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Precision Switching
With Unmatched Durability
Mechanical
Switches Table of Contents
Mechanical Switches
for positioning and limit switching on
machine tools, flexible manufacturing
equipment, robots, assembly and Mechanical Linear Trip Cams ..................... 87-94
conveying equipment.They have
been designed and proven for use
under extreme conditions. Electronic Linear Trip Cams ........................ 95-97
n DIN 43 636
Mechanical Rotary Trip Cams ................... 103-107
n UL
Electronic Rotary Trip Cams ...................... 109-111
n CSA
n CE Robot Zone Limit System ............................. 113-128
http://www.balluff.com/BNS
1-800-543-8390 · www.balluff.com 1
Mechanical Company Overview
Switches & History
State-of-the-art
electronics
Application-specific
customer solutions
2 1-800-543-8390 · www.balluff.com
Mechanical North American
Switches Locations
Balluff Inc.
Florence, Kentucky USA
Florence, Kentucky Our Florence, Kentucky location is
USA conveniently located within the Cincin-
nati Tri-state area, and is just minutes
from the Greater Cincinnati Northern
Kentucky International Airport. Home of
Balluff de Mexico Balluff’s North American operations, the
Queretaro, Mexico Florence plant has recently expanded
to a 2-story 58,000 square foot facility
with more than 100 employees.
Mechanical Switches
Located in the thriving town of
Queretaro, our new and expanding
sales center is within range of some
of the largest industrial operations
in Mexico.
Balluff Canada
Production of microprocessor-
controlled limit switches used Addition of a second
with angle encoders begins Founding of Balluff Inc. in plant in Neuhausen.
Production of optoelectronic Production of rotary encoders New Jersey, USA by John Production of identification
switches begins. begins. Goyer, President and CEO. systems begins.
} }
1978 1979-1980 1981 1984
1-800-543-8390 · www.balluff.com 3
Mechanical Product Range &
Switches Customers
Our Products
Our product range is
engineered for tough
Sensors
positioning and part sensing
applications in a variety of
automated machinery
environments. Our history
designing and producing
rugged limit switches for the
automotive industry provides
the basis for our continued Tubular Inductives Block-style Inductives Capacitives Magnetic Field Sensors
research and development
of tough, cutting-edge
sensing technologies.
Connectors/Accessories
TM
Industries &
Applications
Our primary customer
The rugged choice for extreme conditions.
base in the metalworking, Assembly automation Injection molding Paper and textiles
automotive and plastics
industries has provided a
Automotive: body and assembly Material handling Plastics
stable base from which our Bottling Metal cutting Plastics and rubber
technological innovation has Ceramics and glass Metal forming Robotics
branched into a broad array Hydraulics & pneumatics Packaging Welding
of applications.
Main manufacturing
Balluff, Inc. relocates Production of plant opens in Expansion of Florence, KY
to Florence, KY. linear transducers begins. Vesprem, Hungary. plant to 40,000 sq. feet.
} }
1986 1987 1989 1994
4 1-800-543-8390 · www.balluff.com
Mechanical Technical &
Switches Customer Service
Customer Service
One Call Does It All. Easy. Fast. Personal.
We’re dedicated to your Give us a call.
success You will be instantly con-
Quick service, exceptional nected with experienced · 24 Hour on-call service
products and experienced customer service, technical · Same-day shipping: In
employees are yours when support and application by 2 p.m., out same day!
you call Balluff. We are a engineers who know the · Adequate service or
world leader in sensor industry - your industry. We parts shipped free!
technology with a team of know how to make your · Expedited delivery on
the best people in the work easier, and will go out in-stock items
industry ready to solve your of our way to make sure · Fast, friendly service
automation challenges. We'll you are satisfied with our guaranteed
make your search for the products and services. WE · Direct stop technical
right sensor easier, faster, are what separates us from support
and less stressful. the competition! · Product selection &
application assistance
· Direct tech support
We’ll get to know you. · Cross references
Our service is based on Technical Service/Application Engineering · Competitive pricing
geography, so you'll speak · Customized solutions –
with the same people every Finding the best sensor Over time, Balluff has just ask!
means first selecting the developed a reputation in
time you call. We'll get to · Experienced service and
know your order history and correct sensing technology. the industry for solving the technical support
delivery preferences so you Our customer service difficult applications. We live
don't have to waste time representatives work hand- up to this reputation
repeating the same requests in-hand with the best everyday. How do we do it?
over and over! application engineers and
technicians in the industry.
Products and
people.
Mechanical Switches
Let our Our experienced application
engineering group will help
experienced you choose the best sensor No other sensor company
for your application regard-
professionals less of the technology used.
has our broad range of
products or the customer
help you choose If an optical sensor is better
than an inductive sensor,
and technical experience to
support it. Go ahead, give
the right sensor! we’ll know. We manufacture us a test. We love a
all major types of sensing
technologies and under-
challenge!
We find the
stand better than anyone
where to apply a particular
best sensor for
technology. your application
and apply it
correctly.
1-800-543-8390 · www.balluff.com 5
Mechanical Global
Switches Locations
Germany
World Headquarters
Gebhard Balluff GmbH & Co.
Gartenstrasse 21-25
D-73765 Neuhausen/Filder China
Tel.: (++49 71 58) 1 73-0 Shanghai De-Tong Co., Ltd.
Fax: (++49 71 58) 50 10 Balluff South China
E-mail: balluff@balluff.de Service Center
Web: www.balluff.de Dept of Applied Physics
Shanghai Jiao Tong University
Hua Shan Road 1954
Argentina Shanghai 200030 PRC China
Nortécnica S.R.L. Tel.: (++86 21) 62 83 31 75
103 Heredia 638 Fax: (++86 21) 62 81 29 18
1672-Villa Lynch-San Martin E-mail: detong@online.sh.cn
Pcia. De Buenos Aires
Argentina Croatia Greece
Tel.: (++54 11) 7 57 31 29 SAS Hstec d.d. S. Nazos A.E.
Fax: (++54 11) 7 57 10 88 Jadranska Cesta B B Vertrieb/Service für Balluff
E-mail: 2300 Zadar 73 Verias
nortecnica@synectis.com.ar Tel: (++385 23) 23 31 52 79 GR-57008 Thessaloniki
Fax: (++385 23) 23 31 57 93 Tel.: (++30 31) 78 02 27
Australia E-mail: sas-hstec@zd.tel.hr Fax: (++30 31) 78 41 44
Balluff-Leuze Pty. Ltd. E-Mail: nazos.s.a.@netfiles.gr
2 Rocco Drive
Scoresby, VIC 3179 Czech Republic
(Melbourne) Australia Balluff CZ s.r.o. Hong Kong
Tel.: (++61 3) 97 64 23 66 Peluskova 1400 NO. 42, 18th St.
Fax: (++61 3) 97 53 32 62 CZ-198 00 Praha 9 - Kyie Hong Lok Yuen
E-mail: Tel: (++42 02) 81 94 01 25 Tai Po, NT, Hong Kong
balluff_leuze@matcol.com.au Fax: (++42 02) 81 94 01 02 Tel.: (++852) 26 51 01 86
E-mail: cz@balluff.de Fax: (++852) 26 51 03 88
Austria Web: www.balluff.de/cz Web: www.balluff.com.hk
Gebhard Balluff Vertriebs E-mail: sensortech@attglobal.net
Ges.m.b.H
Industriestr. B 16 Denmark
2345 Brunn am Gebirge Desim Elektronik ApS Hungary
Mechanical Switches
6 1-800-543-8390 · www.balluff.com
Mechanical Global
Switches Locations
Portugal
LA2P, LDA. South Africa
Mechanical Switches
Mexico Rua Almirante Sousa Dias Retron
Balluff de Mexico Loja D - Nova Oeiras P.O. Box 39448
Ave. Meson del Prado #292 P-2780 Oeiras Bramlay, 2018 (Johannesburg)
Fracc. Juriquilla Tel.: (++351 21) 4 42 26 58 Tel.: (0027 11) 7 86 05 53
Queretaro, QRO 76230 Fax: (++351 21) 4 42 28 08 Fax: (0027 11) 4 40 82 75
Tel.: (++52 442) 234-1587 E-mail: la2p@ip.pt E-mail: info@retron.co.za
E-mail:
balluff.mexico@balluff.com Taiwan
Singapore Spain Canaan Electric Corp.
Balluff Asia Pte. Ltd. Elion S.A. 6F-5, No. 63 Sec. 2
Netherlands BLK 1004 Toa Payoh Ind. Park Farell 5 Chang-An East Road
Vierpool b.v. Lorong 8, #03-1489 E-08014 Barcelona RC-Taipei
Industrieweg 2 Singapore 1231 Tel.: (0034 93) 2 98 20 20 Tel.: (00886 22) 5 08 23 31
NL-3606 AS Maarssen Tel.: (++65) 2 52 43 84 Fax: (0034 93) 2 98 20 48 Fax: (00886 22) 5 08 47 44
Tel.: (++31 346) 59 45 11 Fax: (++65) 2 52 90 60 E-mail: automatismos@elion.es E-mail:
Fax: (++31 346) 57 40 55 E-mail: balluff@balluff.com.sg Web: http://www.elion.es canaan1@ms15.hinet.net
Norway Slovakia
Primatec as Sweden Turkey
S & A, Ltd. Balluff Svenska Elektronik AB Mega-Teknik
Lillesandsvn. 44 Celno 567/62
NL-4890 Grimstad Vikhemsvägen 9 Perpa Tic.Is.Mrk. A. Blok
976 98 Podbrezová - Lopej S-241 38 Eslöv Kat:2, No:9/0026
Tel.: (++47) 37 25 87 00 Tel.: (++421) 8 67-61 72-903,-
Fax: (++47) 37 25 87 10 Tel.: (0046 413) 6 92 20 80270 Okmeydani Istanbul
904 Fax: (0046 413) 6 92 21 Tel.: (++90 212) 3 20 04 11
E-mail: primatec@online.no Fax: (++421) 8 67-61 72-250 Fax: (++90 212) 3 20 04 16
E-mail: saa@nextra.sk E-mail: mega@netone.com.tr
Switzerland
Poland Balluff Sensortechnik AG
Balluff Sp. z o.o. Riedstr. 6
ul. Powsinska 106 Slovenia USA
Senzorji SB 8953 Dietikon
PL-02-903 Warszawa Tel.: (0041 1) 7 40 87 20 North American
Tel./Fax: (++48 22) 6 51 96 79 prozvodnja, Headquarters
trgovina in stroitve d.o.o. Fax: (0041 1) 7 40 87 05
Tel./Fax: (++ 48 71) 8 42 97 28 E-mail: sglaser@balluff.de Balluff, Inc.
