Proximity Sensors

Introduction

Principles of Operation for Standard Target for S Flat targets are preferable
Inductive Proximity Sensors Inductive Proximity Sensors S Rounded targets may reduce the
sensing distance
S Nonferrous materials usually reduce
Target
the sensing distance for all-metal
Coil Oscillator Trigger Output sensing models
Circuit Circuit
Proximity Switch
S Targets smaller than the sensing
Inductive proximity sensors are face typically reduce the sensing
Motion Active Face
designed to operate by generating an 1 mm
distance
Direction
electromagnetic field and detecting the S Targets larger than the sensing face
eddy current losses generated when The active face of an inductive may increase the sensing distance
ferrous and nonferrous metal target proximity switch is the surface where a
objects enter the field. The sensor high-frequency electro-magnetic field S Foils may increase the sensing
consists of a coil on a ferrite core, an emerges. distance
oscillator, a trigger-signal level detector
and an output circuit. As a metal object A standard target is a mild steel, 1mm
thick, square form with side lengths Principles of Operation for
advances into the field, eddy currents Capacitive Proximity Sensors
are induced in the target. The result is a equal to the diameter of the active face
loss of energy and a smaller amplitude or 3X the nominal switching distance,
of oscillation. The detector circuit then whichever is greater.
recognizes a specific change in
amplitude and generates a signal which Target Correction Factors for
Probe Oscillator Rectifier Output
will turn the solid-state output “ON” or Inductive Proximity Sensors Filter Circuit
“OFF.”
To determine the sensing distance for
Capacitive proximity sensors are
Target Position materials other than the standard mild
designed to operate by generating an
steel, a correction factor is used. The
electrostatic field and detecting
composition of the target has a large
changes in this field caused when a
effect on sensing distance of inductive
target approaches the sensing face.
proximity sensors. If a target
The sensor’s internal workings consist
constructed from one of the materials
of a capacitive probe, an oscillator, a
listed is used, multiply the nominal
signal rectifier, a filter circuit and an
sensing distance by the correction
output circuit.
factor listed in order to determine the
nominal sensing distance for that target. In the absence of a target, the oscillator
Oscillator Response Note that ferrous-selective sensors will is inactive. As a target approaches, it
not detect brass, aluminum or copper, raises the capacitance of the probe
while nonferrous selective sensors will system. When the capacitance reaches
not detect steel or ferrous-type stainless a specified threshold, the oscillator is
steels. activated which triggers the output
circuit to change between “on” and “off.”
The correction factors listed below can
be used as a general guideline. The capacitance of the probe system is
Output Voltage Common materials and their specific determined by the target’s size,
Releasing Level correction factors are listed on each dielectric constant and distance from
Operating Level On product specification page the probe. The larger the size and
dielectric constant of a target, the more
(Nominal Sensing Range) x (Correction
Output it increases capacitance. The shorter
Off Off Factor) = Sensing Range.
the distance between target and probe,
the more the target increases
A metal target approaching an Correction Factors capacitance.
inductive proximity sensor (above) Approximate
absorbs energy generated by its Target Material Correction Factor
oscillator. When the target is in close Standard Target and Grounding
Mild Steel 1.0 for Capacitive Proximity Sensors
range, the energy drain stops the
oscillator and changes the output Stainless Steel 0.85
The standard target for capacitive
state. Brass 0.50 sensors is the same as for inductive
Aluminum 0.45 proximity sensors. The target is
Copper 0.40 grounded per IEC test standards.
However, a target in a typical
The size and shape of the target may application does not need to be
also affect the sensing distance. The grounded to achieve reliable sensing.
following should be used as a general
guideline when correcting for the size
and shape of a target:

