TomTom-Tools GmbH

Zelgli 20 Phone: +41 79 774 06 44

8905 Arni Info@tomtom-tools.com
Switzerland www.tomtom-tools.com

User Manual:

Mechanical Kiln Monitoring (MKM) System

1. INTRODUCTION:
The MKM-System is an on-line measuring system for rotary kilns with more than 2 Stations to
detect abnormalities during operation, which can lead to mechanical failures. The main objective is
to detect thermal or permanent cranks in the kiln shell, loss of relative movement on kiln tires and
problems in axial movement at an early stage. Analog signal exchange (4 20 mA) allows
connecting it directly with the factory control system in order to set alarm levels and to take
adequate counter-measures. Furthermore the equipment is storing the measured data to a memory
card in way to perform off-line analysis at any stage in order to verify origin of upset condition
(process or mechanical).
The modular setup allows connecting different measurement units:
The main purpose of the system is to measure cranks in the kiln shell via roller shaft bending
measurement. This requires the main unit (1), which includes the control box and a kiln speed
sensor and one roller shaft bending unit (2) for each station.
If the kiln is not already equipped with a reliable system to measure the relative movement of the
tires, it is recommended to add the unit (3) to each tire.
To measure the axial kiln position, unit (4) can be connected; if not already a similar system is in
operation.

Page 1 28 February 2015

TABLE OF CONTENT

1. Introduction: ..........................................................................................................................1
1.1 Safety: .................................................................................................................................3

2. Measuring Principle:.............................................................................................................4
2.1 Roller Shaft Bending Measurement (Unit 1+2)...................................................................5

2.2 Relative Tire Movement (Unit 3) .........................................................................................5

2.3 Axial Kiln Position (Unit 4) ...................................................................................................5

3. Sensor positioning ...............................................................................................................6

3.1 3 Station Kiln .......................................................................................................................6

3.2 4 Station Kiln .......................................................................................................................7

3.3 Relative Tire Movement Sensors .......................................................................................8

3.4 Axial Kiln Position Sensors: ................................................................................................8

4. Sensor Data Sheets: .............................................................................................................9

4.1 Kiln Speed Sensor ..............................................................................................................9

4.2 Roller Shaft Bending Sensors...........................................................................................10

4.3 Relative Tire Movement Sensors .....................................................................................11

4.4 Axial Kiln Position Sensors ...............................................................................................12

5. Control Box..........................................................................................................................13
5.1 Layout ...............................................................................................................................13

5.2 Analogue Outputs .............................................................................................................14

5.3 LED Terminal Block ..........................................................................................................14

5.4 Values displayed in the CCR ............................................................................................15

6. Installation (preparation work) ..........................................................................................16

6.1 3 Station Kiln: ....................................................................................................................16

6.2 4 Station Kiln: ....................................................................................................................17

7. Miscellaneous .....................................................................................................................18
8. Annexes ...............................................................................................................................18

Page 2 Februar 28, 2015

1.1 Safety:

Rotary kilns, dryers and mills, where this tool typically is used, are huge rotating equipments with
many pinch points, they can cause serious injuries. Therefore only specialized and trained
personnel shall work close to these machines. To use the tool, follow strictly the local safety rules
given by the respective plant / factory / local authorities and discuss the application with the safety
engineer in charge.
The tools provided by TomTom-Tools GmbH have proven their functionality in various applications;
nevertheless TomTom-Tools GmbH does not take any responsibility for the application on site
regarding safety. The plant is responsible for the safety, according to the local law, in a way that
nobody can be hurt or injured. The application and safety instructions below are guidelines and not
exhausted which include the experience from previous measurement campaigns and might need to
be adapted to the local safety requirements.

Caution:

Pinching Points:
Do not put your hands nor any items close or into pinching points
(e.g. girth gear / pinion, kiln tires / support rollers, switch flags / sensors,)
Keeps safe distance to avoid getting caught by moving parts

Magnet Fields:
Be aware of the strong magnet field of the magnetic switch flags.
Keep the tool away from people with pace makers or any other sensitive
item as credit cards or magnetic data carrier.

Clamping:
Do not put fingers between the magnets and magnetic surface. There is the
risk for clamping or pinching, due to the strong magnetic force.

Gloves:
Wear proper gloves to protect your hands from hot and rough surfaces and
sharp edges.

Page 3 Februar 28, 2015

2. MEASURING PRINCIPLE:

The MKM System is equipped with different inductive distance sensors with an analogue output of
020mA or with a digital output of 24VDC.
The signals of the sensors are measured and recorded by the data logger in the MKM Control Box.
The data logger (DALOG 376) is calculating the different values (roller shaft bending and its peak
position, relative tire movement and axial kiln position) and provides an output signal (420mA)
accordingly.
Furthermore the control box is equipped with a card reader, where periodically (every 2 weeks) all
the data from the data logger are stored in the SD card. The data download from the data logger to
the SD card can be forced by pushing the button on the card reader.
Note: the download to the SD card takes about 12 minutes (shown by alternating blinking of green
and red LED). Do not remove the card during the download process!!
The software DalogUI (for Windows), which comes together with the measurement tool is made for
statistical analysis of the stored data on the SD card.