E-mail: balluff@balluff.pl Ul. Pohorskega bataljona 14 8125 Holton Drive
2000 Maribor Florence, KY 41042
Tel./Fax: (++386 62) 4 29 63 70 Tel.: 1-800-543-8390
Tel./Fax: (++386 62) 4 29 63 71 Fax: (859) 727-4823
E-mail: sb.elektronika@siol.net Web: www.balluff.com
E-mail: balluff@balluff.com
Product Catalogs
Object detection &
Balluf product measurement
Our broadest line of
documentation is divided inductive,optical,capacitive,
into 4 convenient and easy magnetic sensors and
to use catalogs. Each remote systems used in
industrial automation.
catalog provides complete
technical information in an
easy to read format, along
with a complete list of
product accessories. Sensors
Identification
Complete read/write
All catalogs are also identification system for
available online in the hostile environments.
PDF format.
automation conditions.
Mechanical Switches
Balluff Online
www.balluff.com
8 1-800-543-8390 · www.balluff.com
Mechanical Quality &
Switches Product Warranty
Our Quality Standards
Our Mission:
Reliable quality of products
and services is essential for
a successful and lasting
relationship with our
customers.
Mechanical Switches
on specific quality requirements.
· A high standard of quality
increases profitability, insures
competitiveness in the market, The quality management system
retains and creates jobs, and of Balluff Inc. is registered by
guarantees the continued NSF-ISR to ISO 9001.
existence of the company.
STANDARD WARRANTY
BALLUFF Inc. products are guaranteed to be free from defects in material and workmanship as follows:
Standard 2-year warranty Standard lifetime apply if, in the judgement of consequential damages of
from the date of shipment warranty for inductive BALLUFF Inc., damage or any kind. BALLUFF Inc.
for photoelectric and flow sensors and magnetically failure has resulted from assumes no responsibility
sensors, capacitive sensors, operated sensors sold to accident, alteration, misuse, for selection and installation
read-write ID systems, the original user. abuse, or operation on an of its products. The
magnetostrictive incorrect power supply. foregoing is in lieu of all
transducers (MicropulseTM Balluff Inc. will repair or The guarantee expressly other guarantees
AT)*, connectors and replace at our discretion, does not include any other expressed, implied or
cables, electromechanical without charge, any unit, costs such as the cost of statutory and BALLUFF Inc.
limit and rotary switches, which fails because of removal of the defective neither assumes nor
and all products with defective workmanship or part, installation, labor or authorizes any person to
electromechanical relays material, during this assume for it any other
sold to the original user. guarantee period and WARNING obligation or liability in
which is returned to These sensors are NOT approved for use in personnel safety applications. connection with said
A sensor failure or malfunction can result in either an energized or
BALLUFF Inc. de-energized output state. Never use these sensors for personnel products.
safety. Doing so may result in serious bodily injury or death.
transportation Only products specifically designated as safety products are designed to
meet OSHA and ANSI standards for point-of-operation devices.
* MicropulseTM AT: prepaid. The
1-year warranty from For safety grounding issues please refer to the technical section in the
guarantee will not end of this catalog.
date of shipment
1-800-543-8390 · www.balluff.com 9
Mechanical Product
Precision
Switches Introduction
switching
Product Overview
coupled with
unmatched
durability
Engineered for your most
demanding switching
requirements in harsh
environmental conditions,
the BALLUFF Cam Switch Applications
System is the preference of
automatic machinery
builders around the world. Industrial applications The switching cams are
The BALLUFF Cam Switch include automatic available in several variations:
System offers a package of equipment requiring precise
benefits that make it the and repeatable on-off n
Straight for linear applica-
right position control choice position indication in severe tions in various lengths
anywhere you need operating environments n
Radial for rotary applica-
precision switching coupled such as flooding with tions in various radii and
with unmatched durability. machine tool cutting and swept angles
cooling fluids, shock, n
Surface-hardened solid
vibration, flying chips, dust
Description of System steel for long life with
and dirt, and temperature
and Options variation.
mechanical switches
n
Mild tubular steel for
The BALLUFF Cam Switch non-contact inductive
System consists of two basic The BALLUFF Cam Switch switching
elements: System is ideal for robot
n
U-channel for drop-in
dynamic safety zone installation or T-slot for
1. A rugged multiple limit control. Positive break captive adjustability
switch assembly with safety switches coupled
configurable limit switch with high switching element The cam tray styles include:
inserts density, rugged
2. A set of linear or rotary construction, and long life
n
Straight for linear applica-
Mechanical Switches
n
contact switching
Positive-opening mechani-
machinery
cal safety switch inserts builders
for over-travel limiting
n
Non-contact inductive worldwide!
sensor inserts in a variety of
voltage ratings and logic
types
n
LED switch status
indication
n
Viton sealing membranes
for aggressive solvent
environments
n
Chisel, roller, or ball tipped
mechanical switch plungers
n
Plunger wipers for
improved operation in
sticky or gritty locations
n
Custom pre-wired and
factory-tested with micro or
mini style connectors
n
Custom mixed assemblies
combining snap, safety,
and inductive elements
10 1-800-543-8390 · www.balluff.com
Mechanical Product
Switches Introduction
Build It The Way You Want It
Mechanical Switches
The metallic plunger is and long cams ...Tailored to match correct. Just hook it
sensed internally by an
inductive sensor and the YOUR application up and go!
1-800-543-8390 · www.balluff.com 11
Mechanical Cam Switch
Switches Selection Guide
Series 61 Page 24
n
Compact housing with small terminal compartment
n
Accomodates full size switch elements
n
AS-i option ............................................................ 26-27
n
Electronic output option ........................................ 28-29
n
Series 610-11, 612-11, 613-11 inductive version . 30-31
Mechanical Switches
n
Available with safety switch elements
n
Selectable approach axis
Series 72 Page 34
n
Perpendicular cam approach
n
Compact housing with small terminal compartment
n
Accomodates full size switch elements
n
Electronic output option ........................................36-37
n
Series 605-11 inductive version ............................38-39
Series 46 Page 40
n
Miniature housing with mounting flange
n
Accomodates miniature switch elements
n
Series 603-11 miniature version ............................42-43
Series 40 Page 44
n
Miniature housing with minimum footprint
n
Accomodates miniature switch elements
n
Series 650-11 inductive version ............................46-47
1-800-543-8390 · www.balluff.com 13
Mechanical Series 100
Switches Mechanical
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material standard Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
version X512 hardened aluminum, coolant-lubricated
Terminal compartment gasket material Buna-N rubber (standard) Viton (version X512)
Plunger sealing membrane material “
Conduit plug O-ring material “
Mechanical Switches
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
14 1-800-543-8390 · www.balluff.com
Mechanical Series 100
Switches Mechanical
Number of plungers BSE-30, BSE-61, BSE-85 02...06, 08, 10, 12, 14, 16
BSE-82 02...04
Plunger spacing, mm 12
Switch element
519 & 819 10 = BSE-30 only
3B = BSE-82 only
113 & 813 10 = BSE-61 & BSE-30 mixed
12 = BSE-61 only
Mechanical Switches
20 = BSE-85 & BSE-30 mixed
22 = BSE-85 only
1-800-543-8390 · www.balluff.com 15
Mechanical Series 100
Switches Mechanical with AS-i
Housing Designation Series 100 Mechanical with built-in AS-i bus interface module
Housing Form Full Size Terminal Compartment per DIN 43.697
Axis of Motion Parallel to Mounting Surface
Plunger Centerline Spacing 12 mm
Operation Principle Mechanically actuated and switched
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
Terminal compartment gasket material Buna-N rubber
Plunger sealing membrane material Buna-N rubber
Conduit plug O-ring material Buna-N rubber
Mechanical Switches
16 1-800-543-8390 · www.balluff.com
Mechanical Series 100
Switches Mechanical with AS-i
Plunger spacing, mm 12
1-800-543-8390 · www.balluff.com 17
Mechanical Series 100
Switches Mechanical / Electronic
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
Terminal compartment gasket material Buna-N rubber
Plunger sealing membrane material Buna-N rubber
Mechanical Switches
Contact arrangement & type PNP complementary NPN complementary 2-wire NO 2-wire NC
Applications - solid state switching in metal chip environment 10...30 V DC 10...30 V DC 90...250 V AC 90...250 V AC
Switch actuation force 15 N 15 N 15N 15N
Switching frequency 300/min 300/min 300/min 300/min
Plunger construction telescoping overtravel telescoping overtravel telescoping overtravel telescoping overtravel
Approach velocity Chisel plunger type D 10m/min 10m/min 10m/min 10m/min
Roller plunger type R 20m/min 20m/min 20m/min 20m/min
Ball bearing roller plunger type L 120m/min 120m/min 120m/min 120m/min
Ball plunger type K 8m/min 8m/min 8m/min 8m/min
Switchpoint repeatability refer to individual Sensor Element Data
Electrical characteristics refer to individual Sensor Element Data
LED function indication included included included included
Ordering Code (see facing page)
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
18 1-800-543-8390 · www.balluff.com
Mechanical Series 100
Switches Mechanical/Electronic
Ordering Code BNS - 819 - D03 - R12 - 100 - 14-DH - ####
Plunger spacing, mm 12
Mechanical Switches
1-800-543-8390 · www.balluff.com 19
Mechanical Series 602-11
Switches Inductive
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P
Terminal compartment gasket material Buna-N rubber
Conduit plug O-ring material „
Conduit plug material Polyamid PA 6.6 15% glass fiber reinforced
Dimensions & Installation refer to Installation Notes and Dimensional Information section
Ambient temperature refer to individual Sensor Element Data
BES-516-110 (PA) BES-516-108 (NA) BES-517-410 (WS)* BES-517-421 (WO)**
Inductive Sensor Element
Mechanical Switches
Contact arrangement & type PNP complementary NPN complementary 2-wire NO 2-wire NC
Applications - non-contact sensing, electronic switching, chip- 10...60 V DC 10...60 V DC 90...250 V AC 90...250 V AC
20 1-800-543-8390 · www.balluff.com
Mechanical Series 602-11
Switches Inductive
Sensor spacing, mm 12
Mechanical Switches
NAMUR section of Sensor
Catalog for selection.