2–9
Proximity Sensors
Introduction

Shielded vs. Unshielded Dielectric Constants of Principles of Operation for

Capacitive Sensors Common Industrial Matierials Ultrasonic Proximity Sensors
Acetone 19.5
Shielded capacitive proximity sensors Ultrasonic sensors detect objects by
Acrylic Resin 2.7–4.5
are best suited for sensing low dielectric emitting bursts of high-frequency sound
Air 1.000264
constant (difficult to sense) materials Alcohol 25.8 waves which reflect or “echo” from a
due to their highly concentrated Ammonia 15–25 target. These devices sense the
electrostatic fields. This allows them to Aniline 6.9 distance to the target by measuring the
detect targets which unshielded Aqueous Solutions 50–80 time required for the echo to return and
sensors cannot. However, this also Bakelite 3.6 dividing that time value by the speed of
makes them more susceptible to false Benzene 2.3 sound. This allows these devices to
triggers due to the accumulation of dirt Carbon Dioxide 1.000985 detect objects of any shape and
or moisture on the sensor face. Carbon Tetrachloride 2.2 material that can sufficiently reflect an
Celluloid 3.0 ultrasonic pulse.
The electrostatic field of an unshielded
Cement Powder 4.0
sensor is less concentrated than that of Cereal 3–5
Analog models provide an output
a shielded model. This makes them well Chlorine Liquid 2.0 voltage proportional to the distance
suited for detecting high dielectric Ebonite 2.7–2.9 from the sensor face to the target, while
constant (easy to sense) materials or Epoxy Resin 2.5–6 digital/discrete output models change
for differentiating between materials Ethanol 24 output state when this distance crosses
with high and low constants. For the Ethylene Glycol 38.7 a pre-set threshold.
right target materials, unshielded Fired Ash 1.5–1.7 Because ultrasonic sensors depend on
capacitive proximity sensors have Flour 1.5–1.7
a reflected sound wave for proper
longer sensing distances than shielded Freon R22 & 502 (liquid) 6.11
operation, the correction factors and
versions. Gasoline 2.2
Glass 3.7–10
target requirements used for inductive
Unshielded models are equipped with a Glycerine 47 proximity sensors do not apply. Refer
compensation probe which allows the Marble 8.0–8.5 to the Bulletin 873C product pages in
sensor to ignore mist, dust, small Melamine Resin 4.7–10.2 this catalog for target considerations.
amounts of dirt and fine droplets of oil or Mica 5.7–6.7
water accumulating on the sensor. The Nitrobenzine 36 Hysteresis (Differential Travel)
compensation probe also makes the Nylon 4–5
sensor resistant to variations in ambient Oil Saturated Paper 4.0 The difference between the operate and
humidity. Unshielded models are Paraffin 1.9–2.5 the release points is called hysteresis or
therefore a better choice for dusty Paper 1.6–2.6 differential travel. The amount of target
and/or humid environments. Perspex 3.2–3.5 travel required for release after
Petroleum 2.0–2.2 operation must be accounted for when
Unshielded capacitive sensors are also Phenol Resin 4–12 selecting target and sensor locations.
more suitable than shielded types for Polyacetal 3.6–3.7 Hysteresis is needed to help prevent
use with plastic sensor wells, an Polyamide 5.0 chattering (turning on and off rapidly)
accessory designed for liquid level Polyester Resin 2.8–8.1 when the sensor is subjected to shock
applications. The well is mounted Polyethylene 2.3 and vibration or when the target is
through a hole in a tank and the sensor Polypropylene 2.0–2.3 stationary at the nominal sensing
is slipped into the well’s receptacle. The Polystyrene 3.0
distance.
sensor detects the liquid in the tank Polyvinyl Chloride Resin 2.8–3.1
through the wall of the sensor well. This Porcelain 4.4–7 Vibration amplitudes must be smaller
allows the well to serve both as a plug Powdered Milk 3.5–4 than the hysteresis band to avoid
for the hole and a mount for the sensor. Press Board 2–5 chatter.
Quartz Glass 3.7
Target
Rubber 2.5–35 Motion Direction
Target Correction Factors for Salt 6.0
Capacitive Proximity Sensors Sand 3–5 Switch Point
When Leaving
Shellac 2.5–4.7
For a given target size, correction
Shell Lime 1.2
factors for capacitive sensors are Silicon Varnish 2.8–3.3 Switch Point
determined by a property of the target When Operating Hysteresis
Soybean Oil 2.9–3.5 Approaching
material called the dielectric constant. Styrene Resin 2.3–3.4 Distance
Materials with higher dielectric constant Sugar 3.0
values are easier to sense than those Sulphur 3.4
with lower values. A partial listing of Teflon 2.0
dielectric constants for some typical Toluene 2.3 Proximity
industrial materials follows. For more Transformer Oil 2.2 Switch
information, refer to the CRC Handbook Turpentine Oil 2.2
of Chemistry and Physics (CRC Press), Urea Resin 5–8
the CRC Handbook of Tables for Vaseline 2.2–2.9
Applied Engineering Science (CRC Water 80
Press), or other applicable sources. Wood, Dry 2–7
Wood, Wet 10–30

