a
material which is a good conductor such as copper or aluminium leads to
a shorter operating distance. Conversely, the electrical conductivity of
graphite and ferromagnetism of iron cause greater losses in the oscillator
circuit so that the achievable operating distances are longer. The
surprising consequence is that the better the conductivity of the material,
the worse it is detected.

Figure 23: Correction factor material

The continuous line represents the values to be expected theoretically for

different diamagnetic or paramagnetic materials. The indicated
measurement points show the actually measured values. It can be seen
that the maximum correction factor is achieved for a conductivity of
approx. 10 4 - 105 1/ m. It is approx. 1. A still poorer conductivity results
again in shorter operating distances. Thus substances like water with a
conductivity of approx. 10 0 to 10-2 1/ m or other substances which are
poor conductors cannot be detected. In case of iron there is a point near
the graph maximum because iron is a ferromagnetic material. Since this
ferromagnetism limits the penetration depth of the sensor field to a few
micrometres, the conductivity of the substance is apparently reduced.
From this results the good detectability of iron, steel and alloys containing
iron. If, however, the ferromagnetism of the alloy is weaker, the
operating distance is reduced considerably. For stainless steel the
correction factor is approx. 0.7.

K = 1 (see 3.5 and 4.4.10) Occasionally the dependence of the operating distance on the material is
not desired in applications because it is a possible source of interference
for the detection of different materials. Inductive proximity switches have
been developed which more or less compensate for this dependence on
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32
Induticve Sensors
referred to as K = 1 units (K stands for correction factor). This means that
for these switches the correction factor is virtually always 1, i.e. is
constant. But this feature is not often needed in applications. Sheet metal
working is taken as an example. To position the sheets correctly, their
position is monitored using inductive proximity switches. But it will
happen very seldom that in one and the same installation using the same
methods copper, iron and aluminium sheets are worked alternately. It
must also be said that it is very difficult to optimise a special feature, here
dependence on the material, without deteriorating other features, e.g.
immunity to interference such as temperature variations.

K = 0 (see 3.5 and 4.4.10) This does not mean that the sensor detects nothing at all. What is meant
is a sensor which detects selectively. It is also required in practice that a
sensor for example only detects a target of iron sheet but is immune to
aluminium chips which may deposit on its sensing face. So the correction
factor refers to non-ferrous metals.

Material thickness In the standard IEC 60947-5-2 the thickness of the target for inductive
proximity switches is specified with 1 mm. If, however, a damping
material like thin metal foils is used, the operating distance may be longer
than would have to be expected after having applied the material
correction factor. This is due to the different depth of penetration of the
sensor field into the material – the so-called skin effect (see 2.1).

The depth of penetration of the magnetic field is typical of the skin

effect. It depends on the oscillator frequency. Strictly speaking, the field
intensity does not reach a sharply defined cut-off but rather falls away to
1/e. This is a limit for the thickness of the foil.

In the following table the limit thickness of different electrically

conductive materials is indicated for an oscillator frequency of 100 kHz.
Below this limit thickness a longer operating distance must be expected.

Material [mm] at
100 kHz
Iron ca.
(electrical sheet) 0,02
Silver 0,2
Copper 0,2
Aluminium 0,3
Zinc 0,4
Brass 0,4
Lead 0,7

33
Training manual

3.3.4 Switching times and switching frequency

ms The time which elapses when an object to be detected moves into the
magnetic field and switching of the output of the proximity switch is in
general only a few milliseconds. The switching times are much shorter
than for mechanical limit switches, which is important as these sensors
are used in modern, fast running machines.

Dependence The switching time depends on several factors. On the one hand, it
depends on the energy stored in the oscillator circuit which in turn is
determined by inductance, capacitance and the quality factor of the
oscillator circuit, the oscillator frequency and type of oscillator. On the
other hand, it mainly depends on the level of the eddy current losses in
the circuit. As already mentioned, they depend on the object size,
material and distance from the sensing face. In general, the time for
damping proximity switches (design specific) is between 0.2 and 2 ms
and for undamping between 0.3 and 3 ms.

Ü Û

A Damped condition
B Oscillator voltage
C Switching status of the output stage
D Damping time
E Undamping time
Figure 24: Schematic representation of damping and undamping

Damping and undamping time
If oscillation breaks down, the undamping time, i.e. the time the
oscillator takes to oscillate again at its full amplitude is longer than the
damping time. For units made in the past the typical ratio of
damping/undamping time was 1:2. For more recent switches the
oscillation does not break down completely, which reduces the
undamping time. Nowadays the time ratio of most units is 1:1. Deviations
are more frequent for larger designs.

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Induticve Sensors

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Figure 26: Oscillation and output at present

The switching time has a major influence on the maximum switching

frequency and maximum switching speed at which an object can pass the
sensor so that it is reliably detected. To achieve comparable results for the
maximum switching frequencies despite all these factors a measurement
method to determine the switching frequency is described in IEC 60947-
5-2 which defines that targets (see 3.3.1) with the side length a and fixed
on a disc at a distance of 2 a pass a proximity switch at half the rated
operating distance. The switching frequency thus determined is normally
specified in the data sheets of the proximity switch manufacturers.
The switching time must not be confused with the power-on delay time
which is much higher (see 3.2.3).

Mark-to-space ratio 1 The mechanical mark-to-space ratio of 1:2 results in a damping and
undamping ratio of approx. 1:1. This is so because the output switches
shortly after the leading edge of the target enters the active zone (see
Figure 27). It does not switch off until the trailing edge of the target
leaves the active zone.

35
Training manual

1 Mild steel target

2 Disc of non magnetic and non conductive material
Figure 27: Standard measurement method of the switching frequency

Switching cam Inductive proximity switches are frequently used as pulse generators, e.g.
for monitoring rotational speeds (see training manual ecomat 200). To do
so, a plastic disc is fitted with one (or several) screws. It is placed onto the
axis to be monitored. The screw head serves as the switching cam. For
high rotational speeds it is not sufficient to consider the switching
frequency. One example:
The rotational speed is 60,000 rpm. The calculated pulse frequency is 1
kHz. Most standard sensors have switching frequencies of 1 kHz.
Seemingly the application should function. But if the screw head has a
slightly smaller diameter than the sensing face, it may not stay long
enough in front of the sensor to damp it reliably.

Figure 28: Rotational speed monitoring

What has to be done? The switching cam must be made longer. It should at least be as long as
the target. A sheet strip with a max. length of. 1/3 to 1/2 of the
circumference can be fixed on the plastic disc. See "mark-to-space 2"
below.

Disc with a hole This is even more difficult if instead of the switching cam on a plastic disc
a hole is used in a metal disc to generate pulses. Here a slot would have
to be used instead of a hole.
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36
Induticve Sensors

Figure 29: Rotational speed monitoring using a disc with hole

But the example also shows that this is only important in case of very
high rotational speeds.

Mark-to-space 2 The mark-to-space ratio should be optimised for several reasons. Even if
the rotational speed is not extremely high and the switching cam is
reliably detected, reliable processing of the pulses in an external
evaluation electronics is not ensured. One example:
The rotational speed is 600 rpm. The calculated signal frequency is 10 Hz.
Can the signals be evaluated by a plc?
There are mainly two features of a plc which limit the signal frequency
the plc is able to process. To answer the question they must be known.
Limit frequency The low-pass filter at the input has a limit frequency of 25 Hz (this
component is normally used to protect the standard plc inputs against
spurious peaks). So the signals can be reliably detected by the hardware.
Cycle time The cycle time is 20 ms (i.e. long program or slow plc). Thus the cycle
frequency is 50 Hz. This is much above the signal frequency.
Seemingly, the question can be answered with yes. But in practice
problems occur again and again. It results from the above values that one
revolution takes 100 ms. If the diameter of the switching cam is 1/10 of
the circumference (probably smaller), the estimated signal length is 10
ms. This is half the cycle time. Thus the signals cannot be reliably
detected!

Consequence If the signal frequency is above the cycle frequency, the signals cannot be
evaluated. But this does not mean that a lower signal frequency is
sufficient for evaluation. The mark-to-space ratio must be taken into
account.

What has to be done? There are several options:

Connect a counter
Use fast plc inputs
Make the switching cam longer
The last option is of course the easiest and cheapest one. The optimum
mark-to-space ratio is 1:1 to ensure that the two signal states 1 and 0
can be detected with the same reliability.

1:1 Whenever pulses are unreliably evaluated or counted, the mark-to-space

ratio should first be optimised to 1:1.

The following figures show again the problem. Direct detection of the
teeth of a toothed wheel to monitor rotational speed by evaluating the
pulses is represented, which is not unusual in practice.

37
Training manual

Ó ïè ¨ ï

Figure 30: Toothed wheel 1

Figure 30 shows the normal case. For this sensor type there should be no
problem when objects, here teeth, and gaps have the same length. For
larger designs this can be difficult because the gap is not deep enough.
The mechanical mark-to-space ratio is closer to 1:1 than to 1:2 as defined
in the standard for the measurement method. For higher rotational
speeds the undamping time may not be sufficient. It would then be
better to have a larger, i.e. deeper and wider gap.

Ó ïè ¨ ï

Figure 31: Toothed wheel 2

If the gaps are relatively large as shown in Figure 31, there is a higher risk
of assessing the application incorrectly if only the frequency is taken into
account. It must be additionally checked whether the damping time is
sufficient.

º´«·¼ -»²-±®-
¿²¼ ¼·¿¹²±-¬·½
-§-¬»³-

°±-·¬·±²
-»²-±®-
¿²¼ ±¾¶»½¬
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38
Induticve Sensors

Ó ïè ¨ ï

Figure 32: Toothed wheel 3

Figure 32 shows the opposite case of Figure 31. The same consideration
must be made. The undamping time is critical here.

îí ³³

îí ³³

Ó ïè ¨ ï

ç ³³

Figure 33: Toothed wheel 4

Figure 33 shows a better arrangement than Figure 32. Here the user
must determine the maximum detectable rotational speed from the
specified dimensions. To do so, the catalogue must be consulted.

3.3.5 Notes on practical use

In this chapter some points are added and other points detailed above
are only briefly mentioned.

First it can be said that the inductive proximity switch is simple and
uncomplicated. This is confirmed by the enormous number of switches
used without specialists. Most explanations and notes in this text are
hardly needed in practice. But even with an uncomplicated unit mistakes
can be made. Moreover, there are marginal applications. This manual
helps to find solutions, especially for more difficult applications when the
sensor does not react as expected.

39
Training manual

Material of the object An inductive sensor can detect all materials which are good electrical
conductors. Its function is neither limited to magnetic materials nor
metals, it can also detect, for example, graphite.

Movement of the object Due to the high-frequency electromagnetic alternating field generated by
the inductive sensor it can detect objects regardless of whether they are
moving or not.

Shape of the object
The best target for an inductive sensor is a object with a flat surface as
only there a sufficient amount of eddy currents can be formed. Individual
objects small in relation to the sensor, e.g. pieces of swarf from a
machining process, marks or burrs on the surface of the workpiece do
not affect the function until they are present in large numbers. So
distance measurement is no point measurement but is integrated over a
given surface area. The number of steel balls which can be placed on the
sensing face without affecting the switch is a useful criterion for
assessing the operational reliability of inductive switches.

Interaction on the object
An inductive sensor can be operated with only a few microwatts of
electrical energy. This has the advantage that its high-frequency field
causes no radio interference and no measurable heat in the object. As
the sensor has no magnetic effect either, it is virtually free of interaction.
By the way, it generates no electrosmog either.

Selection The following example briefly describes the selection of a suitable

inductive proximity switch for an application.
An aluminium sheet strip which is 4 cm long and 3 cm high is to be
detected at a distance of 4 mm.
Detection at half the operating distance is optimum. So s should be 8
mm. The correction factor of aluminium is 0.4. Therefore the rated
operating distance should be 20 mm (= 8 mm / 0.4).
There are units type M30 with s n = 22 mm which can be used here
Alternatives In our example the material aluminium is critical. To achieve the required
operating distance for this correction factor a unit with increased
operating distance must be selected. The M30 design corresponds to the
height of 3 cm. A larger design with a longer operating distance is not
more reliable here because the object would then be smaller than the
sensing face. For a smaller type, e.g. M18 the maximum operating
distance sn is 12 mm. Multiplication with the correction factor 0.4 results
in 4.8 mm for sn Al. Calculating the assured operating distance, i.e. 81%
of 4.8 mm, leads to 3.89 mm. This would no longer be reliable for this
application.

Improvement It would make selection much easier if the aluminium sheet could be
replaced by steel sheet.

How do I find these values? In the past this sometimes required some search in the catalogue. The
electronic catalogue (www.ifm-electronic.com) is an advantage. An
automatic selector finds suitable units using defined criteria.

º´«·¼ -»²-±®-
¿²¼ ¼·¿¹²±-¬·½
-§-¬»³-

°±-·¬·±²
-»²-±®-
¿²¼ ±¾¶»½¬
®»½±¹²·¬·±²
¾«-ô
·¼»²¬·º·½¿¬·±²
¿²¼ ½±²¬®±´ -§-¬»³-

40
Induticve Sensors

3.4 Mounting instructions

3.4.1 Flush / Non flush

This is an important criterion for the practical use of the switches. The
flush/non flush feature is determined by the design of the unit and
indicated in the data sheet and on the type label.

f / nf The international designation f (for flush mountable) and nf (for non-

flush mountable) is used (and no longer b and nb).