Axial Kiln Position Sensor

Roller Shaft
Bending Sensor

Relative Tire Movement Sensor

Kiln Speed
Sensor Axial Kiln Position Sensor
Page 4 Februar 28, 2015
 2.1 Roller Shaft Bending Measurement (Unit 1+2)

On a kiln support roller, the variation of the deflection of the roller shafts show possible cranks in the
kiln shell. Cranks are straightness errors in the kiln shell, which are affecting the loads on the roller
stations with each kiln revolution.
There are two types of cranks:
Permanent / Mechanical Crank:
Caused by plastic deformations in the kiln shell or errors during the kiln construction.
Thermal Crank:
Caused by uneven temperature distribution / thermal expansion around the kiln shell
circumference. (most severe close to the middle tire)
The load changes caused by cranks can be very strong and overload the tires and rollers, which
results in cracks in tires, rollers and roller shafts.
The crank pushes the roller down; hence the distance between the sensor and the roller surface is
reduced. Half a kiln revolution later, the crank turns up and the load gets reduced on this station;
hence the distance to the sensor is getting bigger.
To measure the effect of a crank, an inductive sensor is placed under the support roller in the line of
force. That means on the opposite side of the contact to the kiln tire.
Due to the high stiffness of the roller shafts, these movements are very small (within tenths of
millimeter), therefore small sensor 12mm are used to have a high accuracy

Low Load High Load Low Load High Load Low Load High Load

2.2 Relative Tire Movement (Unit 3)

To measure the relative movement of loose tires (also called migrating tires) the speed of the tire
has to be measured and compared with the speed of the kiln. This is done with the magnetic switch
flag and the tire speed sensors, which provides an impulse (24V) to the control box, when the
switch flag is passing by the sensor.

2.3 Axial Kiln Position (Unit 4)

The actual position of the kiln in axial direction is measured with two inductive distance sensors and
two switch flags on both sides of the girth gear. Two sensors are required to enlarge the working
distance of the sensors. When the kiln is in its middle position, both switch flags are in the range of
their sensors. If the kiln moves to one side, the opposite switch flag will go out of the range of its
sensor and only the closer one will measure. The calculation for this sensor range increase is done
in the control box.
Note: for the first reference and to start the calculation of the axial kiln position, the kiln has to be
approximately in the middle position and both sensors have to have a value of max. 45mm

Page 5 Februar 28, 2015

 Tomtom-tools.com

3. SENSOR POSITIONING

3.1 3 Station Kiln

1. Main Unit:
B2.1 Kiln Speed Sensor to be placed at 6 oclock position as indicated in the sketch below
Weld a switch flag (Steel plate) onto the kiln in line with the kiln reference point. Usually the man hole or the position of one of the splits of the girth
gear is used as reference point. Place the switch flag with sufficient distance to the kiln shell (250400mm), to avoid overheating of the sensor.
2. Roller Shaft Bending Unit:
B1.1 / B1.2 / B1.4 Roller shaft bending tire 1, 2, 3, to be placed at in-running roller in force direction (30) (see sketch)
(Note: B.1.3 is not connected)
3. Relative Tire Movement Unit:
B3.1 / B3.2 / B3.3 Relative movement tire 1, 2, 3, Sensor to be placed between 5 and 7oclock position. For safety reason, to avoid that somebody
get pinched between switch flag and sensor it is recommended to install the sensor to 5 oclock position (against rotation, see sketch)
4. Axial Kiln Position Unit
B4.1 / B4.2 Axial kiln position Sensor to be placed on the girth gear (uphill / downhill) in line with the speed sensor (see sketch)