*** EJ & EK are obsolete.
1-800-543-8390 · www.balluff.com 21
Mechanical Series 62
Switches Mechanical
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
Terminal compartment gasket material Buna-N rubber
Plunger sealing membrane material Buna-N rubber
Conduit plug O-ring material Buna-N rubber
Mechanical Switches
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
22 1-800-543-8390 · www.balluff.com
Mechanical Series 62
Switches Mechanical
Plunger spacing, mm 12
Switch element
519 & 819 10 = BSE-30 only
113 & 813 10 = BSE-61 & BSE-30 mixed
12 BSE-61 only
Mechanical Switches
FE = 90...250 V AC/DC
blank = no LED
1-800-543-8390 · www.balluff.com 23
Mechanical Series 61
Switches Mechanical
Mechanical Data
Housing material die-cast aluminum
Housing coating gray anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material standard Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self- lubricating
version X512 hardened aluminum, coolant lubricated
Terminal compartment gasket material Buna-N-rubber (standard), Viton (version X512)
Plunger sealing membrane material
Mechanical Switches
Plunger styles
E Chisel
with wiper
DChisel KBall R Roller L High
Switch Element Data ................ Pages 50-51 speed roller
Linear Cam Trays .......................... Pages 71-85
Linear Trip Cams ............................ Pages 89-97
Rotary Cam Drums ..................... Pages 99-102
Rotary Trip Cams ......................... Pages 103-111
Connectors & Cables ................. Pages 54-57
Accessories & Fittings ............ Pages 58-59
Installation Guidelines .............. Page 60
Dimensions ........................................ Pages 61-69
24 1-800-543-8390 · www.balluff.com
Mechanical Series 61
Switches Mechanical
Plunger spacing, mm 12
Housing designation 61
Mechanical Switches
of first plunger, mm 543 & 819 92, 03 plungers only 242
543 & 819 02 plungers only 303
113 & 813 02...06 plungers A = 121
113 & 813 02, 03 plungers only C = 242
113 & 813 02 plungers only D = 303
Switch element
543 & 819 10 = BSE-30 only
3B = BSE-82 only
113 & 813 10 = BSE-61 & BSE-30 mixed
12 = BSE-61 only
20 = BSE-85 & BSE-30 mixed*
22 = BSE-85 only*
1-800-543-8390 · www.balluff.com 25
Mechanical Series 61
Switches Mechanical with AS-i
Housing Designation Series 61 Mechanical with built-in AS-i bus interface module
Housing Form Compact Terminal Compartment and Minimum Footprint Mounting Flange
Axis of Motion Parallel to Mounting Surface
Plunger Centerline Spacing 12 mm
Operation Principle Mechanically actuated and switched
Mechanical Data
Housing material die-cast aluminum
Housing coating gray anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
Terminal compartment gasket material Buna-N rubber
Plunger sealing membrane material Buna-N rubber
Conduit plug O-ring material Buna-N rubber
Mechanical Switches
26 1-800-543-8390 · www.balluff.com
Mechanical Series 61
Switches Mechanical with AS-i
Housing Form
B = threaded side access only
E = wiper rings (chisel plunger only)
Plunger spacing, mm 12
Housing designation 61
Mechanical Switches
Plunger styles
E Chisel
with wiper
DChisel K Ball R Roller L High
speed roller
1-800-543-8390 · www.balluff.com 27
Mechanical Series 61
Switches Mechanical/Electronic
Mechanical Data
Housing material die-cast aluminum
Housing coating gray anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self- lubricating
Terminal compartment gasket material Buna-N rubber
Plunger sealing membrane material Buna-N rubber
Conduit plug O-ring material Buna-N rubber
Mechanical Switches
Contact arrangement & type PNP complementary NPN complementary 2-wire NO 2-wire NC
Application - solid state switching in metal chip environment 10...30 V DC 10...30 V DC 90...250 V AC 90...250 V AC
Switch actuation force 15 N 15 N 15N 15N
Switching frequency 300/min 300/min 300/min 300/min
Plunger construction telescoping overtravel telescoping overtravel telescoping overtravel telescoping overtravel
Approach velocity Chisel plunger type D 10m/min 10m/min 10m/min 10m/min
Roller plunger type R 20m/min 20m/min 20m/min 20m/min
Ball bearing roller plunger type L 120m/min 120m/min 120m/min 120m/min
Ball plunger type K 8m/min 8m/min 8m/min 8m/min
Switchpoint repeatability refer to individual Switch Element Data
Electrical characteristics refer to individual Switch Element Data
LED function indication included included included included
Ordering Code (see facing page)
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
28 1-800-543-8390 · www.balluff.com
Mechanical Series 61
Switches Mechanical/Electronic
Plunger spacing, mm 12
Housing designation 61
Mechanical Switches
14-JK = BES-516-421-J
1-800-543-8390 · www.balluff.com 29
Mechanical Series 610-11,612-11,
Switches 613-11 Inductive
Housing Designation Series 610-11, 612-11, 613-11 Inductive (similiar to Series 61 Mechanical)
Housing Form Compact Terminal Compartment and Minimum Footrpint Mounting Flange
Axis of Motion Parallel to Mounting Surface
Sensor Centerline Spacing 12 mm
Operating Principle Inductive sensing, electronic switching
Mechanical Data
Housing material die-cast aluminum
Housing coating gray anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Terminal compartment gasket material Buna-N rubber
Conduit plug O-ring material Buna-N rubber
Conduit plug material Polyamid PA 6.6 15% glass fiber reinforced
Dimensions & Installation refer to Installation Notes and Dimensional Information section
Ambient temperature refer to individual Sensor Element Data
Mechanical Switches
Contact arrangement & type PNP complementary NPN complementary 2-wire NO 2-wire NC
Applications - non-contact sensing, electronic switching, chip-free 10...60 V DC 10...60 V DC 90...250 V AC 90...250 V AC
Inductive Sensor Element BES-516-110(PA) BES-516-108(NA) BES-517-410(WS)* BES-517-421 (WO)**
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Mechanical Series 610-11,612-11,
Switches 613-11 Inductive
Sensor spacing, mm 12
distance flange to centerline 24mm = 612-112 threaded side & flange access 2
of first sensor, mm 30mm = 613-113 threaded side & unthreaded flange access with gasket 3
Mechanical Switches
custom pre-wired connector, mixed switching
elements, etc.
blank = standard assembly
Superscripts indicate allowable
1,2,3
1-800-543-8390 · www.balluff.com 31
Mechanical Series F 60
Switches Mechanical
Mechanical Data
Housing material die-cast aluminum
Housing coating gray anodized
Protection class IP 67 (DIN 40 050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material standard Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self- lubricating
version X512 hardened aluminum, coolant lubricated
Terminal compartment gasket material Buna-N-rubber (standard), Viton (version X512)
Plunger sealing membrane material Buna-N-rubber (standard), Viton (version X512)
Conduit plug O-ring material Buna-N-rubber (standard), Viton (version X512)
Mechanical Switches
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
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Mechanical Series F 60
Switches Mechanical
Switch element 519 & 819 101 = BSE-30 approach direction user-configurable: depress plunger, twist 90°, release
and approach direction 113 & 813 183 = BSE-61 approach direction fixed: parallel to mounting surface
113 & 813 185 = BSE-61 approach direction fixed: perpendicular to mounting surface
113 & 813 186 = BSE-85 approach direction fixed: parallel to mounting surface
113 & 813 187 = BSE-85 approach direction fixed: perpendicular to mounting surface
Mechanical Switches
*Consult factory for availability.