What is the background? Inductive proximity switches operate with an electromagnetic field which
is radiated from the sensor. It is almost inevitable that this field does not
only interfere with the object to be detected but also with other objects
near the switch. To ensure the correct function of a proximity switch the
area around the sensing face must be kept clear of detectable materials.
For inductive proximity switches no materials which are good electrical
conductors are allowed in this area.

Clear space for nf The clear space for mounting non-flush inductive proximity switches is
defined in EN 60947-5-2.

d Diameter of the proximity switch

s Rated operating distance
1 Clear space

Figure 34: Non-flush mounting, cylindrical

41
Training manual

1 Clear space
Figure 35: Clear space cylindrical non flush

Figure 35 shows the switch and clear space around the sensing face. A
threaded metal type can be seen here. The metal housing is mounted
flush in metal, only the plastic sleeve is located in the clear space.
Obviously, it must be 2 x s n in the clear space.

ß
ï
ïòë ¨ ¾

í ¨ -²

ß ï
 

Figure 36: Clear space rectangular non flush

º´«·¼ -»²-±®-
¿²¼ ¼·¿¹²±-¬·½
-§-¬»³-

°±-·¬·±²
-»²-±®-
¿²¼ ±¾¶»½¬
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42
Induticve Sensors
Feature for f
Operating distance reduction
Wherever the clear space shown above cannot be adhered to flush
mountable units must be used. The sensing face of the proximity
switches can be mounted flush in metal. For these switches the
electromagnetic field is screened to such a degree that only a negligible
amount escapes at the side of the sensing face. Thus these types are
immune to interference from the side. But the disadvantage of this
screen is that the operating distance of flush mountable proximity
switches is shorter than for the corresponding non-flush mountable
types. Depending on the type the operating distance reduction can be up
to 50% of the rated operating distance. This is one of the reasons why
units with increased operating distance have been developed (see 4.4.8).
Figure 37: Flush mounting cylindrical
1: Clear space
Figure 38: Clear space cylindrical flush
If a non-flush mountable unit – this is indicated on the type label – is
mounted flush in metal, it must be assumed that no defined signal is
provided or the output is constantly switched. What happens in the
opposite case, i.e. a flush mountable unit is mounted non flush? This is
definitely done in practice. If for example both types are needed, the
flush mountable switch is chosen (provided the operating distance is
sufficient) to have fewer types in stock as spare parts. In this case it must
be assumed that the operating distance is slightly shorter because
predamping is reduced. This difference is called operating distance
reduction. To use these switches without problem the operating distance
reduction should be as small as possible. This point is very critical,
especially for units with increased operating distance (cf. switch for
specific applications). For standard efectors the operating distance
reduction is normally not greater than 5% (see 4.4.8). However, the
43
Training manual

permissible tolerances defined in the standard EN 60547-5-2 must not be

exceeded.

If all these requirements are fulfilled, the flush mountable sensor is the
more universal choice because the user does not have to take the (lateral)
clear space into account. Moreover units with metal housing are more
resistant to mechanical influence.

Quasi flush A term which is sometimes found in this context is "quasi flush
mountable". These are units with a smaller permissible clear space than
indicated above. It is in the mm range. However, this term is not
standardised but manufacturer-specific. So the user must follow the
manufacturer's instructions diligently. He cannot rely on the usual
meaning of flush, i.e. sensing face is mounted flush with a metal surface.
This is why ifm only supplies flush or non-flush mountable sensors.

Overflush Especially for switches used for monitoring transport processes it can
happen that a heavy object hits the sensor thus damaging it
mechanically. Here it would be an advantage if the sensor could not only
be mounted flush but recessed in metal or be fitted with a protruding
protective metal cover. For this application a unit was developed. Special
mounting instructions must be adhered to (see 4.4.9). This is also a
manufacturer-specific term. As this does not restrict but exceed the
standard this designation is more acceptable than quasi flush.

Predamping If it cannot be avoided at all that the sensor is influenced by an object in

its vicinity, this is called predamping. This term is explained in 3.3.1. To
avoid predamping the clear space in Figure 35, Figure 36 and Figure 38
must be adhered to. If for an nf switch this clear space is not adhered
to, predamping increases inadmissibly. So it is possible that the unit
switches immediately without object or that it switches once and then
remains in this state.

3.4.2 Mutual interference

If in a plant several proximity switches of the same type are to be

operated close to each other, certain minimum distances between the
units must be adhered to. The minimum distances given in the following
Figure 39 represent a rule of thumb.

º´«·¼ -»²-±®-
¿²¼ ¼·¿¹²±-¬·½
-§-¬»³-

°±-·¬·±²
-»²-±®-
¿²¼ ±¾¶»½¬
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·¼»²¬·º·½¿¬·±²
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44
Induticve Sensors

è¨-²

ß ¼ ¼ ¼ ß

f
ß ß


nf

A: Sensing face
Sn: Rated operating distance
d: Diameter of the sensing face

Figure 39: Mutual interference cylindrical

ß
è ¨-²

ß ¼ ¼ ¼ ß

ß ß

¼  ¼

A: Sensing face
Sn: Rated operating distance
d: Diameter of the sensing face
Figure 40: Mutual interference rectangular

45
Training manual

It can be seen from Figure 40 that in this context there is virtually no

difference between rectangular and cylindrical designs.

Offset frequencies
The range of mutual interference also depends on the random
production-related difference in oscillator frequencies So interference
can often only be noticed with certain specific damping conditions or
after replacement of a switch. If the minimum distances indicated in the
figure cannot be adhered to, it is possible to use ifm switches with an
oscillator frequency that has been changed by a certain amount.

3.4.3 Mechanical stability

In an environment with high vibration the proximity switch must be

carefully fixed. Although many threaded types look like bolts, the
tightening torque for the nuts is limited. Only the fixing elements
supplied or recommended by the manufacturer should be used. This is
especially so for units with a smooth sleeve which must on no account be
fixed using a grub screw.

If the tightening torque for the nuts specified by the manufacturer seems
insufficient, metal threaded units can be used. For small types with plastic
thread rubber washers are recommended to improve fixing. Proximity
switches should be mounted in places where they are protected against
mechanical damage as much as possible. In case of need, they can be
covered. Glass or ceramics is suitable for protecting the sensing face
against sharp-edged or hot chips. For direct use in pneumatic or
hydraulic systems there are special versions which can withstand a
pressure on the sensing face of max. 300 bar.

The standard connection cable of proximity switches is only suitable for

slight mechanical stress. If the operating conditions require a stronger
cable, a conduit is necessary for strengthening. As an alternative, a switch
with terminal chamber can be used. The cable must be laid so that no
forces can be transferred to the housing. If the cable must be moved
constantly, using a conduit is also recommended (see the following
figure).

º´«·¼ -»²-±®-
¿²¼ ¼·¿¹²±-¬·½
-§-¬»³-

°±-·¬·±²
-»²-±®-
¿²¼ ±¾¶»½¬
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46
Induticve Sensors

Figure 41: Mounting and direction of movement

Direction of movement The type of mounting shown at the top is not recommended as there is
the risk of mechanical destruction. The switch should on no account be
used as a "limit stop".

47
Training manual

3.5 Technology and operating principle K1, K0

Overview In this chapter the operating principle of these special types is described
in detail. In addition to new information, the following sections partly
repeat what has already been described in 3.2, 3.3 and 3.4. The readers
who would like to skip these sections can continue with 3.5.3. The
features of these special types which are important for practical use are
described in 4.4.10.

3.5.1 Designations

K = 0, K = 1 The abbreviation of this designation is K0, K1. It stands for the feature of
the new switch families which makes it easier to use inductive proximity
switches under special operating conditions.

In short, these are inductive proximity switches which react

only to ferromagnetic materials (in short K0, in general referred to as
K = 0) and
to any (conductive) materials without different correction factors (in
short K1, in general referred to as K = 1).

Correction factor
To remind you: For the conventional inductive sensor the correction
factor for the material has to be taken into account. In the standard IEC
60947-5-2 which defines the measurement method to determine the
rated operating distance the target material (in addition to other
parameters) is also prescribed, i.e. mild steel. To determine the operating
distance for an aluminium target (Al) the standardised value for mild steel
is multiplied with the correction factor for aluminium which is approx.
0.4, i.e. the operating distance is reduced by 60%. This explains the
requirement for an inductive proximity switch which detects all
(conductive) materials at the same distance, thus having a constant
correction factor (K = 1 or in short K1).

3.5.2 Conventional inductive sensor

K 1 First the conventional type is treated again. In short, it is referred to as K

1. Its operating principle can be explained in several ways. These are
simplified models to make understanding easier. Depending on the
aspect to be illustrated they can be different.
Damping of the oscillation due to eddy current losses in the target
Change in the quality factor in a resonant circuit. This is often
described with a representative circuit diagram where the resistance
which stands for the losses is connected in parallel to the coil.
As an alternative, a series connection can also be used for the
representative circuit diagram (figure 42). These two representations
are equivalent. For a given frequency the corresponding values can
be easily converted.

For a better understanding of the difference between K 1 and K1 the

series connection is used for the representative circuit diagram for K 1.
The letter T for the designations in the following figures means
º´«·¼ -»²-±®-
transmitter.
¿²¼ ¼·¿¹²±-¬·½
-§-¬»³-

°±-·¬·±²
-»²-±®-
¿²¼ ±¾¶»½¬
®»½±¹²·¬·±²
¾«-ô
·¼»²¬·º·½¿¬·±²
¿²¼ ½±²¬®±´ -§-¬»³-

48
Induticve Sensors

L Inductance
RCu Resistance material (Cu)
RAC AC resistance

Figure 42: Representative circuit diagram series connection

For K 1 the change in resistance is evaluated.

Switching frequency The switching frequency of the sensor depends on the oscillator
frequency. A higher oscillator frequency cannot be implemented easily
for the conventional switch. As the change in the quality factor is
evaluated the oscillator circuit operates in the range of its maximum
quality factor. For higher frequencies the quality factor decreases because
the AC resistance increases considerably. This is easier to implement for K
= 1, see 3.5.3.

Resistance characteristics The Figure 43 shows the graph of R = Rcu + R AC represented as a

function of s, which is the distance of the target of Fe (iron, no stainless
steel). sr is the distance at which the sensor switches. Only the qualitative
graph is shown. The axes are without units of dimension. T stands for
transmitter.

49
Training manual

RT Resistance for the transmitter

RT Limit value of the resistance
Fe Iron (ferromagnetic material)
E Sensitivity
RTCu Resistance of the coil (copper)
s Distance of the target
sr Effective operating distance

Figure 43: Resistance and distance

It can be seen from the graph in Figure 43 that the total resistance R
asymptotically moves to a limit value R . The longer the distance, the
smaller is the change in resistance. For the switch point however
(effective operating distance s r) the value is approx. 5% above the limit
value. This 5%, the signal deviation for Fe, is also called sensitivity and is
a tried and tested value. The graph for another material, e.g. aluminium,
is not represented here. It would be difficult to see this graph because it
would virtually overlap with the line for R T . The following table indicates
typical approx. values for the differences:

Al Fe
RT 0% + 5 %...10

LT - 0,4 % - 0, 2 %

The table shows that it is difficult to detect an aluminium target via the
resistance. It can now be understood more easily that an aluminium
target is only detected at a much shorter distance (see 3.5.1, correction
factor). A sensor with s r = 10 mm on a standardised mild steel target only
switches on an aluminium target at 4 mm.

If the goal, however, is that the sensor switches on all materials at the
same operating distance, it can be seen from the table that the change in
inductance L is more suitable. On the one hand, inductance depends less
on the material. On the other hand, it is much lower, i.e. more difficult to
evaluate.

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50
Induticve Sensors

3.5.3 Sensor with K = 1

Here the change of inductance is evaluated. It is related to the change of

the permeability µr. To remind you:

( 4) L = µ0µr n2 A / l

L [Henry] Inductance
µ0 [1,2566 10 -6 Vs/Am] Magnetic field constant
µr Permeability number
A[m2] Area
l[m] Length

( 4) is the formula for the inductance of a coil. µ r is also called relative

permeability. This number describes the property of a material, i.e. the
reaction of a material in the magnetic field. This subject is not further
addressed here. Permeability is described in more detail in the training
manual magnetic sensors, cylinder switches. ( 1) only illustrates how
inductance is related to permeability. µ r is no absolute constant but
depends on the frequency, for example for alternating fields.

Figure 44 shows (again in a qualitative manner) the relation between µ r

and the frequency f.

Figure 44: Permeability and frequency

Figure 44 shows the clear difference between Fe (iron and ferromagnetic

materials) and the virtually constant value for Al (aluminium) for lower
frequencies. This difference is reduced for higher frequencies. This in
short is the difference between K0 and K1.

Frequency evaluation There are different options to evaluate the change in inductance. One
option would be the evaluation of the change of the oscillator frequency
which is caused by the change in inductance. But for K0 and K1 this
method was not applied. But as this technology is used for units which
are available on the market, it is briefly explained below.
Counter
To determine the frequency, pulses can be counted. The required
components, however, are overdimensioned for a standard sensor as
regards volume and price.
Reference resonant circuit

51
Training manual

To compare the frequency with that of a reference resonant circuit, its

components must meet special requirements. It is difficult to obtain
precise and temperature stable capacitors. So it is natural to choose
another option using the available know-how concerning coils.

For the ifm sensor the change in the coupling of two oscillators is
evaluated. The coupling factor describes the change in inductance
between the two coils L T and LR in another way.
(CF) coupling factor

Figure 45: Coupled coils

T and R The coil of the left oscillator which is excited to oscillate can be
considered to be a transmitter (T), the coil of the right high-ohmic circuit
to be a receiver (R). The two oscillators are coupled via the magnetic field.