Rot
atio
Tire 1
Tire 3

Tire 2

n
Material Flow

B3.3 B3.2 B4.2 B4.1 B3.1 B2.1

B2.1

Man Hole 30 B1.x

B1.4 B1.2 B1.1
used as reference point

Power Supply
110...240VAC MKM
Control Box

Page 6 Signal Outputs 28 February 2015

4...20mA
3.2 4 Station Kiln
1. Main Unit:
B2.1 Kiln Speed Sensor to be placed at 6 oclock position as indicated in the sketch below
Weld a switch flag (Steel plate) onto the kiln in line with the kiln reference point. Usually the man hole or the position of one of the splits of the girth
gear is used as reference point. Place the switch flag with sufficient distance to the kiln shell (250400mm), to avoid overheating of the sensor.
2. Roller Shaft Bending Unit:
B1.1 / B1.2 / B1.3 / B1.4 Roller shaft bending tire 1, 2, 3, 4, to be placed at in-running roller in force direction (30) (see sketch)
3. Relative Tire Movement Unit:
B3.1 / B3.2 / B3.3 / B3.4 Relative movement tire 1, 2, 3, 4 Sensor to be placed between 5 and 7oclock position. For safety reason, to avoid that
somebody get pinched between switch flag and sensor it is recommended to install the sensor to 5 oclock position (against rotation, see sketch)
4. Axial Kiln Position Unit
B4.1 / B4.2 Axial kiln position Sensor to be placed on the girth gear (uphill / downhill) in line with the speed sensor (see sketch)

Rot
atio
Tire 1
Tire 4

Tire 3

Tire 2

n
Material Flow

B3.4 B3.3 B3.2 B4.2 B4.1 B3.1 B2.1

B2.1

30 B1.x
B1.4 B1.3 B1.2 B1.1

Power Supply MKM

Man Hole 110...240VAC Control Box
used as reference point
Signal Outputs
4...20mA

Page 7 Februar 28, 2015

 Tomtom-tools.com

3.3 Relative Tire Movement Sensors

For the function, the tire movement sensors do not need to be in a line or at a specific position, but
for safety reason, it is recommended to install the sensors at 5 oclock position (see sketch below)
in order to get more free space for safe work on the tire during operation (e.g. lubrication).

Rota
tion
Safety Note:
In case the full length of the switch
flag on the tire is not necessary,
shorten the switch flag to the
required length.

B3.x

3.4 Axial Kiln Position Sensors:

The Sensors for the axial kiln position have to be installed in the same timing with the kiln speed
sensor. The signal from the speed sensor switch flag has to match the center of the switch flag on
the girth gear. Hence these sensors are preferable installed at 6 oclock position
(see sketch below).
Restrict the axial kiln movement to max 35mm in order not to damage the sensors.
A normal kiln travel is 2025mm within 24 hours.

Material Flow
~300
40 40
~250

B2.1 25 <35
<35
Man Hole, Switch Flags on Kiln and
Girth Gear in same lime / timing

Page 8 28 February 2015

4. SENSOR DATA SHEETS:

4.1 Kiln Speed Sensor

Technical data and wiring diagram of the Sensor B2.1 (M50x1.5 IN500140):

Page 9 Februar 28, 2015

4.2 Roller Shaft Bending Sensors

Technical data and wiring diagram of the Sensor B1.x (NI5-M12-LiU-H1141)

Attention:
For the signal connect only the current output (pin 2, white wire)
The voltage output is not used (pin 4, black wire)

Page 10 Februar 28, 2015

4.3 Relative Tire Movement Sensors

Technical data and wiring diagram of the Sensor B3.x (M50x1.5 IN500140):

Page 11 Februar 28, 2015

4.4 Axial Kiln Position Sensors

Technical data and wiring diagram of the Sensor B4.x (NI50-Q80-LiU-H1141):

Attention:
For the signal connect only the current output (pin 2, white wire)
The voltage output is not used (pin 4, black wire)

Page 12 Februar 28, 2015

 5. CONTROL BOX

5.1 Layout

The cabinet should be placed on a sheltered place away from vibrations and in save distance (min.
5m) of emitting electrical machines like big motors, frequency converters, transformers, etc.

LED Terminal Block Data Logger

for Sensor and (DALOG 376)
Output Signals

SD Card Reader

Power supply 100240VAC

24VDC

Terminal Block
Sensors Power Supply
(Ground / + 24VDC)

Page 13 Februar 28, 2015

5.2 Analogue Outputs

The following max. 7 analogue signals will be transmitted to the Central Control Room (CCR). The
exact number of outputs depends on the installed measurement units and on the number of tires
equipped with the relative movement measurement.
The following tables show the possible output signals in mA and how they have to be interpreted

Unit Signal Output Electrical Mechanical

2 Roller shaft bending (tire 2 / 3) x.1 (4 20) mA (0 0.8) mm
2 Kiln Crank Phasing x.2 (4 20) mA (0 360)
3 Relative Movement Tire 1 x.3 (4 20) mA (0 16) mm/m
3 Relative Movement Tire 2 x.4 (4 20) mA (0 16) mm/m
3 Relative Movement Tire 3 x.5 (4 20) mA (0 16) mm/m
3 Relative Movement Tire 4 x.6 (4 20) mA (0 16) mm/m
4 Axial Kiln Position x.8 (4 20) mA (-40 +40)mm

5.3 LED Terminal Block

The terminal block for the sensors and signal output is equipped with LED bars.
The LEDs indicate the signal level (mA) at the respective channel.
The lowest LEDs show 0mA, the highest show 20mA.
The different colors indicate if the signal is in the recommended range or not.
Green: in good recommended range
yellow: slightly out of recommended range
red: out of recommended range

Note: The LED bars can be enabled / disabled by the two switches on top of each bar, below glass

Page 14 Februar 28, 2015

5.4 Values displayed in the CCR

The following tables show the possible output signals and how they have to be displayed in the
Central Control Room (CCR).