S21
3 RD/WH 2 RD/BK
1 GN
S4
2 WH
3 BU 1 BN
4 BK
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Mechanical Series 72
Switches Mechanical
Mechanical Data
Housing material sand-cast aluminum
Housing coating gray anodized
Protection class IP 67 (DIN 40 050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self- lubricating
Terminal compartment gasket material Buna-N-rubber
Plunger sealing membrane material Buna-N-rubber
Conduit plug O-ring material Buna-N-rubber
Mechanical Switches
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
34 1-800-543-8390 · www.balluff.com
Mechanical Series 72
Switches Mechanical
Plunger spacing, mm 12
Housing designation 72
Mechanical Switches
LED options FD = 6...60 V AC/DC
FE = 90...250 V AC/DC
blank = no LED
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Mechanical Series 72
Switches Mechanical/Electronic
Mechanical Data
Housing material sand-cast aluminum
Housing coating gray anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Plunger material stainless steel
Plunger guide bushing material Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self- lubricating
Terminal compartment gasket material Buna-N rubber
Plunger sealing membrane material Buna-N rubber
Conduit plug O-ring material Buna-N rubber
Mechanical Switches
Contact arrangement & type PNP complementary NPN complementary 2-wire NO 2-wire NC
Application - solid state switching in metal chip environment 10...30 V DC 10...30 V DC 90...250 V AC 90...250 V AC
Switch actuation force 15 N 15 N 15N 15N
Switching frequency 300/min 300/min 300/min 300/min
Plunger construction telescoping overtravel telescoping overtravel telescoping overtravel telescoping overtravel
Approach velocity Chisel plunger type D 10m/min 10m/min 10m/min 10m/min
Roller plunger type R 20m/min 20m/min 20m/min 20m/min
Ball bearing roller plunger type L 120m/min 120m/min 120m/min 120m/min
Ball plunger type K 8m/min 8m/min 8m/min 8m/min
Switchpoint repeatability refer to individual Switch Element Data
Electrical characteristics refer to individual Switch Element Data
LED function indication included included included included
Ordering Code (see facing page)
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
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Mechanical Series 72
Switches Mechanical/Electronic
Plunger spacing, mm 12
Housing designation 72
Mechanical Switches
*Consult factory for availability
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Mechanical Series 605-11
Switches Inductive
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P, 11, 12, 13
Terminal compartment gasket material Buna-N rubber
Conduit plug O-ring material Buna-N rubber
Conduit plug material Polyamid PA 6.6 15% glass fiber reinforced
Dimensions & Installation refer to Installation Notes and Dimensional Information section
Ambient temperature refer to individual Sensor Element Data
Mechanical Switches
Contact arrangement & type PNP complementary NPN complementary 2-wire NO 2-wire NC
Applications - non-contact sensing, electronic switching, chip-free 10...60 V DC 10...60 V DC 90...250 V AC 90...250 V AC
Inductive Sensor Element BES-517-560-H(KHG) BES-517-561-H(KHH) BES-516-410(EJ)* BES-517-421 (EK)**
38 1-800-543-8390 · www.balluff.com
Mechanical Series 605-11
Switches Inductive
Sensor spacing, mm 12
Mechanical Switches
1-800-543-8390 · www.balluff.com 39
Mechanical Series 46
Switches Mechanical
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P
Plunger material stainless steel
Plunger guide bushing material standard Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
(consult factory for availability) version X512 hardened aluminum, coolant-lubricated
Terminal compartment gasket material Buna-N rubber (standard), Viton (version X512)
Plunger sealing membrane material Buna-N rubber (standard), Viton (version X512)
Mechanical Switches
Conduit plug O-ring material Buna-N rubber (standard), Viton (version X512)
Conduit plug material Polyamid PA 6.6 15% glass fiber reinforced
Dimensions & Installation refer to Installation Notes and Dimensional Information section
Ambient temperature -5...+80°C
Model 519 & 819
Switch Element BSE-75 BSE-76 BSE-82*
Contact arrangement & type C+NO+NC snap action C+NO+NC snap action C+NO+NC snap action
Application solder terminals (vibration) side entry screw terminals top entry screw terminals
Switch actuation force 8N 8N 8N
Switching frequency 200/min 200/min 200/min
Plunger construction telescoping overtravel telescoping overtravel telescoping overtravel
Approach velocity Chisel plunger type D 8m/min ±0.02mm 8m/min ±0.02mm 8m/min ±0.02mm
Switchpoint repeatability Type D in wiper ring housing form E 8m/min ±0.02mm 8m/min ±0.02mm 8m/min ±0.02mm
Roller plunger type R 60m/min ±0.05mm 60m/min ±0.05mm 60m/min ±0.05mm
Ball plunger type K 9m/min ±0.03mm 9m/min ±0.03mm 9m/min ±0.03mm
Electrical characteristics Refer to individual Switch Element Data
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
40 1-800-543-8390 · www.balluff.com
Mechanical Series 46
Switches Mechanical
Plunger spacing, mm 08
Housing designation 46
Mechanical Switches
blank = no LED
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Mechanical Series 603-11
Switches Inductive
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P
Terminal compartment gasket material Buna-N rubber standard
Plunger sealing membrane material Buna-N rubber standard
Conduit plug O-ring material Buna-N rubber standard
Conduit plug material Polyamid PA 6.6 15% glass fiber reinforced
Dimensions & Installation refer to Installation Notes and Dimensional Information section
Mechanical Switches
42 1-800-543-8390 · www.balluff.com
Mechanical Series 603-11
Switches Inductive
Plunger spacing, mm 08
Mechanical Switches
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Mechanical Series 40
Switches Mechanical
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P
Plunger material stainless steel
Plunger guide bushing material standard Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
(consult factory for availabilty) version X512 hardened aluminum, coolant-lubricated
Terminal compartment gasket material Buna-N rubber (standard), Viton (version X512)
Plunger sealing membrane material -
Conduit plug O-ring material -
Mechanical Switches
Plunger styles
E Chisel
with wiper
DChisel K Ball RRoller L High
speed roller
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Mechanical Series 40
Switches Mechanical
Plunger spacing, mm 08
Housing designation 40
Switch element
12= BSE-75
13 = BSE-76
Mechanical Switches
custom pre-wired connector,
mixed switching elements, etc.
blank = standard assembly
**Available 2-position only.
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Mechanical Series 650-11
Switches Inductive
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P
Terminal compartment gasket material Buna-N rubber standard
Plunger sealing membrane material Buna-N rubber standard
Conduit plug O-ring material Buna-N rubber standard
Conduit plug material Polyamid PA 6.6 15% glass fiber reinforced
Dimensions & Installation refer to Installation Notes and Dimensional Information section
Mechanical Switches
46 1-800-543-8390 · www.balluff.com
Mechanical Series 650-11
Switches Inductive
Sensor spacing, mm 08
Mechanical Switches
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Mechanical Series 99 and
Switches 100 Mechanical
Mechanical Data
Housing material die-cast aluminum
Housing coating grey anodized
Protection class IP 67 (DIN 40.050); NEMA 4, 4X, 6, 6P
Plunger material stainless steel
Plunger guide bushing material standard Teflon (PTFE) & lead impregnated sintered tin & bronze over steel, self-lubricating
version X512 hardened aluminum, coolant-lubricated
Terminal compartment gasket material Buna-N rubber (standard), Viton (version X512)
Plunger sealing membrane material „
Conduit plug O-ring material „
Conduit plug material
Mechanical Switches
48 1-800-543-8390 · www.balluff.com
Mechanical Series 99 and
Switches 100 Mechanical
Mechanical Switches
Connector Wiring Diagram Connector Wiring Diagram
NC 2
C
3 RD/WH 2 RD/BK C GN
3 1
NO
YE NO NC
1 GN
4
Dual PNP LED version
RD/WH
RD/BK
GNYE
PE
WH
BU
BN
BK
+
_
WH BU
4 BK
BU
BK
PE
WH
BN
BU
BK
+