2–10
 Proximity Sensors
Introduction

Switching Frequency Mounting Considerations for Use the following chart or formulas to
Weld Field Immune Proximities determine the spacing requirements
The switching frequency is the
between the current line and proximity
maximum speed at which a sensor will Reliable operation is dependent on the sensor. Select a distance that falls
deliver discrete individual pulses as the strength of the magnetic field and the within the safe zone.
target enters and leaves the sensing distance between the current line and
field. This value is always dependent on the sensor.
target size, distance from sensing face, S H= I
speed of target and switch type. This
2p r
indicates the maximum possible
Perpendicular Mounting
number of switching operations per H
second. The measuring method for
to the Current Line S B=
determining switching frequency with Current Line
0.796
standard targets is specified by DIN S Gauss = 10* B
EN50010. where:
d
ÉÉ I = welding current (in kA),

ÉÉ r
Sensor

Magnetic Field
H = field strength (in kA/m),
B = flux (in mT), and
Proximity Switch r = distance between sensor and
current carrying lines (in meters).
Motion
Direction
Weld Field Immunity
Parallel Mounting
Targets of to the Current Line 50kA

ÉÉ ÉÉÉÉÉÉ
Sn Mild Steel
2xm
m 2 Sensor 40kA

ÉÉ ÉÉÉÉÉÉ 30kA

ÉÉ ÉÉÉ ÉÉ
Current ( l )
m
r 20kA

ÉÉ
Safe Zone
Nonmagnetic and nonconducting material
10kA

Current Line 0kA

m=d 0mm 10mm 20mm 30mm 40mm 50mm
0.50in 1.00in 1.50in 2.00in 2.50in
Ripple Distance from Current Line (r)

Ripple is the alternating voltage

superimposed on the DC voltage (peak
to peak) in %.
For the operation of DC voltage
switches, a filtered DC voltage with a
ripple of 10% maximum is required
(according to DIN 41755).
U

Uuss
Ud

2–11
Proximity Sensors
Introduction

Series Connected Sensors Parallel Connected Sensors TTL Wiring

Sensors can be connected in series Sensors can be connected in parallel to ( + ) 10-30 V DC
with a load. For proper operation, the energize a load. To determine the
Brown (+) 5V
load voltage must be less than or equal maximum allowable number of sensors
to the minimum supply voltage minus for an application, the sum of the Black
the voltage drops across the series- maximum leakage current of the TTL
Sink
connected proximity sensors. sensors connected in parallel must be
Blue
less than the maximum OFF-state
Wiring Diagram for current of the load device. (-) Common
(-)
Series Connected Current GND
Sink Sensors (NPN) Note: Care should be taken when designing
+ – parallel proximity circuits. If too much
leakage current flows into the load it may ( + ) 10-30 V DC
V DC
cause the solid state input to change state
or a small relay not to drop out. Sensors
connected in parallel do not provide a higher
+ – load current capability.
Load TTL
Wiring Diagram for Source
Parallel Connected (-)
Wiring Diagram for Current Sink Sensors (NPN)
+ –
Series Connected Current (-) 5V GND
V DC
+
Source Sensors (PNP) –
V DC + –
Load
+ – Note: When using sourcing outputs, ground
Load must be floating and cannot be common,
or short circuit will result.