Signal Display Warnings / Alarms* Unit

LL L H HH
Roller shaft bending (tire 2 / 3) 00.8 - - 0.15 0.2 mm
Kiln Crank Phasing 0360 - - - -
Relative Movement Tire 1 016*DiTire 3 5 25 30 mm/rev
Relative Movement Tire 2 016*DiTire 3 5 25 30 mm/rev
Relative Movement Tire 3 016*DiTire 3 5 25 30 mm/rev
Relative Movement Tire 4 016*DiTire 3 5 25 30 mm/rev
Axial Kiln Position -40+40 -35 -30 30 35 mm

Roller Shaft Bending Values:

For displaying the crank in the kiln shell of a 3 Station Kiln, the signal of the roller shaft bending on
station 2 and its phasing is sufficient. On a 4 Station kiln, the values of station 2 or 3 are transferred
to the control room. The signal switches automatically to the station with the higher roller shaft
bending value.
Note:
The value of the roller shaft bending is a +/- Value, that means the halve of the peak to peak value

Relative Tire Movement Calculation:

The signal of the Relative Tire Movement has to be multiplied with the inner diameter of the tire
DiTire [m], to get the correct value in [mm/rev].

Page 15 Februar 28, 2015

 6. INSTALLATION (PREPARATION WORK)

6.1 3 Station Kiln:

The following cables have to be pulled to connect the Control Box:

Electrical Power (10024VAC) to Terminal Block

Sensors with LED Terminal Block (see dashed lines in sketch below)
B1.1 Roller Shaft Bending Sensor Tire 1
B1.2 Roller Shaft Bending Sensor Tire 2
B1.3 (not connected)
B1.4 Roller Shaft Bending Sensor Tire 3
B2.1 Speed Sensor Kiln
B3.1 Speed Sensor Tire 1
B3.2 Speed Sensor Tire 2
B3.3 Speed Sensor Tire 3
B4.1 Position Sensor uphill
B4.2 Position Sensor downhill

Max. 5 analogue outputs 4 20 mA for the complete system to connect it with the CCR
x.1 Roller shaft bending Station 2
x.2 Phasing Peak position of crank
x.3 Relative Movement Tire 1
x.4 Relative Movement Tire 2
x.5 Relative Movement Tire 3
x.8 Axial Kiln position

Please see details in Annex

Rot
atio
Tire 1
Tire 3

Tire 2

n
Material Flow

B3.3 B3.2 B4.2 B4.1 B3.1 B2.1

B2.1

30 B1.x
B1.4 B1.2 B1.1

Power Supply
110...240VAC MKM
Control Box

Signal Outputs
4...20mA

Page 16 Februar 28, 2015

 6.2 4 Station Kiln:

The following cables have to be pulled to connect the Control Box:

Electrical Power (10024VAC) to Terminal Block

Sensors with LED Terminal Block (see dashed lines in sketch below)
B1.1 Roller Shaft Bending Sensor Tire 1
B1.2 Roller Shaft Bending Sensor Tire 2
B1.3 Roller Shaft Bending Sensor Tire 3
B1.4 Roller Shaft Bending Sensor Tire 4
B2.1 Speed Sensor Kiln
B3.1 Speed Sensor Tire 1
B3.2 Speed Sensor Tire 2
B3.3 Speed Sensor Tire 3
B3.4 Speed Sensor Tire 4
B4.1 Position Sensor uphill
B4.2 Position Sensor downhill

Max. 5 analogue outputs 4 20 mA for the complete system to connect it with the CCR
x.1 Roller shaft bending Station 2 or 3
x.2 Phasing Peak position of crank
x.3 Relative Movement Tire 1
x.4 Relative Movement Tire 2
x.5 Relative Movement Tire 3
x.6 Relative Movement Tire 4
x.8 Axial Kiln position

Please see details in Annex

Rot
atio
Tire 1
Tire 4

Tire 3

Tire 2

Material Flow

B3.4 B3.3 B3.2 B4.2 B4.1 B3.1 B2.1

B2.1

30 B1.x
B1.4 B1.3 B1.2 B1.1

Power Supply MKM

110...240VAC Control Box

Signal Outputs
4...20mA

Page 17 Februar 28, 2015

7. MISCELLANEOUS

If there are any questions or problems please refer to Thomas Stutz or Thomas Rheinegger,
thomas.stutz@tomtom-tools.com
thomas.rheinegger@tomtom-tools.com