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Mechanical Snap Switch
Switches Element Data
3 1 2 4 NO NC C 1 2
1 2 NC 1 2
C
3 4 NO
Construction
Housing material duroplastic thermoplastic PA duroplastic
Housing cover material thermoplastic thermoplastic PA thermoplastic
Contact material gold plated fine silver gold crosspoint fine silver
Contact system double break single break double break
Switch system snap action mechanism snap action mechanism creep opening
Contact arrangement NO + NC C + NO + NC positive drive NC to VDE 0113
Contact isolation thermal and galvanic spring not current-carrying thermal and galvanic
Connection means screw terminals with self-lifting clamps screw terminals with self-lifting clamps screw terminals with self-lifting clamps
Mechanical Switches
Mechanical data
Actuation force at plunger 4.8 N 1.55 N 12 N
Switch-back force at plunger 1.3 N 0.75 N 2.5 N
Bounce time at 10mm/min cam velocity 1.5 ms 2 ms 1.5 ms
Switch changeover time 10 ms 10 ms depends on cam velocity
Switching frequency 300/min 3.3 Hz 200/min
Ambient termperature range -30...+90°C -20...+85°C -30...+90°C
Electrical data
Insulation class Group C VDE 0110 Group C VDE 0110 Group C VDE 0110
Nominal voltage rating 240 V AC 4...30 V DC 250 V AC
Constant current rating 6A 5A 6 A, depends on velocity, frequency
Minimum load current @ 24 V DC 20 mA 10 mA 20 mA
Contact resistance when new 40 mW 240 mW -
Current rating, AC inductive loads, 250 V AC, 40...60 Hz 6 A (cos Q = 1) 5 A (cos Q = 1) -
2 A (cos Q = 0.8) 2 A (cos Q = 0.8) -
1 A (cos Q = 0.4) - -
Current rating, 220 V DC, L/R = 200ms 0.5 A 0.5 A -
Current rating, 24 V DC, L/R = 200ms 4A 5A -
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Mechanical Snap Switch
Switches Element Data
NC NO C NC NO C NC NO C NC NO C
21 22
13 14
21 22 NC NC NC NC
C C C C
13 14 NO NO NO NO
Mechanical Switches
18 N 1.45N 1.45N 1.45N 1.45N
0.8 N 0.50 N 0.50 N 0.50 N 0.50 N
3 ms 2 ms 2 ms 2 ms 2 ms
1.5 ms, min. velocity 1mm/min 10 ms 10 ms 10 ms 10 ms
3000/hour 200/min 200/min 200/min 200/min
-30...+85°C -20...+85°C -20...+85°C -20...+85°C -20...+85°C
Group C VDE 0110 Group C VDE 0110 Group C VDE 0110 Group C VDE 0110 Group C VDE 0110
250 V AC 250 V AC, 4...30 V DC 250 V AC, 4...30 V DC 250 V AC, 4...30 V DC 250 V AC, 4...30 V DC
10 A 5 A, 100 mA 5 A, 100 mA 5 A, 100 mA 5 A, 100 mA
20 mA 10 mA 10 mA 10 mA 10 mA
40 mW 240 mW 240 mW 240 mW 240 mW
10 A (cos Q = 1) - - - -
25 A (cos Q = 0.7) 2 A (cos Q = 0.8, 200 V AC) 2 A (cos Q = 0.8, 200 V AC) 2 A (cos Q = 0.8, 200 V AC) 2 A (cos Q = 0.8, 200 V AC)
- - - - -
2.5 A - - - -
4A 5 A (L/R = 10 ms) 5 A (L/R = 10 ms) 5 A (L/R = 10 ms) 5 A (L/R = 10 ms)
> 5 million > 10 million > 10 million > 10 million > 10 million
depends on load, velocity, frequency depends on load, velocity, frequency depends on load, velocity, frequency depends on load, velocity, frequency depends on load, velocity, frequency
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Mechanical Inductive Sensor
Switches Element Data
Series BES-516-110 (PA) BES-516-108 (NA) BES-517-410(WS), BES-516-410 (EJ) BES-517-421(WO), BES-516-421 (EK)
Sensor Type Inductive proximity Inductive proximity Inductive proximity Inductive proximity
Mounting Flush (shielded) Flush (shielded) Flush (shielded) Flush (shielded)
DH DF JJ JK
O10 O10
O10
O10
3 2 4 1 3 2 4 1
3 4 1 2
1 + 1 +
4 N/O 4 N/O 1
2 2 3 ~
~
N/C N/C
3 - 3 - 2 ~
4 ~
Sensing data
Nominal sensing range 2.0 mm 2.0 mm 2.0 mm 2.0 mm
Effective operating distance 0...1.6 mm 0...1.6 mm 0...1.6 mm 0...1.6 mm
Mechanical Switches
Electrical data
Logic DC PNP current sourcing DC NPN current sinking AC AC
Output function 4-wire complementary (NO+NC) 4-wire complementary (NO+NC) 2-wire NO 2-wire NC
Supply voltage 10...60 V DC 10...60 V DC 90...250 V AC,45...65 Hz 90...250 V AC,45...65 Hz
Supply voltage ripple 15% 15% - -
Load current capacity 200 mA 200 mA 20...100mA, 1.0 A inrush 20...100mA, 1.0 A inrush
Switching frequency, max 3 kHz 3 kHz 15 Hz 15 Hz
Voltage drop - - - -
Short circuit protected yes yes no no
LED function display yes yes yes yes
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Mechanical Inductive Sensor
Switches Element Data
BES-517-560-H (KHG) BES-517-561-H (KHH) BES-517-312-Y (TOB) BES-517-311-Y (TNB) BES-516-314-N (NG)
Inductive proximity Inductive proximity Inductive proximity Inductive proximity Inductive proximity, NAMUR
Flush (shielded) Flush (shielded) Flush (shielded) Flush (shielded) Flush (shielded)
3 4 1 3 4 1
1 2 3 1
3 4
1 1
1 + 1 +
+
+/- 3 +/- 4 4 3 -
2 3 - 3
-/+ 4 -/+
-
NAMUR
BES-517-560-H (KHG) BES-517-561-H (KHH) BES-517-312-Y (TOB) BES-517-311-Y (TNB) BES-516-314-N (NG)
Mechanical Switches
20% 20% 15% 15% 20%
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Mechanical Connectors
Switches and Cables
48 48 48
Female
7/8-16UN-2B
Internal Threads
Female
Female
7/8-16UN-2B
Internal Threads
7/8-16UN-2B
Internal Threads
Cable Cable Cable
Length Length Length
Female 3-pin - Face view Female 4-pin - Face view Female 5-pin - Face view
5 1
1 4 1
4 2
3 2 3 2 3
Ordering Code
PVC C05 AE1 00 VY 150F C05 AE4 00 VY 150F CA05 AE18 VY 200F
TPE
PUR
Specifications
7/8”-16UN-2A
7/8”-16UN-2A
7/8”-16UN-2A
Male
Male
Male
1 1 4 1 5
2 3 2 4
2 3
3
Ordering Code
Mounting threads Pg 13.5 Z/03-PIN-MALE-RECP-PG-13.5 Z/04-PIN-MALE-RECP-PG-13.5 Z/05-PIN-MALE-RECP-PG-13.5
Mounting threads Pg 16
Mounting threads Pg 09
Mounting threads 1/2“ NPT
Specifications
54 1-800-543-8390 · www.balluff.com
Mechanical Connectors
Switches and Cables
Circular Mini Circular Mini Circular Mini Circular Micro Circular Micro
Female Cable Female Cable Female Cable Female Cable Straight Female Cable Right Angle
1“-16 UN-2A 1-1/8“-16 UN-2A 1-1/8“-16 UN-2A M12 DC Single Key M12 DC Single Key
8 12 19 4 4
29 32 29
14.5 31
1/2” UNF
1-1/8”-16UN-2A
Female
Internal Threads
63 31
62 62 47
14.5
Female
1-16UN-2B
Internal Threads
1/2” UNF
Female
1-1/8-16UN-2A
Internal Threads
Length Length
Cable Cable
Length Length
10 38 10 38
TX4003
TX4001
CB08 AE18 VY 200F CC12 AE18 VY 200F CC19 AE22 VY 050M C04 AEL 00 VY 050M C04 BEL 00VY 050M
C04 AEL 00 TY 050M C04 BEL 00TY 050M
CC19 AE22 PB 050M
Mechanical Switches
Circular Mini Circular Mini Circular Mini Circular Micro Circular Micro
Male Receptacle Male Receptacle Male Receptacle Male Receptacle Male Receptacle
1“-16 UN-2A 1“-1/8“-16 UN-2A 1-1/8“-16 UN-2A M12 DC Single Key M12 DC Single Key
8 12 19 4 4
External Threads
External Threads
External Threads
External Threads
External Threads
1-1/8”-16UN-2A
1-1/8”-16UN-2A
1”-16UN-2A
Male
Male
M12
M12
Male
Male
Male
2 WH 2 WH
11 1
12
1 6 1 9 8 10 2
7 18 13
9 3
2
10 12
7 17
19
14 3 BU 1 BN 3 BU 1 BN
16 15
2 8 5 11 8 4
3 6
7 5
3 4 4 5 6
4 BK 4 BK
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Mechanical Connectors
Switches and Cables
14.5 31 14.5
1/2” UNF
1/2” UNF
31
47 47
14.5
1/2” UNF
Length
Length Length
10 38
10 38 10 38
TX4003
TX4001
TX4001
Ordering Code
PVC C21 AE3 00 VY 150F C21 BE3 00 VY 150F C21 AE4 00 VY 150F
TPE C21 AE3 00 TY 150F C21 BE3 00 TY 150F C21 AE4 00 TY 150F
PUR
Specifications
External Threads
External Threads
1/2” UNF
1/2” UNF
1/2” UNF
Male
Male
Male
2 RD/WH
3 RD/WH 2 RD/BK 3 RD/WH 2 RD/BK
3 RD 1 RD/BK
1 GN 1 GN 4 GN/YE
Ordering Code
Mounting threads Pg 13.5
Mounting threads Pg 16
Mounting threads Pg 09 R-21-CA3-006M R-21-CA3-006M
Mounting threads 1/2“ NPT Z/04-PIN-MICRO-AC-RECP-1/2“NPT
Specifications
56 1-800-543-8390 · www.balluff.com
Mechanical Connectors
Switches and Cables
31 14.5
M12x1
31
47
14.5
1/2” UNF
Length
Length
10 38 10 38
TX4003
TX4001
15 feet 5 meters
(4) x 22 (8) x 24
300 V 30 V AC, 36 V DC
Mechanical Switches
Circular Micro Circular Micro
Male Receptacle Male Receptacle
1/2“-UNF AC Dual Key M12 DC Single Key
4
External Threads
External Threads
1/2” UNF
M12 x 1
Male
Male
2 RD/WH 3 GN 2 BN
8 RD
3 RD 1 RD/BK 4 YE 1 WH
5GY 7 BU
4 GN/YE 6PK
R04-CA8-003M
Z/04-PIN-MICRO-AC-RECP-1/2“NPT
12“ 12“
(4) x 22 (8) x 24
300 V 30 V AC, 36 V DC
1-800-543-8390 · www.balluff.com 57
Mechanical Accessories
Switches and Fittings
Application Notes Order matching O-Ring separately O-ring included Order matching O-Ring separately
Mechanical Switches
Gauge508
3 2.7
Application Notes Used to gauge distance between Used to gauge distance between
switch face and cam surface. switch face and cam surface.