Coupling factor The coupling factor CF is a characteristic value for the coupling intensity.
It depends for example on the position and arrangement of the coils.
Furthermore on external influences, e.g. presence or absence of a target.
This relation becomes clearer when one imagines the target to be
between the coils similar to a slot switch. The extent of the change in the
coupling factor depends on the material of the target. A parameter for
this is the permeability µ r.

Material It can be seen from the above graph (Figure 44) that for high frequencies
the change of the coupling factor is independent of the material. This
means that this arrangement (for high frequencies!) reacts to every target
in the same way. This is just the requested feature for the K1 sensor.

Now the remaining task "only" is to develop a unit which makes use of
this effect and can be easily made in large volumes at low cost.

Signal deviation This task is difficult because the signal deviation is so small. If the voltage
at the receiver coil is identified as UR, the resulting typical value is

UR/ UR 0,3 %

This value is called basic sensitivity. A direct evaluation would be very

complex. One option to solve this task consists of measuring the
difference between two values. In the representative circuit diagram in
figure 46 this can be shown with 2 coils being connected in series on the
receiver side. If the direction of rotation of the windings is reversed, the
sign of the voltage of the 2nd receiver changes. The voltage across the
two coils is then the difference of the individual voltages. External
º´«·¼ -»²-±®-
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-§-¬»³-

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52
Induticve Sensors
influences, like temperature or magnetic fields, are more or less
compensated for by forming the difference. The first receiver is
influenced by the target as in Figure 47. A suitable arrangement of the
coils ensures that the second coil is virtually not affected by the target. It
serves as a reference to compensate for interference which has the same
effect on both coils.

Figure 46: Generation of the differential signal

The following formula applies to this arrangement:

(UR2 + UR1)/( UR2 + UR1) 10 %

Such a value can now be easily evaluated. The coil arrangement must be
selected so that the above-mentioned properties result. How this is
implemented is schematically shown in Figure 47 and Figure 50.

T Transmitter coil
R1, R2 Receiver coils
--- Housing (for K = 0 incl. stainless steel sensing face)

Figure 47: Structure of the sensor

The operating principle is now explained in more detail. In Figure 47 the

designations T for transmitter and R for receiver are used. R1 reacts to
the target, i.e. is sensitive, R2 is virtually insensitive.

Precision For production maximum precision of the carrier and winding of the coils
is of prime importance to keep individual variations to a minimum. The
carrier consists of a special plastic which was mainly selected because of
its mechanical properties. With this plastic precise injection-moulded
parts can be made with a high repeatability. No ferrite was chosen

53
Training manual

because otherwise the transmitter coil would be virtually shielded from

the target.

Evaluation For evaluation another trick is also used. The voltages at the transmitter
and receiver circuit are further processed by a multiplicator (x in Figure
48). This has the effect of an additional compensation of interference.
The result is integrated ( in Figure 48) and then transferred to a stage
triggering the switching output.

Figure 48: Evaluation of the signal difference

3.5.4 Sensor with K = 0

Selective The special feature of this sensor is its selectivity. This and further features
are briefly described below.

Less interference The reason for developing this sensor was the following requirement: The
sensor is to reliably detect a target of ferromagnetic material, e.g. mild
steel. It is not to be interfered with by aluminium chips even if they are
on the sensor.

Same principle To fulfil this requirement no fundamental new considerations and

developments are necessary. Looking at the graph in Figure 44 where µ r
is represented as a function of the frequency shows that for lower
frequencies µ r of iron increases substantially. This is the characteristic
feature of ferromagnetic material. If the sensor works at lower
frequencies, this effect can be evaluated easily. The coils can be arranged
in the same way as for K1. Differences are the much lower oscillator
frequency and the evaluation which is carried out by a further oscillator
which either starts to oscillate or where the oscillation breaks down.

Figure 49: Cross-section through K0

º´«·¼ -»²-±®-
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-§-¬»³-

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54
Induticve Sensors
Figure 49shows a cross-section through such a sensor. Figure 50 shows
the decisive component, the coil system and the implementation of the
schematic representation in Figure 47.

Figure 50: Coil system

pcb It can be seen that a special PCB is used. For this PCB the connection
between sensor (coil) and the circuit can be established more easily. For
this reason a combination of a flexible film and special PCB is already
used and will be increasingly used in the future.

55
Training manual

4 Inductive proximity switches of ifm

4.1 Mechanical properties

4.1.1 Structure in general

Main groups A distinction can be made between main groups which consist of the
following components:
Housing
Basic sensor
Circuit
Connection
But as these components are in relation with each other, they are not
treated separately.

Structure of an efector
The figure shows the schematic structure of an inductive proximity
switch. The technical implementation resulted in different variants which
were modified considerably with time. For a correct understanding of the
current situation it is useful to know the progress of development. An
overview is given in the following table.

ï î í

ì ë ê

Figure 51: Structure of an inductive proximity switch

4.1.2 Chronological development

Step Housing Circuit

1 plastic potted PCB
2 plastic and/or PCB
metal potted
3 plastic and/or film
metal potted technology
4 plastic and/or film
metal modular technology
modular

Explanation The individual points in the table are briefly explained below.

Time As the transition between the variants was fluid, a classification in steps
º´«·¼ -»²-±®-
and not in years was made.
¿²¼ ¼·¿¹²±-¬·½
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56
Induticve Sensors

Potting In the past filling cavities with a potting compound, e.g. cast resin was a
considerable progress. ifm was granted patents on this. Thanks to this
method it was possible for the first time to use electronic units under
severe operating conditions. With time the following disadvantages
became obvious:
+ Protection against moisture and dust
+ Mechanical fixing of the components
- Resistance to temperature shocks
- Heat dissipation
- Resistance to coolants and cleaning agents
- Separation of the components
Due to the different thermal expansion of the components temperature
shocks lead to mechanical tension which can destroy the unit in the
worst case.
As the chemical components of the above-mentioned substances have
been continuously developed problems have increased recently.
For the disposal of old units it is more economical to separate the
components as toxic substances may only be contained in electronic
components. This requires a high level of input for potted units.

Compound The potting compound was changed several times for different reasons.
For some mixtures for example forming of health-damaging vapours
during curing was reduced. Resistance to coolants was improved.
However, potting must always be monitored carefully and cannot be fully
automated. This depends on the change in volume (contraction) during
curing. Forming of air bubbles which prevent the complete filling of the
cavities is critical. For low viscosity media this does not happen often. But
during potting the compound can leak through the sleeve.

Metal in step 2 The reason for using metal sleeves is their improved resistance to
mechanical stress.

Film technology (step 3) Using this technology has major advantages.

+ Mounting
+ Design
+ Time
+ Quality (fewer faulty circuits)
This is why film technology is preferred to conventional PCBs which are
often still manufactured manually.
Due to the flexible film it is easier to make the small designs required by
the market.
The fully automatic placement of components on the film results in
substantial time saving. Furthermore the circuits can be modified more
easily.
SMD For film technology the designations SMD (surface mount device) and
SMT (surface mount technology) are often used. These terms indicate
that the components and the conductor tracks are on the same side.
ifm ifm pioneered in film technology which was introduced for the
production of standard sensors Only sensors with a circuit on
conventional PCBs are found on the market except special technologies
that are only important for special units.

Figure 51 is relatively "neutral". The schematically shown components

can be conventional PCB mounted or SMD devices. The film as well is
mounted on a carrier. For cylindrical designs it is rolled up, but this

57
Training manual

cannot be clearly seen in the cross-section. In film technology the screen

is applied on the film as a closed layer of conductive material. If the film is
then rolled up, the screen surrounds the circuit. No modular sensor can
be seen in the figure because for modular technology another method is
used to seal the housing. This is described in chapter 4.1.3.

More details The explanation of the table is now finished. Modular technology is
treated in the next chapter. Some information which was not given in the
table for the sake of clarity is now provided below.

Hybrid For efectors as well additive technologies for special units (miniature
designs) are used where the semiconductors are directly bonded onto the
(ceramic) carrier and resistors are applied using the screen printing
method (hybrid technology).

Trend towards integration To reduce the number of components and to implement additional
functions special integrated circuits are increasingly used. These ICs are
made by semiconductor manufacturers according to ifm's specifications.

Basic sensor The basic sensor consists of an oscillator circuit with a coil in a ferrite core
(see 3.2.1). For the sake of clarity it was not included in the table above.
The basic sensor remained more or less unchanged. Only for special units
(electromagnetic field immune and K = 1 or 0) combinations of several
coils are used.

Figure 52: Sensor for non-flush and flush mounting

Flush mountable sensors are also available without a metal ring as shown
in Figure 53. For these sensors the metal housing has the function of the
ring, i.e. lateral screening.

Connection Connection technology has hardly been changed. With time only the
preference for a technology has changed.

Connector units There is a trend towards connector units because for the maintenance of
automated installations, e.g. replacement of a broken cable, time is a
major cost factor. A connection with a failed seal as a possible source of
failure is accepted. But the seal can only fail if the coupling nut is
fastened insufficiently or too tight (risk of mechanical damage). Here the
universal connector with M12 thread is the preferred choice.
For small designs including cylinder switches (magnetic switches) and for
weight reduction, e.g. for use on the arm of a robot, connectors with M8
thread are more and more often used.

Food industry To fulfil the special requirements of this industry optimised units can be
supplied. They have gold-plated contacts and a high-grade stainless steel
housing. For connection a high-grade stainless steel nut should also be
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58
Induticve Sensors
used for the cable plug. The connector housing should be made of PVC
because this material features the best resistance to water and cleaning
agents.

Tightening torque In general it is not necessary to use a key with an adjustable maximum
tightening torque for mounting. It should go without saying that more
care must be taken with plastic threads than with metal threads. For units
with terminal chamber the cable gland must be tightened sufficiently to
ensure the protection rating (see training manual protection ratings).

Housing materials In industrial processes inductive proximity switches are exposed to

environmental influences like heat, cold, dust, vibration, moisture,
aggressive liquids, vapours, etc. Therefore they must be incorporated into
resistant housings.

In general the housing material is a glass-fibre reinforced plastic which

has a good chemical resistance and insulation capacity. To improve the
housing stability with regard to fixing metal sleeves are often used for
threaded units.

PBTP The housing plastic normally used by ifm is a cadmium-free

polybutyleneterephthalate (PBTP) which is for example produced by Bayer
under the trade name Pocan.

Metal In the past ifm used nickel-plated brass for standard cylindrical units.
Nowadays Optalloy is used for coating. This is an allow of copper, tin and
zink which is also known as white bronze.
For special units the designs are also available with a high-grade stainless
steel sleeve, e.g. for the food industry.

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Training manual

4.1.3 Modular technology

efectorm In 2000 the new generation of inductive proximity switches was

presented under the name efectorm. This was preceded by a lengthy
development process.

The existing generation has already featured a high noise immunity and
operational reliability under severe conditions. But some of the points
mentioned above (see 4.1.2) could not be further optimized using this
technology.

Structure Special features of the modular sensor are described below. A

before/after comparison is made.

Circuit The circuit design has remained unchanged except for its modular
structure. This enables reduction of the variety of circuits to a few
modules.
Before Several circuit variants are available for one switch type with a given
operating distance, for example pnp, npn, AC/DC variants. The number
of variants can be double as high for units with cable or plug connection.
After The generation of signals, i.e. the generation of oscillations, the
evaluation of the amplitude, etc. are the same for every unit. For the
modular sensor only one module is used for this. For the output circuit
(pnp, etc.) there is a separate module for each variant. This module is
then connected to the plug or cable module.

Figure 53: Sensor module

Housing The following information refers to metal housings.

Before The circuit is placed onto a carrier, the coil with its core is also applied to
this carrier. For the finished unit it is incorporated in a plastic sleeve which
is surrounded by the actual housing (plastic or metal). The cavities are
potted with cast resin. For the most part, the individual processing steps
can only be carried out manually. In case of temperature fluctuations the
metal sleeve and other components expand differently. If due to special
environmental conditions the sensing face must be protected with a
special material, this requires the production of another complete unit.
After Part of the circuit is placed onto a mechanical carrier which is directly
inserted into the metal sleeve. The ends of the metal sleeve are sealed
with O-rings. The sensing face can consist of different materials such as
PEEK, ceramics, etc. depending on the application requirements. This
eliminates the need for a complex development and production of special
units. With the technology used so far it was hardly possible to make a
sensing face of ceramics. At the other end the connection – cable or plug
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60
Induticve Sensors
– is attached. These ends are the only components that are still potted to
ensure optimum sealing and mechanical stability. Assembly is fully
automated. The seal test as well can be automated easily and reliably.

Figure 54: Modular technology housing

Ingress resistance This feature has also been improved

Before Even in the past a unit with a failed seal seldom went through the quality
tests unnoticed. This was achieved by thorough monitoring of the
production process. Testing every unit was more difficult with the
conventional technology.
After As the efector m is not potted, the seal test can be carried out by a
simple pressure test. This test is integrated in the automated production
process. Every efector m is released for sale only after passing the seal
test. This was one of the major reasons why the development of this
technology required such a high level of input. The units now comply
with the higher protection rating IP 69K and not only with the IP67
requirements (see training manual protection ratings).

There are of course technical developments which are not only useful for
modular units. But as they are the latest generation, they are the first to
benefit from this.