8. ANNEXES

1. Technical Details (Reference and relative tire movement sensor)

2. Technical Details (Roller shaft bending sensors)
3. Technical Details (Axial kiln position sensors)
4. Electrical wiring diagram
5. Technical Details (Sensor mounting)

Page 18 Februar 28, 2015

 Annex 1
(Reference Sensor)
inductive high temperature sensors

sensors with integrated amplifier, 10 to 35V DC, 3-wire version

technical data and article list

design M50x1.5 M50x1.5 M50x1.5 M50x1.5
sensing range Sn 20mm 20mm 25mm 25mm
ambient temperature -25 ... +180C -25 ... +180C -25 ... +180C -25 ... +180C
mounting flush flush non-flush non-flush
voltage drop (max. load) < 2V DC < 2V DC < 2V DC < 2V DC
operating voltage 10 ... 35V DC 10 ... 35V DC 10 ... 35V DC 10 ... 35V DC
short-circuit protection + + + +
reverse polarity protection + + + +
current consumpt. (w/o load) 15mA 15mA 15mA 15mA
output current (max. load) < 150mA < 150mA < 150mA < 150mA
switching output pnp, no pnp, no pnp, no pnp, no
sampling frequency 100Hz 100Hz 100Hz 100Hz
Sn hysteresis 3 ... 15% 3 ... 15% 3 ... 15% 3 ... 15%
status display - - - -
system of protect. (EN 60529) IP65 IP65 IP65 IP65
housing material stainless steel stainless steel stainless steel stainless steel
front cap material Vectra Vectra Vectra Vectra
2m silicone cable IB500150 - IN500150 -
5m silicone cable IB500151 - IN500151 -
10m silicone cable IB500152 - IN500152 -
2m teflon cable IB5001T0 - IN5001T0 -
5m teflon cable IB5001T1 - IN5001T1 -
10m teflon cable IB5001T2 - IN5001T2 -
lemo-connector - IB500140 - IN500140
wiring diagram 1 4 1 4
see page 27
matching cable socket - e.g. VK500940 - e.g. VK500940
see page 26
fixing material AY000102 AY000102 AY000102 AY000102
see page 27

silicone cable 5mm silicone cable 5mm

teflon cable 3mm teflon cable 3mm

ipf electronic gmbh Kalver Strae 27 Fon +49 (0) 2351 / 9365-0 www.ipf-electronic.de Subject to alteration!
D-58515 Ldenscheid Fax +49 (0) 2351 / 936519 E-mail: info@ipf-electronic.de k06/009 01/08 page 13
 inductive high temperature sensors

wiring diagram 1 cable devices 3-wire wiring diagram 2 connection devices 3-wire

wire colors: bn = brown (1), bu = blue (3), bk = black (4) wire colors: bn = brown (1), bu = blue (3), bk = black (4)

wiring diagram 3 connection devices 2-wire wiring diagram 4 lemo-connector devices 3-wire

wire colors: bn = brown (1), bu = blue (3) wire colors: bn = brown (1), bk = black (2), bu = blue (3)
fixing material
AY000098 for design M8x1, stainless steel AY000099 for design M12x1, stainless steel

AY000100 for design M18x1, stainless steel AY000101 for design M30x1.5, stainless steel

AY000102 for design M50x1.5, aluminium AY000103 for design M80x1.5, aluminium

AY000104 for design M30x1.5, aluminium

ipf electronic gmbh Kalver Strae 27 Fon +49 (0) 2351 / 9365-0 www.ipf-electronic.de Subject to alteration!
D-58515 Ldenscheid Fax +49 (0) 2351 / 936519 E-mail: info@ipf-electronic.de k06/009 01/08 page 26
 Annex 2
(Roller shaft
bending Sensor)
 Edition:
Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com

Inductive sensor
with analogue output
NI5-M12-LiU-H1141

threaded barrel, M12 x 1

Chrome-plated brass
4-wire, 1530 VDC
analogue output
&' )
010 V and 020 mA
% connector, M12 x 1
#$
%

( Wiring diagram

!
&'
"



Type NI5-M12-LiU-H1141
Ident-No. 1535535

Measuring range [AB] 0.5 4 mm

Mounting condition non-flush Functional principle
Correction factors St37 = 1, V2A ~ 0.7, Ms ~ 0.4, Al ~ 0.3 Simple control tasks can be accomplished
Repeatability 1 % of measuring range |A - B| with inductive TURCK sensors featuring an
0.5 %, after a warm-up time of 0.5 h analogue output. They provide a current,
Reproducibility 35m voltage or frequency signal that is propor-
17.5m, after a warm-up time of 0.5 h tional to the target's distance. With TUR-
Linearity deviation 3% of full scale CK's analogue sensors, this output signal
Temperature drift 0.06 %/K is linear to the distance of the target over
Ambient temperature -25+ 70 C the entire sensing range.