58 1-800-543-8390 · www.balluff.com
Mechanical Accessories
Switches and Fittings
Accessory Type Increaser O-Ring Adapter
Description Pg to Pg Pg Pg to NPT
Application Notes Order matching O-Ring separately Use pipe compound on NPT thread
Mechanical Switches
Installation Sheets - Ordering Code
Description Part Number Notes
Installation Sheet for BNS 100,72,62,61,F60 BNS-Z/INSTALL-SHEET-I98001 Included with switch
Installation Sheet for BNS 46,40,100/99 BNS-Z/INSTALL-SHEET-I98002 Included with switch
Installation Sheet for BSE-30 BNS-Z/INSTALL-SHEET-I98004 Included w/spare part kit
Installation Sheet for BSE-61 BNS-Z/INSTALL-SHEET-I98005 Included w/spare part kit
Installation Sheet for BSE-85 BNS-Z/INSTALL-SHEET-I98006 Included w/spare part kit
1-800-543-8390 · www.balluff.com 59
Mechanical Cam Switch
Switches Installation Guidelines
60 1-800-543-8390 · www.balluff.com
Mechanical Cam Switch
Switches Dimensions
Series 100
Mechanical Switches
Series 602-11
1-800-543-8390 · www.balluff.com 61
Mechanical Cam Switch
Switches Dimensions
Series 62
Series 62
Mechanical Switches
62 1-800-543-8390 · www.balluff.com
Mechanical Cam Switch
Switches Dimensions
Series 605-11
Mechanical Switches
Series F60 - Single
1-800-543-8390 · www.balluff.com 63
Mechanical Cam Switch
Switches Dimensions
Series 61
Mechanical Switches
Series 61
64 1-800-543-8390 · www.balluff.com
Mechanical Cam Switch
Switches Dimensions
Series 61
Mechanical Switches
Series 610-11
1-800-543-8390 · www.balluff.com 65
Mechanical Cam Switch
Switches Dimensions
Series 612-11/613-11
Mechanical Switches
66 1-800-543-8390 · www.balluff.com
Mechanical Cam Switch
Switches Dimensions
Series 46
Mechanical Switches
Series 603-11
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Mechanical Cam Switch
Switches Dimensions
Series 40
Mechanical Switches
Series 650-11
68 1-800-543-8390 · www.balluff.com
Mechanical Cam Switch
Switches Dimensions
Series 099-Single
Mechanical Switches
Series 100-Single
1-800-543-8390 · www.balluff.com 69
Mechanical Cam Switch
Switches Dimensions
Mechanical Switches
70 1-800-543-8390 · www.balluff.com
Mechanical Linear
Switches Cam Trays
Mechanical Switches
order
1-800-543-8390 · www.balluff.com 71
Mechanical Linear
Switches Cam Trays
10 125
Ordering Code BNL-5304-120-04-0500
72 1-800-543-8390 · www.balluff.com
Mechanical Linear
Switches Cam Trays
Number of Channels Width (A) mm Hole Offset (B)mm Hole Centerline (C)mm
1 17 8.5 -
2 29 14.4 -
3 41.5 20.8 -
4 53 26.5 -
6 77 8.5 60
8 101 8.5 84
Mechanical Switches
10 125 8.5 108
Length (L) Range mm Mounting Holes Hole Spacing (X) mm
1,2,3, & 4 channels 6,8,&10 channels
0-499 (2), one row of two (4), two rows of two (L-20mm)
500-1599 (3), one row of three (6), two rows of three (L-20mm)/2
1600-2500 (4), one row of four (8), two rows of four (L-20mm)/3
Ordering Code BNL-5307-120-04-0500
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Mechanical Linear
Switches Cam Trays
10 146
12 170
14 194
16 218
Ordering Code BNL-5304-120-S04-0500
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Mechanical Linear
Switches Cam Trays
Number of Channels Width (A) mm Hole Centerline (B) mm Flange Width (C) mm
2 50 34 16
3 62 46 16
4 74 58 16
5 86 70 16
6 98 82 16
Mechanical Switches
8 122 106 16
10 146 130 16
12 170 154 16
14 194 178 16
16 218 202 16
Length (L) Range mm Mounting Holes Hole Spacing (X) mm
0-499 (4), two rows of two (L-20mm)
500-1599 (6), two rows of three (L-20mm)/2
1600-2500 (8), two rows of four (L-20mm)/3
Ordering Code BNL-5307-120-S04-0500
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Mechanical Linear
Switches Cam Trays
10 148 17
12 172 17
14 196 17
16 218 16
Ordering Code BNL-5306-120-04-0500
76 1-800-543-8390 · www.balluff.com
Mechanical Linear
Switches Cam Trays
Number of Channels Width (A) mm Hole Centerline (B) mm Flange Width (C) mm
2 50 34 16
3 62 46 16
4 74 58 16
5 86 70 16
6 98 82 16
122
Mechanical Switches
8 106 16
10 146 130 16
12 170 154 16
14 194 178 16
16 218 202 16
Length (L) Range mm Mounting Holes Hole Spacing (X) mm
0-499 (4), two rows of two (L-20mm)
500-1200 (6), two rows of three (L-20mm)/2
Ordering Code BNL-5308-120-04-0500
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Mechanical Linear
Switches Cam Trays
78 1-800-543-8390 · www.balluff.com
Mechanical Linear
Switches Cam Trays
L
3
6.2
12
70
16
Mechanical Switches
Type Designation 5310
Number of channels 04
1-800-543-8390 · www.balluff.com 79
Mechanical Linear
Switches Cam Trays
L
3
6.2
12
70
6.6 11
6.8
10
X 10
Only if L > 499 mm 16
Number of channels 04
80 1-800-543-8390 · www.balluff.com
Mechanical Linear
Switches Cam Trays
Mechanical Switches
10 84
Ordering Code BNL-5304-080-04-0500
1-800-543-8390 · www.balluff.com 81
Mechanical Linear
Switches Cam Trays
10 108 17
12 124 17
Ordering Code BNL-5304-080-S04-0500
82 1-800-543-8390 · www.balluff.com
Mechanical Linear
Switches Cam Trays
Number of Channels Width (A) mm Hole Centerline (B) mm Flange Width (C) mm
2 44 28 44
3 52 36 52
4 60 44 60
5 68 52 68
6 76 60 76
Mechanical Switches
8 92 76 92
10 108 92 108
12 124 108 124
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Mechanical Linear
Switches Cam Trays
10 108 16
12 124 16
14 140 16
16 159 17.5
84 1-800-543-8390 · www.balluff.com
Mechanical Linear
Switches Cam Trays
Number of Channels Width (A) mm Hole Centerline (B) mm Flange Width (C) mm
2 46 30 17
3 52 36 16
4 63 47 17.5
5 68 52 16
6 76 60 16
8 92 80 18
Mechanical Switches
10 108 92 16
12 124 108 16
14 140 124 16
16 159 143 17.5
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Mechanical Linear
Switches Cam Trays
Mechanical Switches
86 1-800-543-8390 · www.balluff.com
Mechanical Mechanical
Switches Linear Trip Cams
Linear Trip Cams for Mechanical Switches
Mechanical Switches
BNN-UB are suitable for U-channel friction wedge or
actuating positive-drive T-nut, which is discarded
safety limit switches when prior to installation. The
permanently affixed to the installer simply drills a
cam tray on at least one end 3.5mm hole (No. 28 tap
with a self-threading screw drill), in alignment with the
Z/SCREW-M4-X-20-ST- cam, into the cam tray and
BE-DIN-7513. drives in the self-threading
screw. Be sure to allow
sufficient clearance behind
the cam tray for the screw
to penetrate through the
cam tray.
1-800-543-8390 · www.balluff.com 87
Mechanical Mechanical
Switches Linear Trip Cams
Form UA
Form UB
Ordering Code BNN-520-UB-0050
Form
single set screw = A
twin set screws = B
Form B
0025, 0040, 0050, 0063, 0100, 0120, 0130, 0140,
0150, 0160, 0180, 0190, 0200, 0225, 0250, 0300,
0400, 0450, 0480, 0500, 0600, 0650, 0800, 1000,
1040, 1100, 1300
Application Notes
Overall length (B) mm
Form A, add 21mm to actuated length
Form B, add 26mm to actuated length
Spare Parts
Set Screw BNN-Z/SET-SCREW-701533
88 1-800-543-8390 · www.balluff.com
Mechanical Mechanical
Switches Linear Trip Cams
12.5
Form UA
18 L1 18
Form UB
Form UB
Mechanical Switches
Form single set screw = A
twin set screws = B
Form B
0025, 0040, 0063, 0080, 0100, 0140,
0224, 0375, 0500, 0650, 0800, 1000
1-800-543-8390 · www.balluff.com 89
Mechanical Mechanical
Switches Linear Trip Cams
Æ
adjusted by means of a 2.5 mm pin
inserted into rotating micrometer heads on
each end. Max. adjustment + 5.5 mm, 11 mm total
scale with 25 graduations, 1 grad = 0.02mm
Adjustment pin not included
Ordering Code BNN-520-120-V
Balluff Mechanical Cam BNN-520
Channel Spacing 12 mm = 120
Designation V
Application Notes
For U-channel cam trays
90 1-800-543-8390 · www.balluff.com
Mechanical Mechanical
Switches Linear Trip Cams
8 S 8 12
Mechanical Switches
Form single set screw = A
twin set screws = B
Form B
025, 040, 050, 063, 080,100
150, 200, 250, 300, 500
Application Notes
Overall length (B) mm Form A, add 28mm to actuated length
Form B, add 40mm to actuated length
Spare Parts
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Mechanical Mechanical
Switches Linear Trip Cams
18 L1 8 10.8
12.5
12.5
Form TA
18 L1 18
12.5
Form TB
Form B
0025, 0040, 0063, 0080,0100
0140, 0224, 0375, 0500, 0650, 0800, 1000
92 1-800-543-8390 · www.balluff.com
Mechanical Mechanical
Switches Linear Trip Cams
L = 1000mm Max.
T-slot Unions
12.5
Mechanical Switches
Actuated length (L) mm 0010, 0016, 0025,
0040, 0063, 0080, 0092, 0100, 0110,
0140, 0224,0250, 0350, 0375, 0500, 0650,
0792, 0800, 0960, 0984,
1000
order any combination and quantity
Application Notes
Cam height above cam tray, mm 12.5
Spare Parts
Mounting shoe for T-slot end ramp, BNN-MTE-012-02
includes T-nut, screw, & spring
1-800-543-8390 · www.balluff.com 93
Mechanical Mechanical
Switches Linear Trip Cams
8 S 3.5 7.5
10
8 S 8
Application Notes
Overall length (B) mm Single set screw,
add 11.5 mm to actuated length
Twin set screw, add 16 mm to actuated length
Spare Parts
Set screw BNN-Z/SET-SCREW-701533
94 1-800-543-8390 · www.balluff.com
Mechanical Electronic
Switches Linear Trip Cams
Mechanical Switches
Linear trip cams are Ordering Code BEN-516-14-050
available in two basic styles:
Balluff Mechanical Cam
n
U-channel mount for
drop-in cam installation BEN-516
n
T-slot mount for captive
Type of mounting channel
cams (won’t fall out
U-channel = 14
when loosened)
Actuated length (L) mm:
Application Note Form A, single set screw
These cams are intended for other lengths on request: 010, 016, 020
non-contact operation of
inductive sensors only. Form B, twin set screws
Misapplication for use as trip 022, 024, 025, 030, 040, 050, 051, 063
cams for mechanical limit 075, 076, 077, 080, 100, 110, 115, 120
switches will result in 140, 150, 152, 160, 165, 170, 180, 190
extremely rapid wear and 200, 220, 240, 250, 262, 270, 280, 282
failure. 300, 304, 305, 330, 360, 370, 400, 429
430, 435, 450, 470, 475, 483, 495, 500
552, 570, 594, 600, 610, 650, 660, 700
710, 750, 800, 900, 1000
Application Notes
Overall length (B) mm
Single set screw, add 15 mm to actuated length
Twin set screw, add 30 mm to actuated length
For non-contact electronic inductive sensors only - not for mechanical applications
Spare Parts
Set screw BEN-Z/SET-SCREW-M5
Clamping retainer (end piece) BEN-516-14-00
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Mechanical Electronic
Switches Linear Trip Cams
Form A
Form B
Application Notes
Spare Parts
96 1-800-543-8390 · www.balluff.com
Mechanical Electronic
Switches Linear Trip Cams
8 S 3.5 7.5
10
8 S 8
Mechanical Switches
Series U-channel = 081-S
Application Notes
Overall length (B) mm Single set screw, add 11.5 mm to actuated length
Twin set screw, add 16 mm to actuated length
Spare Parts
Set screw BNN-Z/SET-SCREW-701533
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Mechanical Electronic
Switches Linear Trip Cams
Mechanical Switches
98 1-800-543-8390 · www.balluff.com
Mechanical Mechanical
Rotary
Switches Rotary
Cam Drums
Trip Cams
Rotary cam drums are Rotary cam drums are Rotary cam trays carry the
machined from solid available in a variety of styles following options:
aluminum into a round to suit your application:
profile. Rotary cam trays are n
T-slot for captive cams
made from extruded n
U-channel for drop-in
aluminum rolled into a semi-
n
With or without pre-
cam installation drilled mounting holes
circle. A rotary drum
provides 360 degrees for
n
T-slot for captive cams n
Radii from 75 to 250 mm
cam mounting, while the (won’t fall out when
rotary cam trays provide loosened)
180 degrees. Two rotary n
20mm diameter shaft
cam trays can be used hole
together to provide 360 n
20mm diameter shaft
degrees for cam mounting.
hole and counterbore
The trip cams are held in
n
Various outside
the U-channels by friction diameters from 80 to
wedges and by T-nuts in the 320 mm
T-slot channels. The cam is
adjusted in the channel to
set the exact switchpoint,
then locked in place with a
hex socket set screw.