Electrical connection More information about the electrical properties and their importance for
the application is given in 4.3. General information about importance and
features of 2 and 3-wire units can be found in the training manual
connection technology.
Before Units made in the tried and tested quadronorm technology also have a
low leakage current as 2-wire units which normally is < 0.4 to 0.6 mA. At
least with regard to this current value easy connection to electronic
controllers is ensured without the need of additional components. But
the plc standard type 1 additionally requires a minimum load current. This
requirement could not always be fulfilled with the quadronorm units.
Moreover, there are 3-wire units with a negligible leakage current..
After For the 2-wire units the leakage current is < 0.5 mA. There is a new
variant for the 3-wire units. They are referred to as 3/2-wire units. This
means that they can be connected either as 2 or 3-wire units. Thus
storage of spare parts is simplified even more. As these units additionally
have a 2nd LED (set-up LED), the maximum leakage current is 0.6 mA for
the 2 and 3-wire operation due to the higher current need. With a
leakage current of 0.5 mA and a minimum load current of 2 mA the
new 2-wire units comply with the plc specification without restriction.

Labelling Electrical units must be fitted with a label.

Before So far most units have been fitted with a type label (for very small designs
also at the cable). With time the label could get dirty or come loose under
severe conditions. Replacing a failed unit which cannot be identified
takes of course longer.
After The units have a permanently legible laser type label. Even if an
aggressive cleaning agent must be used due to soiling, the label remains

61
Training manual

legible. Thanks to the high degree of automation this could be achieved

very easily and reliably for the efector m.

2 advantages The advantages can be summed up as follows:

Application
Production
They are explained in the following section.

4.1.4 Application of the efectorm

Mechanics The mechanical properties have been further optimised.

In the past the protective circuitry was also rated to such a degree that
electrical interference, overload, short circuit, reverse polarity, etc. could
hardly destroy the unit. Mechanical damage is the major cause of failure
of efectors. As a further protection against damage, units with increased
operating distance, especially those with an LED indicating the certain
range can be used.

Temperature resistance
Some units are subjected to a 1000-hour test. During this test the
temperature specified in the data sheet cyclically goes up and down
within the specified limits at an interval of 2 hours. At the limit values the
temperature is maintained for 1 hour. The production release is given
only after this test has been passed. Such tests which normally exceed the
requirements of users and standards have been carried out by ifm for
years. They ensure that the units withstand harsh operating conditions.

Temperature shocks
Especially for applications in the food industry the efector can come in
contact with boiling water (100°C) and then with icy water (0°C). In
accordance with the standard for environmental tests (EN 60068-2-14 N L
test) resistance to temperature shocks is tested using the 2-bath method.
The medium used is water. One measurement cycle consists of 15 to 60
min. at 100°C and 15 to 60 min. at 0°C. The efector m has also passed
this test. The test was stopped after the switch withstood over 50 cycles.

Media Due to the modular design the material with suitable properties for
critical media can be selected easily. The sleeve is made of high-grade
stainless steel. The material for the sensing face is decisive.

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62
Induticve Sensors

Medium Sensing face

Oils LCP
Coolants Ceramics
Hot metal chips Ceramics
Cleaning agents PEEK
food

Gold-plated contacts protect against corrosion.

Identification Permanently legible laser type label.

4.1.5 Production of the efectorm

Modularity With a few modules a wide range of different units can be made. This
concerns mechanics and electronics:
Material of the sensing face (LCP, ceramics, PEEK)
Circuit (pnp-npn, 2-wire, 3-wire)
In the long term it is conceivable that a unit is made and delivered
immediately after receipt of the order.

Automation The degree of automation could be increased considerably compared to

the technology used so far.

Test In addition to the circuit tests already carried out every unit is now also
tested for ingress resistance.

4.2 Designs
ifm's standard range covers rectangular and cylindrical designs commonly
used in industry, cf. IEC60947-5-2.

Rectangular This design is mainly used for:

units with a long operating distance
The long operating distance, for standard units up to 60 mm, is achieved
by means of big coils. They are incorporated on the flat side, e.g. 120 x
80 mm² (see table below).
Units based on standard dimensions
For the formerly common mechanical position switches (see 3.1.2)
standard dimensions were usual. A machine can be designed more easily
with threaded holes being made right from the start for fixing the switch
without the need of knowing the exact type.
The housing is normally made of plastic (Pocan).

Cylindrical and smooth The very first efector generation was made in this design which is still
used today. These switches can be easily mounted and correctly
positioned using a clamp. Normally, the clamp is supplied with the unit. If
the clamp is replaced, care should be taken that it is replaced by the
original clamp to avoid mechanical damage (squeezing). The housing is
normally made of plastic (Pocan).

Cylindrical and threaded This design is also frequently used. The units can be fixed with an angle
bracket (available as accessory) or via a mounting hole with screw and
counternut.

63
Training manual

Another accessory is a special mounting sleeve for M8, M12, M18 and
M30 units. It enables quick replacement of a failed unit without having
to readjust the new part.
This design is typical of flush mountable units (see 3.4.1). The housing is
made of plastic or metal. The efectorm belongs to this last group. .

The following table gives an overview. It does not indicate all dimensions.
In particular threaded designs are often supplied with short housings so
that the large number of types which only differ in length are not listed
for the sake of clarity.

Design Dimensions in mm Material

52 x 8 x 8 metal
27,8 × 16 × 10,2
40 × 26 × 12
rectangular 40 x 40 x 66
60 × 36 × 10 plastic
121,3 × 40,5 × 40,5
90× 60 × 40
120 × 80 × 30
105 × 80 × 39,2
4 × 30
4 x 45
6,5 x 35 metal
6,5 x 49
6,5 × 35
smooth 11 x 60
18 x 70
cylindrical 11 x 54
20 × 77,4 plastic
20 × 92
34 × 82
M5 × 0,5
M8 × 1 plastic
threaded M12 × 1 or
M18 x 1 metal
M30 ×

For the cylindrical designs diameters or thread dimensions and length are
indicated. The length refers to the housing, i.e. up to where the cable or
the threaded block starts.

I would like to know more!
More details, scale drawings, information on permitted tolerances of the
dimensions, etc. can be found in the catalogue or at
www.ifm-electronic.com.
The requested design can be quickly and easily found using the selector
of the dynamic product search.
For the overview of the designs the attached type key (page 96) is
helpful.

Is this all? In addition to this basic product line ifm offers a wide selection of more
switches: Designs compatible with mechanical switches (e.g.
microswitches to DIN 41635, encapsulated limit switches to DIN 43694),
designs according to the international CENELEC standards as well as a
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64
Induticve Sensors
There are also new inductive sensors for use with special switching
amplifiers for safety-related applications. Details can be found in the
training manual safety technology.

Below are 2 examples of further types which are also available on the
market.
.
Application-oriented designs cover slot and ring sensors even if these two
types are no proximity switches in the conventional sense.

Due to the special shape of the sensing field slot sensors are preferably
used where a high repeatability is required. Ring sensors can detect small
objects like balls, needles, nuts, etc. without problems.

Connection 3 variants are available:

Cable The cable is firmly connected to the unit. So the fault source of a
connector with failed seal due to incorrect mounting is excluded.
Connector These quick-disconnect units are increasingly used. A fault by reversing
the wires is excluded even for first mounting. Due to the increasing
importance a connector brochure is available. Moreover standard
connectors or connectors with special features, e.g. for the food industry,
are recommended for proximity switches with plug connection in the
catalogues, brochures and on the internet (see above).
Terminal chamber Another variant are special units with terminal chamber where the user
can choose the cable to connect. Sealing of the terminal chamber is
achieved by a cable gland through which the cable is passed. There are
cylindrical designs where the cable runs in direction of the longitudinal
axis or, where space is at a premium, is angled by 90° by rotating the
patented end part.

4.3 Electrical data

There are several electrical data which are common to all electronic,
binary position sensors (cf. 3.1.1), e.g. inductive and capacitive proximity
switches, photoelectric sensors, etc. Therefore they are detailed in the
training manual connection technology. Only important points and
special features are indicated below without a detailed explanation of the
technical terms.

Interface directive The IEC 61131-2, the current plc standard, defines requirements for units
for connection to plcs. The electrical data have thus become even more
important.

4.3.1 Important parameters

The connection technology is important for every sensor, so it is

separately treated in the respective training manuals. Here only some
important points are summed up.

Connection technology Binary switches are available in 2-wire, 3-wire and (for special cases) 4-
wire technology. For 3 and 4-wire switches the operating voltage is
applied between +UB and 0 V and the load is switched via a signal wire.
For 2-wire switches the operating voltage is the voltage commonly
available for connecting the proximity switch and the load in series. A

65
Training manual

special case are the modular sensors with types which can either be used
as 2 or 3-wire units. The following points have to be taken into account:
Voltage drop and leakage current for 2-wire units
Voltage drop reduces the voltage applied to the load.
For former units the leakage current of a few mA could lead to uncertain
switching states, e.g. when connected to electronic controllers type 1 (for
mechanical switches). For more recent units, especially the quadronorm
units, the leakage current was reduced to typically 0.4 to 0.6 mA. For the
2-wire modular units it is 0.5 mA, the voltage drop is 2.5 V and the
minimum load current 2 mA. These technical data correspond to the plc
standard type 1. As the wiring complexity is substantially reduced the
current 2-wire switches are a low-cost alternative to the 3-wire units
(unless a fieldbus system like AS-interface is used anyway).
Series and parallel connection
For state-of-the-art technology electronic positions sensors are directly
connected to plc inputs and then logically combined via the program. So
series and parallel connection is hardly important any more. But if it
cannot be avoided, some special points have to be taken into account,
see the training manual connection technology. They concern again the
leakage current and voltage drop for 2-wire units and for 3-wire units
possible effects on the power-on delay time.

Voltage supply The voltage range in which the units operate reliably and not the nominal
voltage is important for practical use. It is specified in the data sheets and
on the type label. The standards for the CE marking define the degree of
the conducted interference the unit has to withstand, see training
manual CE marking.

Residual ripple Note for DC voltage that the residual ripple does not exceed the limit
values. It is not sufficient to check the root-mean-square value. If a power
supply of inadequate quality is used so that no sufficiently smoothed
voltage is provided, a reliable function is no longer ensured.

Figure 55: DC current supply and residual ripple

If the residual ripple falls below the limit value of the operating voltage of
the proximity switch, a smoothing capacitor must be used. A rule of
thumb for this is: 1000 µF per 1 A current intensity.

Protective circuitry
Depending on the design and type the units are fitted with different
protective components. They protect against
overload
short circuit
reverse polarity
conducted interference

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66
Induticve Sensors
4.3.2 Overview

The following overview shows the tree structure of the "family" of

inductive proximity switches. DC and AC should be terms which are
known. UC stands for universal current or dual voltage. Such units can be
connected to DC or AC within the specified range.

The figure is in preparation. For information see Figure 64.

..

The * refers to units with short-circuit protection

It can be seen that the current rating for solid-state outputs is between
approx. 100 and 400 mA depending on the design.

A nominal voltage of 24 V DC is now more or less used as control

voltage. Other voltages are used in special industries or countries.

quadronorm quadronorm units (see 4.4.4) are something special. They operate in both
polarities.

67
Training manual

4.4 Switches with special features

4.4.1 Use in hazardous areas

Note As this is important for many binary position sensors and fluid sensors
(see 4.3), this subject is also treated separately in the training manual
ATEX. In this manual the terms, designations, in particular marking of the
units, standards, etc. are detailed. In this section the term ATEX is briefly
explained. It stands for a directive of the EU which is now in force.
Former terms, e.g. Ex units, NAMUR units, are still often used. Some
definitions and designations have been changed. An example for experts:
The former zone 10 is now called zone 20.

Important! The sensor manufacturer can have his units tested and approved by
notified bodies. Due to the wide range of applications ifm gives no advice
as to which unit is allowed for a specific application. Every user is
responsible for knowing and correctly applying the standards and
regulations which are valid for his application, e.g. ATEX 100a and ATEX
118a.

The use in hazardous areas in the chemical industry, paint spraying

cabins, in mill or tanks is the oldest application area for proximity
switches. As only very small voltages are allowed in these areas problems
often occur with mechanical switches. In proximity switches, however, no
sparks, arcs or inadmissibly high temperatures are formed during
operation. In the past many versions could be directly used in hazardous
areas. This is no longer so with the ATEX directive.

This has briefly described the requirements for the unit. On no account is
a spark allowed which can trigger an explosion, e.g. in case of
mechanical destruction of a unit, short circuit through a component
which stores electrical energy, i.e. a coil or capacitor. For less hazardous
areas as well (zone 2, the exact definition is given in the ATEX training
manual) every electrical apparatus must be clearly identified as being
suitable for use in hazardous areas even if it has already met the
requirements as standard unit. In areas with a higher risk of explosion the
requirements can for example be fulfilled by mounting the sensor
separately from the switching amplifier. For these so-called NAMUR
sensors (see training manual ATEX) there are maximum values for current
and voltage which must be strictly adhered to. Power is only switched in
the switching amplifier which must be located outside the hazardous
area, e.g. in an encapsulated control cabinet. Rules must also be applied
to the cables which connect the sensor and amplifier.

As a special feature for the zone and group classification the inductive
and capacitive values of the units caused by sensors and cables are taken
into account for the ia IIc area (see training manual ATEX).