Operating voltage 15 30VDC Measuring range

Residual ripple 10 % Uss
No-load current I0 8 mA
Rated insulation voltage 0.5 kV A B
Short-circuit protection yes U [V] I [mA]
Wire breakage / Reverse polarity protection yes / complete
Output function 4-wire, analogue output 11 max 22 max
10 20
voltage output 0 10 V
current output 0 20 mA
Load resistance voltage output 4.7 k
Load resistance current output 0.4 k
Measuring sequence frequency 100 Hz
Output recovery time 12 ms 0,05 0,1
0 A B 0
Housing threaded barrel, M12 x 1
Dimensions 62 mm
Housing material metal, CuZn, chrome-plated
Material active face plastic, PA12-GF30
Tightening torque of housing nut 10 Nm
Connection Connectors, M12 x 1
Vibration resistance 55 Hz (1 mm)
Shock resistance 30g (11 ms)
Degree of protection IP67
Edition: 10.06.2009

Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com
 Edition:
Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com

Inductive sensor
with analogue output
NI5-M12-LiU-H1141

Mounting instructions minimum distances

Distance D 36 mm
Distance W 12 mm
Distance T 3xB
Distance S 18 mm
Distance G 24 mm
Distance N 8 mm

Diameter of the active area B 12 mm

- *

,
+

Edition: 10.06.2009

Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com
 Edition:
Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com

Inductive sensor
with analogue output
NI5-M12-LiU-H1141

Accessories
Type code Ident- Short text Dimension drawing
No.
QM-12 6945101 quick-mount fixing clamp with dead-stop; material:
chrome-plated brass male thread M16 x 1. Note: The
switching distance of proximity switches can be $

reduced by the use of quick mounting brackets.

(/0
. 

BST-12B 6947212 fixing clamp with dead-stop; material: PA6

&0

) 1 )

. )

MW-12 6945003 mounting bracket; material: stainless steel A2 1.4301

/#
(AISI 304)

0/0 /#
(/0 /( 1/

(/
1/ /
/1
/1 #/(

BSS-12 6901321 fixing clamp; material: polypropylene

0
)
.

%/0

 )

IM43-13-SR 7540041 limit value monitor; single channel; input 0/420 mA

or 0/210 V; supply of 2- or 3-wire transmitters/sen-
sors; limit value adjustment via teach button; three )
1(

relay outputs with one normally open contact each;

removable terminal blocks; 27 mm wide; universal )
#
voltage supply 20250 VUC; further limit value
monitors are described in our "Interface Technology"
catalogue.
Edition: 10.06.2009

Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com
 Annex 3
(Electrical wiring
diagram)
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LJ45*)+4C*$O* f\X ")@CL,+@ 5+44$5*)+4C D6)44$, ")@C*+ D6)44$, f\X LJ45*)+4C*$O*

78C\/1 =< ^/PQ0RMNV^b=9N = Y3)*$ ^c=^b=79 . V 78C\/1

R?/ =< ^/PQ0RMNV^b=9N 8 G$EE+Y ^c=^b=79 ^ V R?/

> =< ^/PQ0RMNV^b=9N < #,$G ^c=^b=79 ^ V >

78C\/1 =< ^/PQ0RMNV^b=9N V !)46 ^c=^b=79 . V 78C\/1

/"*$ 9:;9<;79== > P?

'()*+, %- . 1"KE$AE"4
53$56$( %&% &"K$E!E"4C>%&%.1+4*,+ES-+O^XM !"#$ 79
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 1"KE$CAE"4 /PQ0RSCU9:S99=