PLC Wiring
Wiring Diagram for For PLC wiring information for Inductive
Wiring Diagram for
Series Connected and Capacitive sensors, refer to
Parallel Connected
AC Sensors publication 871–4.5, June 1996.
L1 L2 Current Source Sensors (PNP)
V AC + –
V DC
+ –
Load Load

Wiring Diagram for

Parallel Connected
AC Sensors
L1 L2
V AC
R*

R* Load

* Add R in series with sensor to maintain

minimum voltage when sensor is switching.

2–12
 Proximity Sensors
Introduction

Shielded vs. Unshielded Inductive Sensors

Shielded Sensor Unshielded Sensor

Metal Metal
Shield Shield

Ferrite Core
Ferrite Core
Shielded construction includes a metal Unshielded sensors do not have
band which surrounds the ferrite core and this metal band.
coil arrangement.

Spacing Between Shielded Sensors (Flush-Mountable) and Nearby Metal Surfaces

Shielded proximity sensors allow the face. Shielded construction allows the surrounding metal without causing a
electro-magnetic field to be proximity to be mounted flush in false trigger.
concentrated to the front of the sensor

ÉÉÉÉÉÉÉÉ
Cylindrical Style

É É
ÉÉÉ ÉÉÉÉÉ É É
d d d 3 Sn

ÉÉÉ ÉÉÉÉÉ É É
ÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉ
É
É
2d*
É
É
*8d for capacitive sensors

É É
ÉÉÉÉÉÉ É É
Limit Switch Style (871L and 872L)

ÉÉÉÉÉÉ É É
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
É
É
2d
É
É
ÉÉÉÉÉÉ d
d

Limit Switch Style (802PR)

É É
ÉÉÉÉÉÉ É É
ÉÉÉÉÉÉ É É
ÉÉÉÉÉÉ É 1.8d
É
ÉÉÉÉÉÉ É É
ÉÉÉÉÉÉ
d
1.3d*
d

* 802PR–LB or 802PR–XB can be mounted side by side.

d = diameter or width of active sensing face

Sn = nominal sensing distance

2–13
Proximity Sensors
Introduction

Spacing Between Shielded Sensors (Flush-Mountable) and Nearby Metal Surfaces (continued)
Cube Style (871P VersaCube)

ÉÉÉ ÉÉÉÉÉ ÉÉÉÉÉÉÉ

Active Face d d

ÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉÉÉ
ÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ d
d

Miniature Flat Pack Style (871FM)

3 Sn

d = diameter or width of active sensing face

Sn = nominal sensing distance

2–14
 Proximity Sensors
Introduction

Spacing Between Unshielded Sensors (Nonflush-Mountable) and Nearby Metal Surfaces

Longer sensing distances can be require a metal-free zone around the closer than 3 times the rated nominal
obtained by using an unshielded sensing face. Metal immediately sensing distance of the sensor.
sensor. Unshielded proximity sensors opposite the sensing face should be no

ÉÉÉÉÉÉÉÉÉ
Cylindrical Style

≥3d

ÉÉÉÉÉÉÉÉÉÉ 3d Ë d 3 Sn

ÉÉÉÉÉÉÉÉÉÉ
dÊ

ÉÉÉÉÉÉÉÉÉÉ 4d Ì

ÉÉÉÉÉÉÉÉÉÉ

ÉÉÉÉÉÉÉÉ
Limit Switch Style (871L, 872L, and 875L)

ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
0.4d Í

ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
d
4d Ë

ÉÉÉÉÉÉÉÉ d 4d Ì

ÉÉÉÉÉÉÉ
Limit Switch Style (802PR)

ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
0.4d

ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
1.5d
d
d 0.4d

Ê d for capacitive sensors if mounted in plastic. 3d (12, 18mm

models) or 1.5d (30, 34mm models) if mounted in metal.
Ë For capacitive sensors, 3d at medium sensitivity to 8d at
maximum sensitivity.
Ì 8d for capacitive sensors.
Í d for capacitive sensors.
d = diameter or width of active sensing face
Sn = nominal sensing distance

2–15
Proximity Sensors
Introduction

Spacing Between Unshielded Sensors (Nonflush-Mountable) and Nearby Metal Surfaces (continued)

Cube Style (871P VersaCube)

ÉÉÉÉÉÉÉÉÉÉÉ
Active Face
2d d d

ÉÉÉÉÉÉÉÉÉÉÉ
0.4d

ÉÉÉÉÉÉÉÉÉÉÉ 40mm typ.

15mm

ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ 0.4d

ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ d

ÉÉÉÉÉÉÉÉ d
2d

Side View
(amount of overhang)
Miniature Flat Pack Style (871FM)
0.5L

6 Sn

d = diameter or width of active sensing face

Sn = nominal sensing distance

2–16
 Proximity Sensors
Applications

Machine Tools Plating Line Plating Line

Inductive Proximity
Sensor for Horizontal
Lathe Trigger Position Detection

ÂÂÂÂÂ
Tool
Chuck

ÂÂÂÂÂ
ÂÂÂÂÂÂ
Inductive
Proximity

ÂÂÂÂÂ
ÂÂÂÂÂÂ
Sensor Work to be
Dipped

ÂÂÂÂÂ
ÂÂÂÂÂÂ
ÂÂÂÂÂ
ÂÂÂÂÂÂ
ÂÂÂÂÂ
Inductive
Proximity
Sensors for
Inductive Inductive
Vertical Position
Proximity Proximity Detection
Sensor Sensor

Grinding Machines Wood Industry Conveyor Belts

Capacitive Proximity
Sensor

Wood
Inductive
Metal Parts
Proximity
Sensor

Inductive
Proximity Inductive
Sensor Saw Blade Returns for Proximity
Another Cut Sensor
Inductive
Proximity
Sensor

Petroleum Industry—
Valve Position

Handwheel Acts as Target

A
871TM
B
871TM

A: Open Valve Indicator

B: Closed Valve Indicator

2–17
Proximity Sensors
Applications

Inductive

Ë ËË
Proximity
Sensor

Ë Ë
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
Inductive proximity sensor used to detect a foil
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
Ferrous selective inductive proximity sensor used to
seasoning bag inside of a cardboard container. sort ferrous and nonferrous can tops.

Food Industry Stainless Steel Sheet Welder

Inductive
Proximity
Sensor

Inductive Bottle
Proximity Cap
Sensor 871Z Hole to
Metal Identify Weld

ÉÉÉÉÉÉÉ
Can - (Cathode)

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
Insulation
+ (Anode)

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ Conveyor
871Z

ÉÉÉÉÉÉÉ Conveyor

Food Processing Printing

Capacitive Proximity
Sensors for Container
Full" Verification

Capacitive Proximity
Sensors for Low Paper
Level" Indication

2–18
 Proximity Sensors
Applications

On Line Parts Sorting Railroad Yard Position Sensing Coolant Resistant Sensing

871TM

Coolant
Bad
Good

DETAIL
Inductive
3/
7/ 4″ Dia. Proximity
16″
1/
Sensors
2″

1″ 871C
7/
8″ Dia.