Note for the connection of different external energy stores to the control
circuit: As the energy content of the control circuit is changed by the
cable and the sensor (e.g. cable capacitances) compliance with the values
indicated on the type label is absolutely required. Therefore general
information about the maximum admissible cable length cannot be
given.
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Induticve Sensors
Use of efectors in ATEX areas
ATEX switching amplifier
NV 0100
IND
Only approved and marked sensors are allowed for use in hazardous
areas. The former generation of these sensors supplied an analogue
output signal which was evaluated by the switching amplifier. Today a
binary output signal is provided. To do so, more components than in the
past are integrated in the sensor. The circuit must of course still comply
with the strict specifications.
The switching amplifiers with an electrically isolated output stage
generate binary information from the signals of the intrinsically safe units
in the hazardous areas.
The amplifiers can be triggered by all conventional switching elements:
Mechanical contacts
Proximity switches to DIN 19 234
The amplifier has a blue type label and terminal strips in different colours
for the sensor side (blue) as intrinsically safe circuit and for the power
supply side (black). The operating voltage for the control side (sensor) is
8.2 V DC. The corresponding 2-wire DC efectors also have a blue cable to
identify them for use in ATEX areas (blue = note ATEX area).
4.4.2 Switch for quarter-turn actuators
With the IND switch for quarter-turn actuators it is possible to monitor
the open and closed position of quarter-turn actuators for valves in
accordance with the standard interface VDI / VDE 3845.3.1 without
having to mount and wire two separate switches – as usual so far.
Installation input and related cost are thus considerably reduced. The
mechanical design of the IND and the connector in combination with a
disc with switching cams available as accessory eliminate the need of
mounting and wiring in an additional terminal box. The switch can be
directly mounted onto the quarter-turn actuator via two long holes with
standardised spacing.
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Training manual

Figure 56: IND

AS-i The introduction of this system (see catalogue) opened up new

applications for this sensor or its modified versions. As position
monitoring and valve triggering are combined in one unit quarter-turn
actuators can be controlled at low cost. This is an example that this
system enables implementation of new units with a high integration
density.

4.4.3 Units with mounting aid

efectors with a two-colour LED function meet the requirements for a

simple, non-polarised connection and an optical mounting and setting
aid. A red and green (or yellow) LED indicate the position of the object to
be detected in the sensing zone. As soon as the object is detected both
LEDs light. When coming close to a value below 80% of the rated
operating distance only the switching LED lights and indicates a safe
mounting distance. In addition, the units feature a long operating
distance for flush and non-flush mounting.

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Induticve Sensors

Figure 57: Function diagram two-colour LED

AS-i For some types of photoelectric sensors another switching output has
been brought out to signal an uncertain switching state. This is also
called failure warning and can for example be used to remove soiling
before problems occur. This option is also conceivable for inductive
proximity switches but has not been implemented so far. The extra work
involved when two outputs per sensor must be connected to the
controller is for example a reason not to do so. Therefore the uncertain
switching state of these sensors is only indicated via the LED which serves
as a mounting aid. However, this is different with the intelligent sensors.
They are direct participants of the AS-i system (see catalogue) and have
up to 4 data bits. In addition to the uncertain switching state it is also
possible to monitor readiness for operation.

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4.4.4 quadronorm units

Leakage current For the 2-wire switches of the former generations the leakage current
could be some mA. Thus a reliable signal processing, e.g. by plc inputs,
was no longer guaranteed.

Polarity For solid-state DC outputs polarity must be taken into account. In many
countries and industries pnp switching sensors are commonly used. By
importing controlgear or exporting complete installations to countries
where the other polarity is common, the different polarities are a possible
source of failure, in particular if a failed sensor must be replaced. In Japan
for example npn units are still frequently found.

Normally open / normally closed
Often two units are needed which only differ in their switching function
and are otherwise completely identical. This doubles storage of spare
parts. Moreover, replacement of a failed unit is a possible fault source.
Especially for units with terminal chamber the switching function can be
determined by selection of the terminals. But this is not possible with
standard units.

The goal of the development of the quadronorm units was to improve

the above-mentioned points. They have the following features:
Leakage current normally 0.4 to 0.6 mA
Automatic recognition and adaptation to the polarity
Switching function is inverted by reversing the wires.

Core colours For the colour marking of the wires a new approach had to be pursued
as the usual colours, e.g. BN für L+ could not be used (cf. 4.3.2).

Figure 58: Wiring diagram quadronorm

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72
Induticve Sensors
Safety for machines and equipment
Safety of people? No!
Past
4.4.5 Non polarised units
They are special quadronorm units. Non-polarised connection means that
the function of the unit, e.g. normally open, is maintained no matter how
the switch is connected. This function comes closest to the mechanical
switch.
The two black wires are typical of efectors with non-polarised
connection. They show that connection in either way is possible.
¾µ Ôõ
¾µ
Ôó
Figure 59: Wiring diagram non polarised
This avoids the only mistake which can be made when connecting
quadronorm units, i.e. undesired inversion of the switching function by
reversing the two wires.
4.4.6 Self-monitoring systems
According to a statistical analysis 90% of all faults in a plant are caused
by peripheral equipment, i.e. sensors (e.g. electronic proximity switches)
and actuators (e.g. solenoid valves).
This is easily understood when taking into account that these units and
their cables are often exposed to extreme environmental conditions.
Failures caused by wire break, short circuit or mechanical damage cannot
be excluded. An unnoticed failure of a sensor or actuator may lead to
destruction of machinery, damage to products or even danger for
operators.
In principle, self-monitoring systems indirectly also concern the safety of
people. However, this subject is treated by safety technology. Units which
are allowed for use in applications where the safety of people must be
ensured are subject to strict rules, standards and regulations. Special
approvals are required as for ATEX units. These units are therefore
treated separately in the training manuals ATEX and safety technology.
As indicated above, this is about safety of machines and equipment.
A combination of sensors, called s efectors, with the control monitor
F400 were supplied in the past. They are now no longer available but still
used.
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Training manual

Current solution: AS-i
These units were not taken from the product line because the
applications do not exist any more. An optimum protection of machinery
and valuable production equipment is always important. But today there
are alternatives to such units.
The intelligent AS-i sensors (see catalogue) described above (see 4.4.3)
are such an alternative. Moreover there are also units which are used for
the safety of people. But this is also treated separately for AS-i (see the
training manual safety technology).

4.4.7 Weld-field immune units

Use in welding equipment with high constant and alternating fields.

Inductive proximity switches are used in welding lines (see IEC 60947-5-2,
annex E), for example:
for welding robots in the immediate vicinity of the welding tongs or
welding electrodes to monitor their position during welding;
to monitor the position of the chuck;
to detect the parts to be welded in the tool, e.g. metal sheets;
for the automatic control and positioning of the tool during the
different welding operations.

Influence of the magnetic field
During welding a welding current of 8 to 30 kA flows depending on the
characteristics of the material,
thickness of the metal sheets,
intended use of the parts for cars (e.g. sheets for the body shell
whose surface characteristics must not be negatively affected),
wear of the welding electrodes.

Why? The magnetic field thus generated can interfere with inductive proximity
switches in the immediate vicinity
by a magnetic saturation of the ferrite core when they are not
switched,
by induced voltages within the electronics when they are switched or
not.

Position in the magnetic field The position of the proximity switch in the magnetic field plays an
important role with the axial position being the most unfavourable due to
the high magnetic field intensity.

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74
Induticve Sensors

1: Conductor with welding current I

2: Sensor in the radial field
3: Sensor in the axial field
Figure 60: Position in the magnetic field

Welding current and distance from the conductor

The application of weld-field immune inductive sensors depends on the
level of the welding current I and the distance r from the conductor
where the welding current flows.

The graph of the magnetic inductance B in dependence on the distance r

of the current-carrying conductor is shown in the following figure.

Figure 61: Magnetic field and distance from the conductor

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Training manual

Equation Reference values for sensor mounting are calculated with the magnetic
inductance equation.
200 I I
( 5) Bã
r
B[mT]: Magnetic inductance
I[A]: Current intensity
r[mm]: Distance

The electromagnetic-field immune efectors of ifm electronic, also called

weld-field immune efectors, can be used at close range to welding
electrodes in alternating and constant fields. For example M12 and M18
efectors were tested successfully in an alternating field with a welding
current of 21 kA and a distance of 30 mm between the sensor and
conductor where the welding current flows. These operating conditions
correspond to a magnetic inductance B = 140 mT.

To compare: At a distance of 1 mm from a conductor where a current of

I = 1 A flows B is 0.2 mT. The Earth's magnetic field is in the range of
0.01 mT.

How? The magnetic field immunity was achieved using

a special oscillator
a new coil structure.
an air-core inductor

To protect the electromagnetic-field immune inductive efectors against

weld spatter they were fitted with an anti-adhesive and temperature-
resistant sensing face. The coating contains no silicone as silicone breaks
down the paint surface tension, which can cause flemishes in car
paintwork. For the more recent units PTFE is used.

Depending on the application, PTFE (teflon) caps can be ordered as

accessories for M12, M18 and M30 switches to provide additional
protection against mechanical damage. Sockets with irradiated cables are
also available as accessories which are particularly suitable for
applications in welding lines.

Special features of the electromagnetic-field immune switches:

Electromagnetic-field immune (weld-field immune) for 50 Hz and
1000 Hz welding
Insensitive to predamping (flush mountable units)
Coil structure: 1 and 2-coil technology
Sensing face protected against mechanical damage
Sensing face of PTFE (teflon) or with anti-adhesive (safecoat) coating,
heat-resistant
Design for the automotive industry, length 60 mm, incl. plug
High switching frequency
Designs M12 f/nf, M18 f, M30 f and rectangular with universal US-
100 plug.

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76
Induticve Sensors

4.4.8 Units with increased operating distance

In industrial applications units with increased operating distance are more

and more often used. This is so because the installation conditions in
plants no longer correspond to IEC 60947-5-2, i.e.
the required clear space for mounting non flush units in metal is no
longer available,
smaller designs or smaller targets are used,
the division into flush and non-flush mountable switches is to be
eliminated to reduce mounting, servicing and storage of spare parts.

To comply with these customers' requests ifm developed units with

increased operating distance. Important requirements for the units are as
follows:
Small operating distance reduction, i.e. the difference of the
operating distance of flush units when mounted flush and non flush,
see 3.3.1.
Sufficient excess gain to avoid uncontrolled switching for example
due to conductive dust and high temperatures
Compliance with the installation conditions according to IEC 60947-
5-2 for flush and non-flush mounting of inductive proximity switches
At least the same correction factors as for units with normal
operating distance, i.e.:
Longer operating distance for materials other than mild steel
Series production, i.e. cost-optimised volume-limited sensor
technology

How is this achieved? Operating distance and quality factor of the oscillator circuit are in direct
relation, i.e. the better the quality, the higher the attainable operating
distance. The quality factor is improved by changing the following
parameters:
Core material and geometry
Coil wire
Magnetic field distribution (development of a sandwich sensor)
Oscillator frequency
Use of NTC networks for temperature compensation

Mounting flush units non flush results in an operating distance reduction,

especially for large designs (M18, M30), see 3.3.1 and the following
Figure 62:

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Training manual

Figure 62: Operating distance reduction

Normally ifm units have an operating distance reduction below 10%,

see graph 1 and graph 2
If the operating distance reduction for an increased operating
distance is only insufficiently compensated for, large designs have a
higher operating distance reduction, see graph 3 and graph 4
or even switch on permanently, see graph 5

The following table indicates some typical values for increased operating
distances of ifm units.

flush mountable non-flush mountable

alt neu alt neu
M8 1 2 (+ 100 %) 2 4 (+ 100 %)
M12 2 4 (+ 100 %) 4 7 (+ 75 %)
M18 5 8 (+ 60 %) 8 12 (+ 50 %)
M30 10 15 (+ 50 %) 15 22 (+ 47 %)

All indications are for s n [mm]. "Old" means according to IEC 60947-5-2,
"new" stands for the increased value.

4.4.9 Units for overflush mounting

In 3.4.1 the term overflush has already been explained. For monitoring
transport processes, in particular when moving heavy objects, long
operating distances as achieved with rectangular units, are required. Such
a unit is overflush mountable. Figure 63 shows the clear space to be
adhered to. The unit can be recessed by a maximum of 5 mm. To do so,
a lateral clear space of 3 to 4 mm must be adhered to.

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78
Induticve Sensors
Overview of inductive units
Figure 63: IDC overflush mounting
In 3.4.1 the term overflush has already been explained. For monitoring
transport processes, in particular when moving heavy objects, long
operating distances as achieved with rectangular units, are required. Such
a unit is overflush mountable. Figure 63 shows the clear space to be
adhered to. The unit can be recessed by a maximum of 5 mm. To do so,
a lateral clear space of 3 to 4 mm must be adhered to.
Due to the wide selection of types and variants an overview can no
longer be given in a simple table. Here the screen representation of the
selector is shown as an example. Note that when working with the
selector not every combination of features is possible. It is recommended
to get familiar with the selector because you can then obtain a good
overview of the variety of switches.
Figure 64: Overview of inductive switches in the selector
There is one special feature for the large rectangular units: the sensitivity,
i.e. the operating distance is adjustable with a potentiometer. For the
other units it is fixed.
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Training manual

4.4.10 Special correction factors, K1, K0

K=1 The operating principle was detailed in 3.5. Below the special features of
this type which are important for the user are described.

Features In principle, this sensor behaves like a conventional inductive proximity

switch. But for special applications certain features must be taken into
account. The switch-on graph is much narrower than with the
conventional type. The coil arrangement has a certain sensing direction
which has a higher effect with this type.

The broken line in Figure 65 shows the switch-on graph for the
conventional sensor (not to be confused with the hysteresis graph, Figure
20), the unbroken line the graph of the K1 sensor. For the sake of
illustration the figure is a little exaggerated.