5"KE$C4"@$ 5"KE$C*G!$ 4J@K$,C+LCD6)44$, Y)(*3 5"KE$CE$4#*3 LJ45*)+4C*$O*

>%&%.1+4*,+ES-+O^X8 P4"E+#CaW9 7< 9eN<

LJ45*)+4C*$O* f\X ")@CL,+@ 5+44$5*)+4C D6)44$, ")@C*+ D6)44$, f\X LJ45*)+4C*$O*

PaC=CH9;;;79I@P =< ^/PQ0RMNV^b=9V = Y3)*$ ^cM N =8 _+EE$,CD3"L*CK$4()4#C=

PaC7CH9;;;79I@P =< ^/PQ0RMNV^b=9V 7 K,+Y4 ^cM ` =8 _+EE$,CD3"L*CK$4()4#C7

PaCMCH9;;;79I@P =< ^/PQ0RMNV^b=9V M #,$$4 ^cM : =8 _+EE$,CD3"L*CK$4()4#CM

PaC8CH9;;;79I@P =< ^/PQ0RMNV^b=9V 8 G$EE+Y ^cM =9 =8 _+EE$,CD3"L*CK$4()4#C8

PaC<CH9;;;79I@P =< ^/PQ0RMNV^b=9V < #,$G ^/PQ0RMNV^b=9V V =< PaCVCH9;;;79I@P

P0C=CH8;;;79I@P =< ^/PQ0RMNV^b=9V =N Y3)*$^#,$G ^cM =: =8 "O)"EC&)E4C!+D)*)+4

P0CMCH8;;;79I@P =< ^/PQ0RMNV^b=9V =: Y3)*$^!)46 ^cM =` =8 ,$E"*)2$C@+2$@$4*CT),$C8

P0C8CH8;;;79I@P =< ^/PQ0RMNV^b=9V 79 !)46^K,+Y4 ^cM =N =8 ,$E"*)2$C@+2$@$4*CT),$CM

P0C<CH8;;;79I@P =< ^/PQ0RMNV^b=9V 7= Y3)*$^KEJ$ ^cM =V =8 ,$E"*)2$C@+2$@$4*CT),$C7

P0CVCH8;;;79I@P =< ^/PQ0RMNV^b=9V 77 K,+Y4^KEJ$ ^cM =< =8 ,$E;CT),$C=C@+2$@$4*

P0CNCH8;;;79I@P =< ^/PQ0RMNV^b=9V 7M Y3)*$^,$( ^cM =8 =8 F3"L*C-$4()4#CA3"D)4#

P0C`CH8;;;79I@P =< ^/PQ0RMNV^b=9V 78 K,+Y4^,$( ^cM =M =8 F3"L*C-$4()4#C0J*!J*

R?/ =< ^/PQ0RMNV^b=9V 7< Y3)*$^KE"56 ^b7 M8 N R?/

/"*$ 9:;9<;79== > P?

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 1"KE$CAE"4 /PQ0RSCU9:S99=

5"KE$C4"@$ 5"KE$C*G!$ 4J@K$,C+LCD6)44$, Y)(*3 5"KE$CE$4#*3 LJ45*)+4C*$O*

>%&%.1+4*,+ES-+O^X< _F7M7^= : 9e< 9eM

LJ45*)+4C*$O* f\X ")@CL,+@ 5+44$5*)+4C D6)44$, ")@C*+ D6)44$, f\X LJ45*)+4C*$O*

_O =V ^/PQ0RMNV^b=9: 7 #,$$4 ^b7 M9 =M

TO =V ^/PQ0RMNV^b=9: M K,+Y4 ^b7 M= =M

R?/ =V ^/PQ0RMNV^b=9: < #,$G ^cM R?/ =8 R?/

/"*$ 9:;9<;79== > P?

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 1"KE$CAE"4 /PQ0RSCU9:S99=

5"KE$C4"@$ 5"KE$C*G!$ 4J@K$,C+LCD6)44$, Y)(*3 5"KE$CE$4#*3 LJ45*)+4C*$O*

>%&%.1+4*,+ES-+O^XV /)#)*"ECa0 7< 9e< 9eN<

LJ45*)+4C*$O* f\X ")@CL,+@ 5+44$5*)+4C D6)44$, ")@C*+ D6)44$, f\X LJ45*)+4C*$O*

/aC= =V ^/PQ0RMNV^b=9` = Y3)*$ ^cM M =8 T),$C=C,+*"*)+4

/aC7 =V ^/PQ0RMNV^b=9` 7 K,+Y4 ^cM 8 =8 T),$C7C,+*"*)+4

/aCM =V ^/PQ0RMNV^b=9` M #,$$4 ^cM < =8 T),$CMC,+*"*)+4

/aC8 =V ^/PQ0RMNV^b=9` 8 G$EE+Y ^cM V =8 T),$C8C,+*"*)+4

/aC< =V ^/PQ0RMNV^b=9` < #,$G ^cM 7 =8 &)E4C,+*"*)+4

_FC7M7^7CTO =V ^/PQ0RMNV^b=9` =` #,$G^K,+Y4 ^b7 79 =M _FC7M7^7CTO

_FC7M7^7C_O =V ^/PQ0RMNV^b=9` =: Y3)*$^!)46 ^b7 7= =M _FC7M7^7C_O

R?/ =V ^/PQ0RMNV^b=9` 77 K,+Y4^KEJ$ ^b7 M8 N R?/

> =V ^/PQ0RMNV^b=9` 7M Y3)*$^,$( ^b7 M8 N >

> =V ^/PQ0RMNV^b=9` 78 K,+Y4^,$( ^b7 M8 N >

> =V ^/PQ0RMNV^b=9` 7< Y3)*$^KE"56 ^b7 M8 N >

/"*$ 9:;9<;79== > P?