Mechanical Switches
1-800-543-8390 · www.balluff.com 99
Mechanical Rotary
Mechanical
Switches Cam Drums
Rotary Trip Cams
Style A Style B
7
8
9
10
12
Application Notes
Length L1 mm 7
Inside diameter d1 mm
For drum diameter
80 mm NA
100 mm NA
150 mm 120
200 mm 170
250 mm 220
320 mm 290
Style A Style B
Mechanical Switches
6
7
8
9
10
12
Application Notes
Length L1 mm 7
Inside diameter d1 mm
For drum diameter
80 mm NA
100 mm NA
150 mm 120
200 mm 170
250 mm 220
320 mm 290
Radius tolerance, mm
For cam tray nominal radii r1 r2
75 mm 75 ± 2 59 ± 2
100 mm 100 ± 2 84 ± 2
125 mm 125 ± 2 109 ± 2
160 mm 160 ± 3 144 ± 3
250 mm 150 ± 3 234 ± 3
Accessories
Mechanical Switches
cam tray on at least one end cam, into the cam tray and
with a self-threading screw drives in the self-threading
Z/SCREW-M4-X-20-ST- screw. Be sure to allow
BE-DIN-7513. sufficient clearance behind
the cam tray for the screw
The self-threading screw to penetrate through the
can be ordered separately cam tray.
and takes the place of the
U-channel friction wedge or
12.5
.5
12
.5
12
Mechanical Switches
250 mm BNN -UR -015 -250 -12 69 25 2
BNN -UR -030 -250 -12 137 40 2
BNN -UR -045 -250 -12 206 55 2
BNN -UR -060 -250 -12 275 70 2
BNN -UR -075 -250 -12 343 85 2
BNN -UR -90 -250 -12 412 100 2
BNN -UR -105 -250 -12 481 115 2
BNN -UR -120 -250 -12 549 130 2
Application Notes Spare Parts
Cam height, mm 12.5 End ramp for U-channel, includes ramp & mounting
shoe assembly
Special radii and radii 40...50 mm
swept angles available radii 75...124 mm BNN-URE-040-12
on request radii 125...249 mm BNN-URE-075-12
radii 250 mm & up BNN-URE-125-12
Positive-drive safety BNN-URE-250-12
switches Friction block for U-channel,
Z/SCREW-M4-X-20-ST-BE-DIN-7513 no spring or screw included BNN-URENU-1202
12.5
.5
12
.5
12
Style 1 Style 2
Mechanical Switches
BNN -TR -045 -250 -12 206 55 2
BNN -TR -060 -250 -12 275 70 2
BNN -TR -075 -250 -12 343 85 2
BNN -TR -90 -250 -12 412 100 2
BNN -TR -105 -250 -12 481 115 2
BNN -TR -120 -250 -12 549 130 2
Application Notes Spare Parts
Cam height, mm 12.5 End ramp for U-channel, includes ramp & mounting
shoe assembly
Special radii and radii 40...50 mm
swept angles available radii 75...124 mm BNN-TRE-040-12
on request radii 125...249 mm BNN-TRE-075-12
radii 250 mm & up BNN-TRE-125-12
Positive-drive safety BNN-TRE-250-12
switches Friction block for U-channel,
Z/SCREW-M4-X-20-ST-BE-DIN-7513 no spring or screw included BNN-TRENU-1202
Mechanical Switches
109
Mechanical Electronic
Switches Rotary Trip Cams
Style 1
Style 3
Style 2
Nominal Radius Ordering Code Other Information
Rotary Cam U-Channel Swept Angle Radius r1 Cam Spacing Arc Length Style
Cam b (°) (mm) (mm) (mm)
BEN -IR -004 -040 -12 4 1
BEN -IR -010 -040 -12 10 2
BEN -IR -015 -040 -12 14 2
40 mm BEN -IR -030 -040 -12 28 2
BEN -IR -045 -040 -12 41 3
BEN -IR -060 -040 -12 55 3
Mechanical Switches
110
Mechanical Electronic
Switches Rotary Trip Cams
Mechanical Switches
BEN -IR -030 -250 -12 137 3
BEN -IR -045 -250 -12 206 3
BEN -IR -060 -250 -12 275 3
BEN -IR -075 -250 -12 343 3
BEN -IR -90 -250 -12 412 3
BEN -IR -105 -250 -12 481 3
BEN -IR -120 -250 -12 549 3
Application Notes Spare Parts
Cam height, mm 12.5
T-nut friction block, BEN-Z/IR-M4-T-NUT
Special radii and no screw included
swept angles available
on request
For non-contact
electronic inductive
sensors only - not for
mechanical applications
111
Mechanical Electronic
Switches Rotary Trip Cams
Mechanical Switches
112
Mechanical Robot Zone
Switches Limit System
Mechanical Switches
Robot clear of IP
operator 67
Shared Robot/
Operator
Work Area
Features Design
n
Monitors up to three The system is composed of a
independent work zones heavy-duty mechanical cam
with a six-channel cam switch assembly that mounts
system to the stationary base of the
robot, a rugged circular cam
n
Robot work zones tray that attaches to the
configurable from 15° robot’s rotating flange, and
to 345° in 7.5° increments hardened circular cams that
n
Implements dynamic mount on the cam tray at
restricted envelope per rotation boundary locations.
ANSI/RIA R15.06-1999
n
Addresses need for
Category 4 control Each zone is monitored by a
reliability pair of switches tripped by a
n
Safety limit switches pair of complementary cams
designed to VDE 0113 covering the full 360° of the
n
Limit switch housing robot’s range of motion. A
sealed to IP67 single point fault in any part of
n
Conforms to General the system will not
Motors’ Global Common compromise the safety
Technical Specification for function:
Production Robots RS-1,
Section 3.10.3 "Zone n
Missing cam(s)
Limit Switches/Dynamic n
One cam overlapping the
Limiting Devices“ other
n
Open/short circuit
n
Welded contact
n
Stuck plunger
n
Switch disconnected
Mechanical Switches
The maintenance-free
mechanical cam switch
assembly is a double-
changeover switching system
made up of six limit switches
actuated by solid stainless
steel plungers with high-
speed ball-bearing rollers.
Positive-break, force-guided
contacts to VDE 0113 are
rated for five million
operations. The switch
assembly has an anodized
aluminum housing sealed to
IP67 and can tolerate
temperatures ranging from -5
to 80°C. Connector options
range from rectangular
Harting to circular Brad
Harrison styles.
Precision-machined, nitrite-
hardened cams are designed
for long-wearing durability.
Circular Cams
n The cam length
corresponds to the size
of the operator area.
n Made of hardened
material for longest life
Mechanical Switches
Cam Switches
n Per DIN 43697
21 22
n Safety switch inserts per 13 14
EN 947-5-1, VDE 0113,
VDE 0660
n Patented plunger guide
and plunger mechanism 21 22
n UL, CSA approval 13 14
This sheet metal destacking Without a zone limit system, Rejected material is This application represents a
area requires three indepen- the robot would be stopped collected at Stack C. When three-zone system. Each
dently configurable safety the moment the safety gate the safety gate is opened to zone is diverse complemen-
zones. was raised. The zone limit remove a full pallet, the tary redundant and indepen-
system, by positively robot can continue opera- dently configurable. The
During normal operation, monitoring the robot tions from Stack A to the zone limit system generates
the robot picks up new position, allows the safety conveyor, but will be a separate, control-reliable
sheet stock from Material gate switch to be muted blocked from moving across 'Clear of Operator' signal
Station A and places it on when the robot is clear of Stack C while the safety when it is outside of each
the conveyor for transport the operator. The operator gate is open. respective operator area.
into the stamping is able to enter the robot cell Each 'Clear of Operator'
operation. When all of the at Stack A without stopping The door for maintenance signal is sent to an approved
raw material has been the robot from working at personnel is never muted. safety relay or cell controller
removed from Stack A, the Stack B. However, should Whenever a that monitors the interaction
robot program transfers the Stack B become depleted maintenance person opens of the zone limit system with
pickup over to Stack B. while Stack A is being the door with a keyed the light curtains, gate
replenished, the robot will interlock, all motion in the switches, and the robot.
At this time, a forklift halt and will not enter Stack robot cell stops. Typically,
operator opens the safety A until the safety gate is the robot would be parked Balluff accomplishes control
gate in front of Stack A, closed. in the maintenance area for reliability with two limit
removes the empty pallet, service to its end effector switches and a set of two
and puts a new pallet of tooling. complementary cams per
material in place. zone. In this application,
there would be a total of six
limit switches contained in a
single housing and six cams
held in a single cam tray.