Up and Downslope Control of

ÊÊÊÊÊÊÊÊ
Continous Tube Welder Nut Placement on Transformer Closed Barrier Indicator

ÊÊÊÊÊÊÊÊ
Transformers
and

ÊÊÊÊÊÊÊÊ
Rectifiers
871Z

ÊÊÊÊÊÊÊÊ
+ (Anode)

ÊÊÊÊÊÊÊÊ
ÊÊÊÊÊÊÊÊ
Insulation 871Z

ÊÊÊÊÊÊÊÊ
Downslope - (Cathode)
Sensor

ÊÊÊÊÊÊÊÊ
871TM Indicates
Transformer When Barrier Is
Closed
871P
Upslope
Pressure Sensor
Roll 871P

Detect Presence of
Bushing in Piston

871C

A = Sensing Path

2–19
Proximity Sensors
Applications

Control Presence of Mild Steel Bars in Grate Welding

+ (Anode)

871Z

Check Parallelism
of Transversal Bar
with WFI Control

- (Cathode)

871P
871Z
871Z 871Z

Look for Position

of Steel Bar
with WFI Control

Elevator Positioning

Proximity
Rail Guide
Sensor

Target

2nd Floor

Target

1st Floor

Allen-Bradley produces rail guide inductive proximity sensors for the positioning of elevator cars. These sensors offer
increased accuracy and longer life when compared to typical mechanical switches. They are a cost effective solution for
lowering your repair costs and down-time. Contact your local Allen-Bradley salesperson for a proximity tailored to your
requirements!

2–20
 Proximity Sensors
Applications

Material Handling Printing Level Detection

ÎÎÎÎÎ
ÉÉ ÉÉ
É
ÉÉ
ÎÎÎÎÎ
ÉÉ
É
Ultrasonic
Proximity

ÉÉ
ÎÎÎÎÎ
É
Sensor

ÉÉ
ÎÎÎÎÎ
É
Plastic
Canister

ÉÉ ÉÉ
ÎÎÎÎÎ
É
Granular

ÉÉÉÉÉÉÉ ÉÉ ÉÉ
ÎÎÎÎÎ
Fill

ÉÉÉÉÉÉÉ Conveyor
Ultrasonic proximity sensor used to
indicate when paper supply is almost
ÉÉ
ÎÎÎÎÎ
ÉÉ
ÉÉ ÉÉ
ÎÎÎÎÎ Capacitive Proximity
Sensors for High and
exhausted. Low Level Detection

Liquid Level Detection

ÉÉ ÉÉ
ÉÉ
ÏÏÏÏÏ
ÉÉ
ÉÉ
ÏÏÏÏÏ
ÉÉ ÉÉ
ÏÏÏÏÏ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÏÏÏÏÏ
ÏÏÏÏÏ
ÉÉ
Liquid

ÏÏÏÏÏ
ÉÉ ÉÉ
ÏÏÏÏÏ
ÉÉ ÉÉ Capacitive Proximity
Sensors for High and
Low Level Detection

2–21
Proximity Sensors
Applications

Top 23 Reasons to Use the 871TM

Robust Electrical Design

S Your choice of AC/DC, 2wire or 3wire DC
S Short circuit protection
S Overload protection
S Reverse polarity protection (DC models)
S Radio frequency protection
S Transient noise protection
S False pulse protection Stainless Steel Barrel
S Epoxy potted for protection against mechanical S Superior Strength of Impact and Abrasion
shock and vibration Resistant Stainless Steel
S Superior Chemical and Cutting Fluid Resistance
S One Piece Barrel for Mini Q.D. Eliminates
Stainless Steel Face Joint" Leaking
S Superior Strength of Impact and Abrasion S Increased Mounting Torque
Resistant Stainless Steel
S Superior Chemical and Cutting Fluid Resistance
S Leakproof

SOOW-A ToughLinkt Cable

S Superior Abrasion and Chemical Resistance
S Cutting Fluid Resistant
S Superior Strength of #18AWG
LED Lens and Grommet Conductors and Jacket Materials
S Provide Mechanical Seals for Primary S Fire Retardent
Fluid Barrier S Outdoor Approved
S Chemical Resistant S Plastic Filler Provides Increased
DC and long barrel AC/DC Fluid Wicking" Resistance
models only.

2–22