'()*+, %- . 1"KE$AE"4
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 1"KE$CAE"4 /PQ0RSCU9:S99=

5"KE$C4"@$ 5"KE$C*G!$ 4J@K$,C+LCD6)44$, Y)(*3 5"KE$CE$4#*3 LJ45*)+4C*$O*

>%&%.1+4*,+ES-+O^XN : 9e=<

LJ45*)+4C*$O* f\X ")@CL,+@ 5+44$5*)+4C D6)44$, ")@C*+ D6)44$, f\X LJ45*)+4C*$O*

78C\/1 =N ^c7^b==9 = Y3)*$ ^b= N N 78C\/1

R?/ =N ^c7^b==9 < #,$G ^b= == N R?/

TO =N ^c7^b==9 N KEJ$ ^b7 M9 =M

_O =N ^c7^b==9 ` ,$( ^b7 M= =M

/"*$ 9:;9<;79== > P?

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 Annex 4
(Sensor mounting)
 !"#$%&12
  !
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 Exploded view Roller shaft bending Sensor


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Reference / Tire migration Sensor
assembled
Roller shaft Sensor assembled
 Inductive sensor
With analog output
BI7-Q08-LIU

Rectangular, height 8 mm
Active face on top
Metall, zinc die casting
4-wire, 1530 VDC
Analog output
010 V and 020 mA
Cable connection

Wiring diagram

Type code BI7-Q08-LIU

Ident no. 1534605

Measuring range [AB] 14mm Functional principle

Mounting condition flush Inductive TURCK sensors with analog output
Repeatability 1 % of measuring range |A - B| accomplish simple control tasks. They provide
0.5 %, after warm-up 0.5 h a current, voltage or frequency signal propor-
Reproducibility 30 m
tional to the target's distance. The output sig-
15 m, after a warm-up time of 0.5 h
nal is linear to the distance of the target over
Linearity deviation 5%
the entire sensing range.
Temperature drift 0.06 % / K
Ambient temperature -25+70 C
Measuring range
Operating voltage 1530VDC
Residual ripple 10 % Uss
No-load current I0 8 mA
Rated insulation voltage 0.5 kV
Short-circuit protection yes
Wire breakage / Reverse polarity protection yes/ complete
Output function 4-wire, analog output
Voltage output 010VDC
Current output 020mA
Load resistance voltage output 4.7 k
Load resistance, current output 0.4 k
Measuring sequence frequency 200 Hz

Construction rectangular, Q08

Dimensions 32 x 20 x 8 mm
Housing material metal, GD-Zn
Connection cable
Cable quality 4 mm, LifY-11Y, PUR, 2m
Cable cross section 4 x 0.25 mm
2

Vibration resistance 55 Hz (1 mm)

Shock resistance 30 g (11 ms)
Protection class IP67
MTTF 751 years acc. to SN 29500 (Ed. 99) 40 C
Edition 2014-10-24T05:56:59+02:00

1/3 Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com
 Inductive sensor
With analog output
BI7-Q08-LIU

Distance W 12 mm
Distance S 1.5 x B
Distance G 6 x Sn

Width of the active face B 20 mm

Edition 2014-10-24T05:56:59+02:00

2/3 Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com
 Inductive sensor
With analog output
BI7-Q08-LIU

Accessories
Type code Ident no. Description Design

IM43-13-SR 7540041 Trip amplifier; 1-channel; input 0/420 mA or 0/210 V;

supply of 2- or 3-wire transmitters/sensors; limit value adjust-
ment via teach button; three relay outputs with one NO con-
tact each; removable terminal blocks; 27 mm wide; universal
voltage supply 20250 VUC; further Limit value indicators
are described in our "Interface Technology" catalog.
Edition 2014-10-24T05:56:59+02:00

3/3 Hans Turck GmbH & Co.KG D-45472 Mlheim an der Ruhr Witzlebenstrae 7 Tel. 0208 4952-0 Fax 0208 4952-264 more@turck.com www.turck.com
 Fixation
Bolts
Sensor
Holder

30
Sensor Holder

Support Roller

Turck Sensor
Spacer Block A BI7-Q08-LIU
DRAWN
NAME
ABC
DATE
07/05/15 Sensor Holder
e

TomTom-Tools GmbH
anc

T T
Zelgli 20 TITLE
Dist
40

T O O LS
8905 Arni / Switzerland
For KHD Support Rollers
Sen 2 mm

M M
sor

www.tomtom-tools.com
~

UNLESS OTHERWISE SPECIFIED SIZE DWG NO REV

M3
20

A4
DIMENSIONS ARE IN MILLIMETERS
DIMENSIONS 0.1 mm ANGLES 0.1 FILE NAME: Sensor Holder KHD.dft
10

TYPICAL EDGE CHAMFER 0.3x45 SCALE: WEIGHT: SHEET 1 OF 1