Mechanical Switches
A common application is the While the robot is clear of This application represents a Balluff accomplishes control
two-station robotic arc both Stations A and B, the two-zone system. Each reliability with two limit
welding cell. A human outputs of the safety light zone is diverse switches and a set of two
operator moves between curtains are muted. This complementary redundant complementary cams per
Station A and Station B, allows the robot to perform and independently zone. In this application,
removing finished parts and its automated tip cleaning configurable. The zone limit there would be a total of
replacing them with parts to and tip changing tasks at system generates a four limit switches contained
be welded. the rear of the cell. If the separate, control-reliable in a single housing and four
robot attempts to move into 'Clear of Operator' signal cams held in a single cam
The robot follows the work either operator zone while when it is outside of each tray.
of the human operator, an operator is present, the respective operator area.
applying welds to materials safety light curtains are re- Each 'Clear of Operator'
held in the fixturing. While enabled and the robot halts. signal is sent to an
the human operator is approved safety relay or cell
working at Station A, the The keyed door interlock controller that monitors the
beam of the safety light switches are never muted. interaction of the
curtain is broken, but the Anytime a maintenance zone limit system with the
robot is allowed to continue worker enters the cell to light curtains, gate switches,
working at Station B. If the perform service on the and the robot.
robot attempts to move robot, the robot stops all
toward Station A while the motion.
operator is still present, the
safety light curtain is re-
enabled and the robot halts.
Mechanical Switches
118
Robot Zone Limit
Mechanical System Application
Switches Light Curtain Muting
Page 1 of 2
Zone A robot supervising relay Robot is clear of Zone A Robot is not clear of Zone B Zone B robot supervising relay
LS2 LS4
DC Supply DC Supply
Status Status
Robot power is on
Automatic Reset Automatic Reset
in
ta St
c ur at
ion
ht B
lig sa
ty
fe fe
sa ty
nA
lig
ht
Status io c Status
at ur
St tai
n
Station A Station B
welding fixture welding fixture
°
90
A
ne
Zo
Mechanical Switches
Zo
ne
Station A light curtain supervising relay Station B light curtain supervising relay
B
90
°
Zone A robot supervising relay Robot is clear of Zone A Robot is not clear of Zone B Zone B robot supervising relay
LS2 LS4
DC Supply DC Supply
Status Status
in St
at
rta ion
t cu B
h sa
y lig fe
fet ty
sa lig
A h tc
on ur Status
Status ati ta
St in
Station A Station B
welding fixture welding fixture
Mechanical Switches
°
90
A
Zo
ne
ne
Station A light curtain supervising relay Station B light curtain supervising relay
Zo
B
90
°
Limit switch with 8-pole circular, Includes limit switch and cable
cam drum, switch bracket, BNL-2000-AXIS-2-1-ZONE BNS-113-B02-L12-61-A22-02-C093
FANUC R-2000i 2 1 8-pole flex cable, hardware BKS-08-PIN-FEMALE-MINI-HI-FLEX
Cam set BNN-UR-xxx.x/yyy.y-125-12 One set required
Set-up gauge BNL-Z/GAUGE-X508 Reusable
Mechanical Switches
Cam set BNN-520-R373-xxx.x/yyy.y One set required per zone
Set-up gauge BNN-520-R373-10 Reusable
Limit switch with 8-pole circular, cam Includes limit switch and cable
drum, switch bracket, 8-pole flex cable, BNL-FANUC-430-AXIS-2-SYSTEM BNS-113-B02-L12-61-A22-02-C093
FANUC S-430i/iw 2 1 hardware BKS-08-PIN-FEMALE-MINI-HI-FLEX
Cam set BNN-UR-xxx.x/yyy.y-125-12 One set required
Set-up gauge BNL-Z/GAUGE-X508 Reusable
Limit switch with 8-pole circular, cam Includes limit switch and cable
drum, switch bracket, 8-pole flex cable, BNL-FANUC-430-AXIS-3-SYSTEM BNS-113-BO2-L12-61-A22-02-D016
FANUC S-430i/iw 3 1 hardware BKS-08-PIN-FEMALE-MINI-HI-FLEX
Cam set BNN-UR-xxx.x/yyy.y-125-12 One set required
Set-up gauge BNL-Z/GAUGE-X508 Reusable
Limit switch with 8-pole circular, integrated Includes limit switch and cable.
rotatable 180°/180° cams, with bracket BNL-FANUC-420-AXIS-2-SYSTEM BNS-113-B02-L12-61-A22-02-D016
FANUC S-420i 2 1 8-pole flex cable, hardware BKS-08-PIN-FEMALE-MINI-HI-FLEX
Set-up gauge BNL-Z/GAUGE-X508 Reusable
Limit switch with 8-pole circular, cam drum Includes limit switch and cable
switch bracket, 8-pole flex cable, hard stop BNL-FANUC-M710i-2-1-ZONE BNS-113-B02-L12-61-A22-02-D016
hardware BKS-08-PIN-FEMALE-MINI-HI-FLEX
FANUC M-710i 2 1 Cam set BNN-UR-xxx.x/yyy.y-125-12 One set required
Set-up Gauge BNL-Z/GAUGE-X508 Reusable
Limit switch with Harting Han 24DD BNS-113-X518-D04-L12-100-22-04 Call Balluff for application assistance
Cam tray without hardware BNL-5310-120-S04-... Must specify side slung or underslung
Switch bracket without hardware CALL BALLUFF
FANUC M-710iT 1 2 Linear cams BNN-ZN-...-12, BNN-HNT, BNN-MTE-012 80m/min max speed
(track) Self-threading screws Z/SCREW-M4-X-20-ST-BE-DIN-7513
Set-up gauge BNL-Z/GAUGE-X508 Reusable
Application Notes
Rectangular Harting Han 24DD 24/C, 18 AWG, FA F to flying leads BKS-X518-CABLE-xxxFT Data sheet U01447
mating cable accessories 24/C, 18 AWG, ST F to flying leads BKS-X518-CABLE-ST-xxxFT Data sheet U01456
31/C, 16 AQG, RAF to flying leads BKS-X518-CABLE-HI-FLEX-100FT For flex track
24/C, 18 AWG, RAF to ST M BKS-X518-CABLE-EXTENSION-xxxFT Data sheet U01457
Mechanical Switches
Radii 250 mm & up BNN-TRE-250-12
Limit switches Harting Han 32EE connector (GM) BNS-113-X524-D06-L12-100-22-06 Data Sheet F818953
Harting Han 24DD connector BNS-113-X518-D06-L12-100-22-06 Data Sheet F81398
Harting Han 24DD connector BNS-113-X518-D04-L12-100-22-04 Data Sheet F813899
8-pole circular connector BNS-113-D02-L12-100-22-02-C040 Data Sheet U01309
8-pole circular connector BNS-113-B02-L12-61-A22-02-C093 Data Sheet U01385
8-pole circular connector BNS-113-B02-L12-61-A22-02-D016 Data Sheet U01464
8-pole circular connector BNS-113-B02-L12-61-A12-02-D058 Data Sheet T01808
8-pole circular connector BNS-113-B03-L12-61-A12-03-D008 Data Sheet U01459
8-pole circular connector BNS-113-B03-L12-61-A12-04-D027 Data Sheet U01466
Alternate style cam trays and cam sets Fanuc S430i 1-zone, 2-zone U-channel cam tray BNL-5304-120-05-R342 Consult factory
Use with U-channel cam set BNN-520-R350-xxx.x/yyy.y
Mechanical Switches
Technical Data Construction
Switch actuation force at plunger max. 18 N Housing material Thermoplastic (fiberglass reinforced)
Switch-back force min. 0.8 N Contact material BSE 85 Silver
Bounce time < 3 ms Contacts Normally closed (21+22)
Contact opening width 2 x 1.2 mm Normally open (13+14)
Changeover time 1.5 ms Electrical Terminations M 3.5 screw terminals with
Actuation velocity min. 1 mm/min self-lifting clamps
No. of switching actuations max. 3000/h Switching system Double interrupting sliding contact
operation. 1 NO + 1 NC. Normally
Repeatability of switch point ± 0.02 mm
closed, positive opening per IEC
Ambient temperature range -30oC...+85oC 947.5.1. Actuation via setbolt
Figure 1
Switch Wiring
Requirements
10.2.3 Dynamic 10.1 Requirements 4.5.4 Control Reliable n The monitoring shall
Limiting Devices of Safety Circuit generate a stop signal if a
Performance Control reliable safety
fault is detected. A
Dynamic limiting is the warning shall be provided
automatically controlled circuitry shall be designed,
The ultimate design constructed and applied if a hazard remains after
change in a robot’s cessation of motion;
requirement for safety such that any single
restricted space during a
systems is that, should they component failure shall
portion of the robot’s fail, the associated hazard is n Following detection of a
system cycle. Control not prevent the stopping
left in a safe state. Safety fault, a safe state shall be
devices such as, but not action of the robot.
related parts of control maintained until the fault is
limited to, cam operated systems shall be designed, cleared.
limit switches, light curtains
constructed, selected, and These circuits shall be
or control activated n Common mode failures
assembled using basic hardware based or comply
retractable hard stops may safety principles for the shall be taken into
with 6.4, and include
be utilized to further limit account when the
intended application and automatic monitoring at the
robot movement within the probability of such a
can withstand: system level.
restricted space while the failure occurring is
robot performs its task significant.
program provided the n The expected operating
device and stresses. n The single fault should be
associated controls n The influence of the detected at time of failure.
(hardware based or processed material. If not practicable, the
compliant with 6.4) n Other relevant external failure shall be detected at
are capable of stopping the influences. the next demand upon
robot motion under rated
Mechanical Switches
the safety function.
load and speed conditions.
Dynamic limiting devices The performance criteria
shall be electrically listed in 4.5 shall be used in
integrated in accordance the design of the safety
with 10.4.6. circuit consistent with the
associated level of hazard.
10.4.6 Safeguarding These circuit requirements
Device Electrical are for new
Integration installations.
Figure B.5 - Multiple operator station cell with muting base limit sensors
Mechanical hard stops complimentary fashion and normally utilized to enhance devices, indicators, and
prevent robot operation are monitored for timing and muting performance when circuitry are monitored by
between 90 and 270 proper operation. The robot the robot is at a safe the muting control for
Mechanical Switches
degrees, and allow opera- control will allow motion into distance from the operator proper operation cyclically or
tion between 270 and 90 adjacent operator station stations. when change of status
degrees. Base limit switches only if the light curtain in that Gate interlock is always occurs or should occur.
are configured to operate in station is clear. Additional active in automatic mode NOTE: Muting devices are
a diverse redundant base limit sensors are (never muted). Muting not necessarily mechanical
switches.
BNS
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Balluff Inc. Balluff Canada, Inc. Balluff de Mexico
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Edition 052002
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