K1
- - - - - Conventional sensor

Figure 65: Switch-on graphs

Narrow objects If stacks of sheets, e.g. transformer sheets, are detected, the selected
position should be transverse to the layers (horizontal arrow in Figure 66).
The other position (vertical arrow) is unfavourable. It is known that the
layers of transformer sheets are electrically isolated to minimize eddy
current losses. But for K1 this can have the effect that the individual
sheet directly opposite the sensor (lower position in Figure 66) which
"sees" the sensor from the edge has too small dimensions, i.e. is too
narrow to be detected. Due to the sensing direction detection of the
sheets positioned on the side is especially poor.

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80
Induticve Sensors

Figure 66: Detection of transformer sheets

Which designs? The following information refers to the new cylindrical designs.

Frequency The K1 sensor has a higher switching frequency due to the higher
frequency of the oscillator.

Temperature To be on the safe side, the maximum value of the temperature range is
specified with 70°C for the K1 sensor.

Welding current Due to the operating principle the K1 sensor is weld-field

(electromagnetic-field) immune without additional measures being
required.

Predamping In practice, problems can arise due to predamping, especially for the non-
flush mountable conventional type. The influence of predamping is much
smaller for K1 (all the more so for K0, see 3.5.4). So it functions more
reliably.

Small objects However, the disadvantage of low susceptibility to predamping is that the
sensor does not detect small objects as reliably as the conventional
sensor.

K=0 The features of the K0 sensor are more or less the same as for the K1
sensor except for the switching frequency.

Operating distance reduction Compared to the conventional sensor, the opposite effect of predamping
is a remarkable feature. In case of predamping the operating distance can
become even smaller. Due to this effect a sensing face of high-grade
stainless steel can be used.

Area of applications In metalworking applications proximity switches are directly exposed to

harsh environmental conditions. The "ferrous-only" efector m ingress-
resistant design incorporates high-quality materials such as Viton O-rings
or a stainless steel sensing face. They guarantee long life.

Ferrous-only The new efector m ferrous only switches only detect ferrous metals.
Aluminium chips which build up on the sensing face during the process
and lead to incorrect switching of conventional sensors are ignored due
to this principle.

Absolutely ingress-resistant The sensor is resistant to oil and coolants due to the special design,
additional seals as well as the use of a stainless steel cover as sensing

81
Training manual

face. This results in a long life. These efector m units have the protection
ratings IP68 and IP67 (see training manual protection ratings).

Robust The full metal housing of the K0 sensor is for example more resistant to
abrasion than standard sensors. Due to the laser type label units can still
be identified afters years.

Features
Aluminium chip immune, therefore no malfunction caused by
aluminium chips.
IP68, IP67. Absolutely reliable in permanent contact with oil and
coolants.
High vibration and shock resistance.
Robust design with stainless steel sensing face and reinforced
housing.
Permanently legible laser type label.

Units The first type with K = 1 was rectangular. The new generation also covers
threaded housings.

Rectangular IMC (see catalogue, type IM5067)

Thread IFK (M 12), IGK (M 18), IIK (M30)

K=0 Designs: IF and IG (see catalogue, types IFC211 and IGC211).

4.5 Criteria for practical use

Overview Most of the following points have already been discussed in detail and
are again briefly summed up below.

Since sensors in production processes are normally mounted at exposed

machine locations, they are directly subjected to harsh environmental
conditions like heat, cold, shock, vibration, dust, moisture, chemically
aggressive liquids, etc. Therefore they must be protected against
malfunction caused by such harsh operating conditions. The data sheets
contain information about applications and environmental conditions
where the units can be used without problem.

Operating temperature
This indicates the temperature of the medium surrounding the proximity
switch. The specified permissible temperature range is often –25°C to
+80°C. Within these limits the switch is allowed to be operated as long
as desired. Temperatures which are slightly above or below these limits
for a short time are normally tolerated by the switches. This means that
the switch is not destroyed but the operating distance can be outside the
permissible range within this time. Special units are available for other
temperature ranges.
Resistance to temperature shocks and high temperature fluctuations
within a short time is much better for the modular units.

Shock and vibration resistance Proximity switches have no moving parts. They are thus extremely
resistant to shocks or vibrations. A standard value for the maximum
shock resistance is 30 times the gravitational acceleration (30 g). A
reference value for the maximum vibration resistance is a frequency of up
to 55 Hz with an amplitude of 1 mm. Furthermore the efector m units for
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82
Induticve Sensors
mobile use have been specially developed to withstand increased shocks
and vibrations in mobile applications. The features of these units are
much above the standard requirements.

Foreign bodies and dust Inductive proximity switches are in no way influenced by build-up of
electrically non conductive materials. Smaller conductive particles like
metal chips do not lead to eddy current losses that are so high that they
can influence the switch.
To identify ingress resistance of electrical apparatus (see training manual
protection ratings) an internationally standardised combination of figures
is used by the proximity switch manufacturers to indicate ingress
resistance of their units, e.g. IP 67. IP stands for "international
protection". The first figure indicates protection against contact with live
parts and ingress of solid foreign objects. 6 means protection against
ingress of fine dust and complete protection against contact with live
parts. The second figure refers to the protection against ingress of water.

Moisture and water The function of inductive proximity switches is not directly influenced by
water, moisture, mist and vapours. Their function is only restricted in case
of long-term exposure.
To be on the safe side, it is however important to know how well a
proximity switch is protected against ingress of water. This is shown by
the second figure of the IP rating. 7 for example means that a proximity
switch is protected against ingress of water so that it can be placed in 1
m water depth for half an hour without water penetrating in harmful
quantities.
As a rule proximity switches are offered with the protection ratings IP65
and IP67 according to the requirements of the standard. In general, units
with potted cable have the protection rating IP67. For units with terminal
chamber or connector IP65 is specified. But they can also be often used
under conditions where IP67 is required. This protection rating is
indicated because incorrect mounting, e.g. incorrect placing of seals, can
result in another protection rating.
For the modular units ingress resistance has been improved even more.

Chemical influence Whenever solid, liquid or gaseous chemical substances can interfere with
the operation of a proximity switch it must be carefully checked whether
housing and cable sufficiently withstand this substance. The common
plastic housings of glass fibre reinforced material or the units with
additional metal sheath are in most cases a good option for use in a
chemical environment. For especially difficult applications special
housings of corrosion-resistant stainless steel or PTFE sleeves are available
as accessories.
In particular the continued development of additives for cleaning agents
or coolants in the chemical industry place increasing demands on the
units. They are fulfilled best by the modular units.

Electromagnetic influence In applications for proximity switches, i.e. in industrial environments,

various high-energy electromagnetic disturbances occur caused e.g. by
radio transmitters, switching operations in the mains, switch-off of
inductive loads or lightning strikes. Such electromagnetic interference can
be picked up by the sensing field or the connection cable. Due to the
dimensions of the sensor which are small compared to the length of
radio waves the risk of influence of such periodic interference is very low.
Abrupt and short disturbances can be filtered by suitable circuit
components so that the noise immunity of proximity switches is high.

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Training manual

Interference can also be picked by the cable. When the cable has not
been laid favourably, it can happen that the cable to the proximity switch
acts as an antenna for radio waves or numerous abrupt disturbances can
be picked up by cables with a high noise component laid in parallel. In
particular the further development of frequency inverters leads to
increased requirements. In special cases using interference-suppression
filters can help.
Limit values for immunity to this interference are defined in the EMC
directive (see training manual CE marking). The units must pass a number
of tests to be allowed to carry the compulsory CE mark. Here immunity to
defined interference is tested.
The requirements for units for mobile use (road traffic) are much higher
than laid down in the EMC law (CE marking). ifm offers units (with e1
approval) for this area as well.

Other influences Compared to other sensor types the function of inductive proximity
switches cannot be disturbed by sound and light. The only interference to
which a proximity switch is not immune is intensive X-ray radiation or
radioactivity. Strong magnetic fields close to the proximity switch, e.g.
for electrical welding equipment can affect the function of inductive
proximity switches. For this application ifm offers so-called weld-field
immune special versions.

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Induticve Sensors

5 Application examples
Proximity switches are mainly used as position switches as an alternative
to mechanical position switches. Mechanical switches are cheaper but
subjected to wear. If they fail, complete plant sections, conveyor belts,
etc. can be brought to a standstill for hours. Therefore it makes sense to
use non-contact and wear-free electronic proximity switches instead of
mechanical switches for these applications.

Proximity switches are also a good choice for rotational speed

monitoring. High switching frequencies must be achieved and a large
number of switching cycles are required for a correct function of the
monitoring system. Moreover a clearly defined switching signal is
important for an exact evaluation. Proximity switches with a high
switching frequency and solid-state output are an excellent choice to
provide clearly defined output signals (see 3.3.4).

Hazardous areas in the chemical industry, mills or tanks are the oldest of
all applications for proximity switches. Since in this area only very small
voltages are allowed, proximity switches with additional safety are
available for such applications. Many types of proximity switches hold an
ATEX approval for use in hazardous areas. These switch types are
standardised in the DIN 19 234 and are frequently referred to as NAMUR
switches.

For applications where failure of a proximity switch, e.g. due to

mechanical damage is not acceptable, many manufacturers supply self-
monitoring systems where the proximity switch itself is continuously
monitored for its function.

This is only a short overview of the universal suitability of inductive

proximity switches. The user comes across many tasks which are not
obvious at first sight during the design stage of his installation. So sooner
or later the knowledge alone of the function and features of inductive
proximity switches helps to solve application problems.

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Training manual

»º»½¬±®

»º»½¬±®

Figure 67: Robot arm

The two possible end positions of the robot arm are monitored without
contact by inductive proximity switches.

»º»½¬±®

Figure 68: Pipe production

For the pipe production the inductive proximity switch monitors the
supply of new pipes for further processing.

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86
Induticve Sensors

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Figure 69: Rotational speed monitoring

Inductive proximity switches used for rotational speed monitoring of a

machine (see 3.3.4). The proximity switch detects the teeth of the
toothed wheel without contact. Mounting additional targets or switching
cams is not necessary.

Figure 70: Car washer

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Training manual

Inductive proximity switches with increased operating distance used in an

automatic car washer. The increased operating distance ensures reliable
detection even in case of mechanical tolerances

Figure 71: Welding robot

Electromagnetic field immune efectors monitor the end position, e.g. on

welding robots close to the welding electrodes.

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88
Induticve Sensors

Figure 72: Conveyor

Inductive efectors monitor the position on automatic transport systems

and conveyors, e.g. in the automotive industry.

Figure 73: Elevator

efectors used to monitor an elevator. In combination with speed and

skew monitors the sensors signal misalignment of the conveyor and
monitor the rotational speed of the drive.

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Training manual

Appendix

Advantages In general it can be assumed that efectors do not only meet the specified
data, but are on the safe side. Standards are complied with and even
exceeded. IP 67 means that the unit operates correctly in 1 m water
depth for 30 min. There are applications where efectors operate
continuously without problem in deep water. Values above or below the
specified temperature range of e.g. –25° C to +80°C are possible within
certain limits (cf. 3.3.1). Modular units are distinguished by their high
resistance to temperature shocks.
Further advantages:
Product availability
Reliability (5-year warranty for standard units)
Service (large sales force)
Compliance with special requests (custom-made units)
Use of film and modular technology

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Induticve Sensors
Technical glossary
Active zone / sensing zone
The active zone is the area over the sensing face in which the proximity
switch reacts to the approach of the damping material, e.g. changes its
switching status.

Assured operating distance (s a) The assured operating distance is the distance from the sensing face
where a proximity switch operates reliably under given temperature and
voltage conditions (see operating distance). It is the minimum value of
the usable operating distance.
Cable material
PVC In order to avoid cable break PVC cables must not be moved if the
temperature falls below -5° C.

Correction factor If the shape, material or thickness of the target is different from the
standard target, operating distances other than the standard operating
distance result. They can be calculated using correction factors which are
specified in the technical data sheet. The following factors must also be
taken into account:
Shape factor If instead of the standard target, a smaller or non square target is used or
if the target is not flat, the operating distance must be corrected with a
shape factor.
Material factor If instead of the target material defined in the standard, e.g. FE360 to ISO
630, another target material is used, the operating distance must be
corrected with a material factor. For inductive sensors it depends on the
conductivity and the permeability of the material.
For K1 units it is constant ( = 1), K0 units only detect steel (ferromagnetic
materials).
Material thickness factor If a target is used with a thickness below the penetration depth of the
sensing field (e.g. metal foil), the operating distance must be corrected
with a material thickness factor. For inductive switches this factor is in
general greater than 1, i.e. the conductivity of the material seems to be
less than normal as part of the magnetic field emerges behind the metal
foil due to the skin effect. This leads to a longer operating distance.
For capacitive switches this factor is normally below 1.

Current rating/peak Switch-on and switch-off capacity under usual/unusual conditions.

The peak current rating is the maximum current which may flow for a
short time at the moment of switch-on without destroying the proximity
switch.
Especially AC units are rated so that they can be operated with six times
the nominal current for a short time due to the high inrush currents of
many AC loads (pilot lamps, contactors...) (also see utilization categories).

Effective operating distance sr The effective operating distance of a proximity switch is the operating
distance measured at rated voltage and room temperature (23 ±5°C). It
must lie between 90 % and 110 % of the rated operating distance (see
operating distance).

Flush mounting The sensing face can be mounted flush with the surface of the damping
material.

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Training manual

Housing materials
Metal housing Aluminium
Stainless steel *
Steel sheet galvanised
Brass with Optalloy (nickel-free)*
PTFE coated brass (safecoating)*
*: Inductive units
Stainless steels (rust-free stainless steel and acid-resistant high-grade
stainless steel):
Stainless steel: 303S22 (X10CrNiS 189)
304S15 (X2CrNiMo)
High-grade steel: 316S12 (X2CrNiMo 17132)
316S12 (X2CrNiMo 18143)
320S31 (X6CrNiMoTi 17122)

Plastic housing
PBTP (polybutyleneterephtalate) The housing is largely resistant to aliphatic and aromatic hydrocarbons,
oils, greases, hydraulic fluids, fuels; no stress cracking when exposed to
air.
The housing is not resistant to hot water, hot steam, acetone,
halocarbons, concentrated acids and alkalis.
Modified PPO The housing is largely resistant to diluted mineral acids, weak alkalis,
some alcohols, oils and greases depending on the additives.

Chemically resistant fluoroplastics: PTFE (polytetrafluoroetylene)

LCP, PEEK, PEI, PA, mod. PC

The resistance of plastics depends on the environmental and operating

conditions. Therefore certain properties or the suitability for a certain
application cannot be guaranteed.
For frequent or permanent exposure to chemicals it is recommended to
test all housing materials prior to use.

The chemical resistance of the cast resin used for potting is comparable
to that of the plastics for the efector housings. For unpotted efector m
units protection against contact with the medium other than the housing
materials has been further improved due to the design..

Hysteresis The hysteresis is the difference between switch-on and switch-off point
of the proximity switch. It is indicated in percent referred to the switch-on
point measured under the same conditions and serves to prevent
uncontrolled switching of the proximity switch when the target is near
the switch point ("output chattering").

Leakage current in 2-wire units The leakage current is the current which flows through 2-wire units when
the output is blocked in order to supply the electronics with current. The
leakage current also flows through the load.

Measurement of the operating distance The operating distance is determined according to EN 60947-5-2.

NAMUR NAMUR stands for Normenarbeitsgemeinschaft für Meß- und

Regeltechnik (standardisation group for metrology) in the chemical
industry. A NAMUR switch is a special version of a 2-wire DC unit to DN
19234 suitable for use in hazardous areas (today ATEX, see training
manual).

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92
Induticve Sensors
No-load current for 3-wire units
The no-load current is the intrinsic current consumption of the proximity
switch when it is not switched.
A very low leakage current of about 0.1 µA flows through the output
transistor when the output is not switched (open collector).

Nominal operating distance See rated operating distance.

Non-flush mounting A proximity switch is non-flush mountable when a specified free zone
around its sensing face is necessary in order to maintain its
characteristics.

Normally closed Principle of normally closed operation. If an object is in the area of the
active zone, the output is blocked (see output function).

Normally open Principle of normally open operation. If an object is in the area of the
active zone, the output is switched.

Operating distance
The operating distance of a proximity switch is the distance at which an
object approaching the sensing face axially causes the output to change
its state (see correction factors and measurement...).
Also see rated operating distance, usable operating distance, effective
operating distance and assured operating distance.

Operating temperature range
The temperature range specifies the temperatures at which proximity
switches can be used.
Common ranges for ifm efectors:
Standard units -25...80° C
Units with special features (e.g. increased operating distance)
-25...70 °C
0...100 °C
-40...85 °C

Operating voltage The voltage range (around the nominal voltage) in which the proximity
switch operates reliably. For DC units the minimum and maximum values,
including the residual ripple, must be adhered to.

Output function
Normally open Object within the active zone – output switched / high signal
Normally closed Object within the active zone – output blocked / low signal
Programmable Normally closed or normally open selectable
Complementary Normally open and normally closed output functions are available
simultaneously.

Overload protection The output of a proximity switch is protected against overload if any
currents between nominal load current and short-circuit current can flow
continuously without damage.

Passing speed If the proximity switch is damped and undamped by one single target
which moves through the active zone at high speed, there is a maximum
passing speed at which a reliable switching signal is just provided.

Power-on delay time
The time the proximity switch needs to be ready for operation after
power on. It depends on the switch type and is in the ms range (5 ms to
over 200 ms depending on the type). Within this time the internal voltage
supply must stabilise and the oscillator must start to oscillate. The
output is not active.

93
Training manual

Programming For some efector types the output function can be programmed to be
normally open or normally closed. Depending on the efector type the
output function is programmed via a wire link, a jumper or pin
connection.

Protection rating See the training manual protection ratings.

IP 65 Complete protection against contact with live parts. Protection against
the ingress of dust. Protection against water jets.
IP 67 Complete protection against contact with live parts. Protection against
the ingress of dust. Protection against the ingress of water when
submerged in 1 m depth for 30 minutes.

Rated impulse withstand voltage U imp This is the voltage reference for clearance rating.

Rated insulation voltage Ui This is the voltage reference for the dielectric voltage tests and creepage
distances. For units with protection class II the voltage of the adjacent
mains supply is considered to be Ui, 250 V AC.

Rated operating current The rated operating current (continuous current rating) indicates the
current at which a proximity switch can be continuously operated (also
see current rating/peak).

Rated operating distance (sn) The rated operating distance is a value which does not take into account
individual variations and changes due to external influence like
temperature and voltage (also see operating distance).

Repeatability (reproducibility)
The difference between two operating distance measurements carried
out for 8 hours under standardised conditions is called repeatability and
specified in percent referred to the effective operating distance. The
difference between two random measurements must not exceed 10% of
the effective operating distance.

Reverse polarity protection
A switch is protected against reverse polarity if the wire connection to the
terminals can be reversed without damage to the switch. As a rule 3-wire
switches which are protected against reverse polarity must be short-
circuit protected because otherwise reversing the output and ground
connection (0 V) would destroy the unit.

Sensing face The sensing face is the face on the proximity switch where the
electromagnetic field is generated.

Sensing zone see Active zone

Short-circuit protection The output of a proximity switch is short-circuit protected according to

VDE 0160 if it withstands a short circuit of the load or a short to ground
at the output permanently without damage and if it is ready for
operation again without any switching after the short circuit has been
removed.
In the event of a short circuit the output transistor is blocked
immediately. After rectification of the short circuit the unit is ready again
for operation immediately. Reversing the connection wires does not
destroy the units. Short-circuit protected units are normally protected
against overload and reverse polarity.

Smallest operating current in 2-wire units This is the current which must at least flow in the switched state to
ensure reliable operation of the proximity switch (sometimes also called
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94
Induticve Sensors

Switching delay The switching delay is the time which elapses between moving the target
into the active zone and switching of the output. The switching delays for
damping and undamping can differ considerably. For ifm efectors these
times (depending on the type) are normally 0.2 to 2 ms for damping and
0.3 to 3 ms for undamping. For units with F-IC a ratio of 1:1 for these
two times can be achieved.

Switching frequency The switching frequency is the limit frequency at which each periodic
damping and undamping operation of the proximity switch is just reliably
converted into a switching signal. Since the attainable switching
frequency depends on several factors, a standard measurement
arrangement is defined in EN 60947-5-2 to obtain values for comparison.
The switching frequencies in real applications are often much higher.
If the proximity switch is operated with a high inductive load (contactor,
relay, solenoid valve) for a longer period and high switching frequency,
additional protective measures must be taken to reduce the switching
overvoltage (e.g. free-wheeling diodes).

Temperature / switch point drift Switch point drift is the shifting of the switch point caused by a change
of the operating temperature.

Types of mounting When inductive proximity switches are mounted, a distinction is made
between flush and non-flush mounting.
Flush mounting (f) The sensing face can be mounted flush with the surface of the damping
material.
Non-flush mounting (nf) The sensing face must be surrounded by a clear space (see mounting
instructions).
When proximity switches are mounted side by side or opposite each
other defined minimum distances depending on the design must be
adhered to.

Usable operating distance s u The usable operating distance is measured within the permissible
operating voltage and operating temperature ranges according to EN
60947-5-2. It must lie between 90 % and 110 % of the effective
operating distance (see operating distance).

Utilization category The categories are listed and explained in the following table according
to EN 60947-5-2.
Utilization categories for switching elements
Category Typical applications
Alternating current AC-12 Control of resistive and solid-state loads
AC-140 Control of small electromagnetic loads with
holding current < 0.2 A; e.g. contactor relays

Direct current DC-12 Control of resistive and solid-state loads

DC-13 Control of electromagnets
Category AC -140 applies to AC/DC efectors, category DC -13 to 2 and
3-wire DC efectors and category DC-12 to NAMUR types.

Voltage drop (on-state voltage)
As the switching output of the proximity switch is equipped with a solid-
state component (transistor, thyristor, triac), a (small) voltage drop occurs
in series to the load in the switched state. In two-wire technology the
voltage drop also serves to supply the electronics of the proximity switch
with energy. The amount of the voltage drop depends on the type and
lies between 2.5 V (DC) and 6.5 V (AC/DC).

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Training manual

Type key
Pos. Designation Contents

1 Sensing principle inductive

2 Type
3 Design of housing
1 = cylindrical, smooth plastic housing 100mm
2 = cylindrical, smooth plastic housing 164mm
3 = rectangular housing 8 x 8 x 40mm (old, now = L)
6 = special unit (Still)
A = cylindrical, smooth plastic housing 20mm
B = cylindrical, smooth plastic housing 34mm
C = rectangular plastic housing 90 x 60 x 40mm
D = rectangular plastic housing 120 x 80 x 30mm
DC = rectangular plastic housing 92 x 80 x 40mm
DE = rectangular plastic housing 105 x 80 x 40mm
E = cylindrical housing M8 x 1
F = cylindrical housing M12 x 1
G = cylindrical housing M18 x 1
I = cylindrical housing M30 x 1.5
J = rectangular plastic housing 27 x 25 x 10.5mm and further special units
L = rectangular housing 8 x 8 x 40mm
M = rectangular plastic housing 120 x 40 x 40mm
MC= rectangular plastic housing 66 x 40 x 40mm
N = rectangular plastic housing 40 x 26 x 12mm
ND = rectangular plastic housing 40 x 26 x 26mm
NS = power clamp switch
O = rectangular plastic housing 26 x 26 x 70mm
Q = rectangular plastic housing 30 x 28 x 15mm (cable)
rectangular plastic housing 30 x 28 x 24mm (plug)
R = high-pressure special type
S = rectangular plastic housing 28 x 16 x 10mm
T = cylindrical, smooth housing 6.5mm
V = rectangular plastic housing 118 x 40 x 40mm
rectangular plastic housing 118 x 55 x 55
W = rectangular plastic housing 60 x 36 x 10mm
Z = cylindrical, smooth housing 4mm
Y = cylindrical housing M5 x 0.5
9 = special type
– = standard / plastic housing
A = standard / metal housing
B = short body / metal thread
C = short body / plastic thread
D = dual sensor (IND)
E = housing with terminal chamber
G = smooth housing
K = intermediate length / metal thread
W = cube

4 Connection system 2 = two-wire system

3 = three-wire system
4 = four-wire system
C = 2/3-wire system (modular technology)
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Induticve Sensors
8 Additional designations – = standard
B = flush installation (for extended sensing range)
D = 2 separate output stages (IND)
P = 2 distance-related outputs
S = s-efector
R = series connection possible
U = electromagnetic-field immune
Z = temperature-resistant
9 Switching function A = normally open for two-wire units and for three-wire NPN units
normally closed for three-wire PNP units
normaly open for 2/3-wire modular technology
B = normally closed for two-wire units and for three-wire NPN units
normally open for three-wire PNP units
normaly closed for 2/3-wire modular technology
C = complementary output
D = analog output
E = NO and NC (independent, not complementary)
F = output function programmable
V = voltage output
N = NAMUR sensors (positions 10-12 not used)
S = safety switch (positions 10-12 not used)
asi = asi sensors (position 12 not used)
10 Output B = semiconductor output for AC and AC / DC units
N = semiconductor output negative switching
P = semiconductor output positive switching
R = semiconductor output positive or negative switching
S = 2/3-wire modular technology (3-wire PNP; 2-wire PNP/NPN)
T = 2/3-wire modular technology (3-wire NPN; 2-wire PNP/NPN)
11 Short-circuit protection K = with short-circuit protection
L = latching
O = without short-circuit protection
12 Supply voltage A = choice of AC or DC voltage (AC / DC)
G = DC voltage
W = AC voltage
13 Slash
14 Options 2LEDs = 2 LED's
SL = earth wire
V2A = V2A metal housing
V4A = V4A metal housing
MS = metal conduit attachment
UP = non-polarised output
SC = safecoated
F = frequency offset
xm = cable x m long
SF = increased noise immunity
AC = with AC connector (only with ... / xm - JAPAN)
DC = with DC connector (only with ... / xm - JAPAN)
T2 = dual sensor T2
M = modular technology
K0 = Ferrous only
K1 = no correction factor
xD = ATEX approved for x category Dust
xG = ATEX approved for x category Gas
xxV = with Ub=xxV

97
Training manual

Production code

Explanation production code

The coding is indicated on the type and box labels of our products or on an alternative type of
labelling, e.g. 'direct laser labelling' as it is used with the units in modular technology.

The coding covers information about Legend 'production site'

production site E ifm ecomatic, Kressbronn
production month K ifm prover, Kressbronn (from 1/3/2000)
P (bought-in products)
special designation S ifm syntron
(meaning registered in the production site)
T ifm Tettnang (parent plant)
production status U ifm USA (efector inc.)
W ifm Sweden
F ifm France

Current production code:

Standard coding Direct laser labelling

(conventional units) (modular units)

spec. prod. site prod. Prod. year prod. year prod. month
des. (see month (last pos.) (last two pos.) (dec.) 01...12
legend) (hex.)
1...9,
A,B,C

prod. status
AA...ZZ prod. site spec. prod. status
(see legend) des. AA...ZZ

Example: SA8 made by Example: 9903 made in 1999,

ifm Syntron in in March (03)
October (A) 1998
- no special designation -
AA first production T AB in the parent plant
status (AA) ifm Tettnang ;
second prod.
status (AB)
- no special designation -

Old coding (until September 1995)

prod. month prod year

spec. (last pos.)
(dec.) 01...12
des.

d:\dokumente und einstellungen\dezeyegu\eigene dateien\lokalab05-04\materiallevele\originale\prodcode-e.doc

This copy was printed on 03.06.04 enclosure to EA SIT-015

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98
Induticve Sensors
Index
#
............................................................................33
2 connection cable ......................................................46
2-wire units........................................................61, 66
3 connector units ........................................................58
3/2-wire units...........................................................61
3-wire units........................................................61, 66
A coolants ...................................................7, 57, 63, 83
AC ...........................................................................67
active zone...............................................................91
advantages ..............................................................90
aggressive media........................................................7
Al ................................................................48, 50, 51
alternating current ...................................................95
aluminium chips.......................................................54
analogue....................................................5, 6, 12, 18
angle bracket ...........................................................63
angle of approach....................................................13
application examples................................................85
AS-i..............................................................70, 71, 74
assured operating distance.................................25, 91
ATEX............................................................68, 69, 85
axially.......................................................................29
B damped .............................................................19, 20
b ............................................................................41
basic inductive sensor...............................................15
basic sensor ...............................................................5
basics ...................................................................7, 11
binary ..................................................5, 6, 12, 18, 20
block diagram ..........................................................21
blue cable ................................................................69
C direct current ...........................................................95
cable ........................................................................65
cable gland ..............................................................65
cable length .............................................................68
cable material ..........................................................91
car washer ...............................................................88
carrier ......................................................................53
category...................................................................95
CE marking ........................................................66, 84
ceramics.............................................................60, 63
change in the quality factor .....................................48
change of the switch point ......................................13
chemical influence ...................................................83
cleaning agents........................................7, 57, 63, 83
clear space ...................................................27, 41, 78
coil.....................................................................16, 58
coil system ...............................................................55
complementary ........................................................93
conductivity .............................................................10
conduit ....................................................................46
connection ...............................................................58
connection technology.......................................61, 65
connector.................................................................65
contact bouncing ...............................................13, 14
contact resistance ....................................................13
continuous current rating.........................................94
core colours .............................................................72
correction factor ........... 30, 31, 32, 33, 40, 48, 77, 91
corrosion..................................................................14
cost..........................................................................69
counted pulses.........................................................37
coupling factor.........................................................52
cross-section ............................................................55
curing ......................................................................57
current ...............................................................93, 94
current rating.....................................................67, 91
cycle frequency ........................................................37
cycle time.................................................................37
cylindrical and smooth .............................................63
cylindrical and threaded ...........................................63
D
damping ..................................................................34
DC ...........................................................................67
degree of automation ..............................................63
depth of penetration................................................33
design ................................................................14, 63
difference.................................................................53
digital.........................................................................6
dimensions...............................................................18
direction of movement.............................................47
dirt...........................................................................14
disc with a hole ........................................................36
distance ...................................................................18
distance measurement .............................................18
dust .............................................................14, 57, 83
E
eddy current ............................................................18
eddy currents ...............................................10, 11, 17
edge ........................................................................80
efector .......................................................................6
efectorm .........................................................7, 60, 64
effective operating distance .........................25, 50, 91
electrical conductivity .........................................18, 32
electrical data...........................................................65
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Training manual
electrically conductive material .................................17
electromagnetic induction ..........................................9
electromagnetic influence ........................................83
electronic catalogue .................................................40
electronic circuits......................................................14
elevator ....................................................................89
EMC law ..................................................................84
energy......................................................................10
environmental influences..........................................25
evaluation ................................................................54
excess gain...............................................................77
F
f .......................................................... 41, 43, 45, 95
failure warning.........................................................71
FAQ............................................................................7
Faraday's law ...........................................................10
Fe.............................................................................50
ferrite core ........................................................ 16, 58
ferromagnetic ............................................. 32, 48, 51
field..........................................................................16
film technology ........................................................57
fixing elements.........................................................46
flush................................................ 17, 28, 43, 77, 95
flush mountable .......................................................41
flush mounting.........................................................91
food .........................................................................63
food industry....................................................... 6, 58
for non-flush mountable ..........................................41
formula ......................................................................7
frequency.......................................................... 15, 54
G M12 .................................................................. 58, 64
gold-plated contacts.......................................... 58, 63
graphite ............................................................ 32, 40
guarantee ..................................................................2
H magnetic flux ............................................................ 9
half the rated operating distance....................... 30, 35
hazardous areas ................................................ 68, 85
heat dissipation ........................................................57
high-grade stainless steel................................... 58, 62
hot metal chips ........................................................63
housing ....................................................... 53, 56, 60
housing material ......................................................59
housing materials .............................................. 59, 92
hybrid technology ....................................................58
hysteresis .............................................. 22, 28, 29, 92
I metal foil........................................................... 33, 91
ICs............................................................................58
IDC...........................................................................79
IEC 60947-5-2..........................................................24
ifm ...................................................................... 6, 57
increased operating distance ....................... 27, 40, 77
IND...........................................................................69
individual variations..................................................25
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100
information ............................................................... 2
ingress resistance .......................................... 7, 61, 63
ingress-resistant ...................................................... 81
installation input ..................................................... 69
intelligent sensor ....................................................... 5
interaction............................................................... 40
interference............................................................... 6
IP ............................................................................ 94
IP 67........................................................................ 83
IP 69K ..................................................................... 61
iron ......................................................................... 32
is K0........................................................................ 48
K
K 1 ....................................................................... 48
K = 0................................................................. 33, 48
K = 1................................................................. 32, 48
K1 ........................................................................... 48
L
label ........................................................................ 61
laser type label .................................................. 61, 63
lateral approach ...................................................... 29
LC oscillator............................................................. 15
leakage current ..................................... 61, 66, 72, 92
Lenz's Law............................................................... 11
life time............................................................. 13, 14
limit for the thickness .............................................. 33
limit frequency ........................................................ 37
M
M18 ........................................................................ 64
M30 ........................................................................ 64
M8 .................................................................... 58, 64
magnetic field immune............................................ 74
magnetic-field immune ........................................... 76
magnetizability ........................................................ 10
mark-to-space ratio ........................................... 35, 37
material....................................................... 32, 40, 48
material factor......................................................... 91
material thickness.................................................... 33
material thickness factor.......................................... 91
measurement ............................................................ 5
mechanical limit switch ........................................... 13
mechanical stability ................................................. 46
metal....................................................................... 59
metal housing ......................................................... 92
metal ring................................................................ 58
metal sleeve ............................................................ 57
mild steel........................................................... 24, 48
minimum distances ................................................. 44
minimum load current............................................. 94
mist......................................................................... 83
modular technology ................................................ 60
moisture...................................................... 14, 57, 83
Induticve Sensors
mounting.................................................................95
mounting aid ...........................................................70
mounting instructions ........................................41, 44
mounting sleeve.......................................................64
movement ...............................................................40
multiplicator.............................................................54
mutual interference..................................................44
N
NAMUR ...................................................................92
narrow objects .........................................................80
nb ............................................................................41
nf ................................................................41, 45, 95
no-load current ........................................................93
nominal operating distance ......................................93
nominal voltage .......................................................66
non-contact output..................................................14
non-flush .........................................41, 43, 77, 93, 95
non-flush mountable................................................27
non-polarised...........................................................73
normally closed ............................................23, 72, 93
normally open ..............................................23, 72, 93
notation .....................................................................7
npn ..........................................................................72
NV 0100 ..................................................................69
O
offset frequencies ....................................................46
oil ............................................................................14
oils ...........................................................................63
on-state voltage .......................................................95
operating distance23, 33, 40, 43, 79, 81, 91, 93, 94,
95
operating distance reduction............27, 28, 43, 77, 81
operating temperature .............................................95
operating temperature range ...................................93
operating voltage.....................................................93
operational reliability..........................................15, 40
Optalloy ...................................................................92
O-ring ......................................................................60
oscillator circuit ........................................................19
oscillator frequency ......................................49, 51, 54
output .........................................................21, 23, 67
output function........................................................93
overflush............................................................44, 78
overload...................................................................66
overload protection..................................................93
P
parallel connection...................................................66
passing speed ..........................................................93
PBTP ..................................................................59, 92
pcb ..........................................................................55
peak ........................................................................91
PEEK ..................................................................60, 63
penetration depth ....................................................91
permeability .......................................................18, 51
pipe production .......................................................86
plastic housing ........................................................92
plc............................................................................37
pnp ..........................................................................72
Pocan.......................................................................63
point measurement..................................................40
polaritiy....................................................................67
polarity.....................................................................72
position....................................................................18
position sensor.........................................................12
potting.....................................................................57
power-on delay time ....................................22, 66, 93
PPO..........................................................................92
precise .....................................................................26
precision ..................................................................53
predamping .................................................27, 44, 81
Production code .......................................................98
programmable .........................................................93
programming ...........................................................94
protection ................................................................94
protection rating ....................................59, 61, 83, 94
protective circuitry....................................................66
proximity switch...................................................6, 14
PTFE .........................................................................76
PVC....................................................................59, 91
Q
quadronorm.......................................................67, 72
quarter-turn actuator ...............................................69
quasi flush................................................................44
R
radially .....................................................................29
rated impulse withstand voltage ..............................94
rated insulation voltage............................................94
rated operating current ............................................94
rated operating distance ..................23, 40, 43, 48, 94
readiness for operation ............................................71
receiver ..............................................................52, 53
rectangular...............................................................63
reference resonant circuit.........................................52
reliably detected.........................................................6
repeatability .................................................26, 29, 94
representative circuit diagram ..................................48
reproducibility ..........................................................94
residual ripple ..........................................................66
resistance characteristics ....................................20, 49
resolution...................................................................6
response times .........................................................14
reverse polarity.........................................................66
reverse polarity protection........................................94
robot arm.................................................................86
room temperature....................................................91
rotational speed ........................ 36, 37, 39, 85, 87, 89
rule of thumb...............................................26, 30, 31
rules.........................................................................26
S
sa ......................................................................25, 91
101
Training manual
safe mounting distance ............................................70
safecoat ...................................................................76
safety of people .......................................................73
safety technology .....................................................73
scale drawings..........................................................64
screen ......................................................... 17, 43, 58
seal test....................................................................61
selector ............................................................. 40, 79
sensing elements......................................................14
sensing face .......................................... 46, 60, 91, 94
sensitivity .................................................... 50, 52, 53
sensor ........................................................................5
sensor module..........................................................60
serial connection ......................................................66
series connection......................................................48
setting aid ................................................................70
shape .................................................... 18, 31, 40, 91
shock resistance .......................................................82
short circuit ..............................................................66
short-circuit protection ...................................... 67, 94
short-circuit voltage..................................................10
side length ........................................................ 24, 31
signal deviation ........................................................52
signal frequency .......................................................37
skew monitor ...........................................................89
skin effect ................................................................11
small objects ............................................................81
SMD.........................................................................57
smoothing capacitor.................................................66
SMT .........................................................................57
sn ...................................................................... 25, 94
sr ...................................................................... 25, 91
stainless steel ...........................................................32
standard...................................................................24
standard dimensions ................................................63
standard square target .............................................24
su ...................................................................... 25, 95
switch off reliably .....................................................25
switch point .............................................................50
switch point drift......................................................95
switching amplifier ............................................ 68, 69
switching cam ................................................... 36, 37
switching cycles................................................. 13, 14
switching delay ........................................................95
switching force.........................................................13
switching frequency .................. 13, 14, 35, 49, 81, 95
switching function............................................. 23, 72
switching response...................................................14
switching speed .......................................................35
switching time................................................... 14, 34
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102
switch-on graph .................................... 13, 14, 29, 80
switch-on graphs..................................................... 29
T
target ................................................................ 24, 48
temperature .................................... 25, 62, 81, 82, 95
temperature range .................................................. 93
temperature shocks..................................... 57, 62, 82
temperature variations ............................................ 25
terminal chamber .................................................... 65
Tesla.......................................................................... 9
test.......................................................................... 63
thickness ................................................................. 33
thin foils .................................................................. 11
tightening torque .............................................. 46, 59
time response.......................................................... 22
toothed wheel......................................................... 37
transfer resistance ................................................... 13
transformer ............................................................. 17
transmitter .................................................. 49, 52, 53
transport processes ................................................. 78
travel................................................................. 13, 14
trigger stage...................................................... 20, 54
type key ............................................................ 64, 96
types of mounting................................................... 95
U
UC .......................................................................... 67
uncertain switching state......................................... 71
undamping.............................................................. 34
universal current...................................................... 67
unreliably detected.................................................... 6
usable operating distance.................................. 25, 95
utilization category.................................................. 95
V
valves ...................................................................... 69
vapours ................................................................... 83
vibration resistance.................................................. 82
voltage drop...................................................... 66, 95
voltage supply ......................................................... 66
W
warranty.................................................................... 6
water ...................................................................... 83
wear.................................................................. 13, 14
weld spatter ............................................................ 76
weld-field immune ................................ 74, 75, 76, 81
welding robot ......................................................... 88