autosen AI050, AI051, AI052, AI053, AI054 User Manual

Operating principle of an inductive

proximity sensor

autosen AI001- AI065
autosen AI401- AI408
autosen AI801- AI816
autosen AI901- AI908

UK

2502588 / 00 02 / 2019

Made in EU

1. Operating principle of an inductive proximity sensor

1: Connection
2: Housing
3: Downstream electronics
4: Capacitor
5: Pot core
6: Coil

7: Alternating electromagnetic eld = active face
8: Target = electrically conductive material

The coil and capacitor form an LC circuit, also known as a basic sensor. Eddy current
losses in electrically conductive materials are used for a switching signal.

2. Terms:

Active zone / active
face

Output function Normally open: Object within the active zone

Rated insulation
voltage

Rated short-circuit
current

Rated impulse with­stand voltage

Power-on delay time The time the sensor needs to be ready for operation after application of

Operating voltage The voltage range in which the sensor functions safely. A stabilised and

Space (room) above the sensing face in which the sensor reacts to the
approach of the damping material.

Normally closed: Object within the active zone

Programmable: Normally closed or normally open can be freely selected.
Positive switching: Positive output signal (to L–).
Negative switching: Negative output signal (to L+).

DC units with protection class II: 250 V AC
DC units with protection class III: 60 V DC

For short-circuit-proof units: 100 A

DC units with protection class II: 4 kV (≙ overvoltage category III)
DC units with protection class III: 60 V DC: 0.8 kV (≙ overvoltage
category II)

the operating voltage (in the millisecond range).

smoothed direct voltage should be used!
Take into account residual ripple!

> Output switched.

> Output blocked.

2

Hysteresis Difference between the switch-on and the switch-off point.

Short-circuit pro­tection

Standard target Square steel plate with a thickness of 1 mm and a side length identical

Product standard IEC 60947-5-2

Repeatability = Repeat precision

Switch point drift Shift in the switch point owing to changes in the ambient temperature.

Switching frequency Damping with standard target at half Sn. The ratio damped to undamped

Current consumption Current for the internal supply of 3-wire DC units.

Degree of soiling Inductive proximity sensors are designed for degree of soiling 3.

If autosen sensors are protected against excessive current by means of
a pulsed short-circuit protection, the short-circuit protection may cut in
with incandescent lamps, electronic relays and low resistance loads.

to the diameter of the sensing face or 3 x Sn, depending on which value
is greater.

Difference between any two Sr measurements. Max. 10% of Sr.

(mark to space) = 1 : 2.

3. Sensing range (referred to the standard target)

Nominal sensing range Sn= characteristic value of the unit

Real sensing range S

Useful sensing range Su= switch point drift between 90% (Su

Safe sensing range =

operating distance S

Safe switch-off distance = Su

= individual deviation at room temperature between 90% and 110%

r

of S

n

of S

r

= reliably switched between 0% and 81% of S

a

+ max. hysteresis = 143% of S

max

= Sa) and 110% (Su

min

n

n

max

)

4. Correction factors

The sensor-specic values can be

found in the data sheet (exception
K1 units:
Same sensing range for all

4

5. Inuence of the standard target size

X axis: Ratio between actual
target and the standard
target

6. Lateral approach and distances

1. Typical switch-on curve (for slow approach)

2. Typical switch-off curve (for slow approach)

3. Poor repeatability

4. Good repeatability

The following applies for good repeatability of the
switch point: The closer the damping element is to
the sensor face the better. General recommendation:

a = 10% of the nominal sensing range.

1. Distance to the background

2. Recommended target distance

3. Recommended degree of coverage of
the sensing face

4. Recommended target size

7. Tips on ush and non-ush mounting in metal
Installation instructions for cylindrical designs

The special feature of sensors which can be installed ush is the additional outer metal ring which
surrounds the coil. This shields the alternating eld and bundles it at the front.

Shielded coil with a ush

mountable sensor

The principle of inductive sensor technology is based on an electromagnetic alternating eld created

via a copper coil embedded in an open pot core made of ferrite. An resonant circuit is created using
the capacitor. Thanks to an electrically conductive metal, located within a certain range in front of the
sensor, the eddy currents of the magnetic eld are strongly attenuated. These changes in the oscilla­tion amplitude are detected by the sensor and the sensor is switched.

non-ush mountable

sensor

Flush and non-ush mountable

In principle, “ush” and “non-ush” mounting are only of relevance in metal environments. All non-met­als such as plastics, wood and glass have no inuence on the mounting.
With ush mountable sensors, the sensing face of the sensor may be aligned level with the metal
installation environment. Needless to say, these sensors can also be mounted in a non-ush manner.
Sensors which are non-ush mountable, on the other hand, must not be installed level with the sur-

rounding metal surface. The metallic installation environment would cancel out the sensor’s alternating

eld and cause the sensor to switch continuously.

non-flush

Free zones

Free zones refer to areas around the sensor which must be kept free of metallic materials in order not
to compromise with the operating principle of the device.
With inductive sensors, a distance of at least three times the nominal sensing range must be main­tained between a metallic material and the sensing face. The correct installation of non-ush mounta­ble sensors also requires that there is no interference material within a distance less than the diameter
of the detection face. The sensing face projects out of the metallic environment by twice the length of
the nominal sensing range of the sensor.

d d≥ d

Sn = Nominal sensing range
(details in data sheet)

mountable sensor

d d≥ 2 x d

≥ d

≥3 x S

n

≥2 x S

flush
mountable sensor

d = diameter of the

sensing face

(details in data sheet)

n

≥3 x S

n

6

Mutual inuence

In applications in which two inductive sensors must be installed opposite each other, they should be
spaced out at a distance of at least eight times that of the nominal sensing ranges. With series connec­tion, the spacing between the units must be observed.

≥8 x S

n

8. Installation instructions for rectangular designs AI006-AI009, AI407, AI408

ush: AI006, AI008, AI407

non-ush: AI007, AI009, AI408

h=any

Align the sensing face

flush

non-flush

Sn = Nominal sensing range

8

9. Classication of inductive sensors

autosen inductive sensors - standard class

for standard applications & factory automation in the standard designs M8, M12, M18, M30 & cubic
Find a wealth of technical information, incl. engineering data and suitable genuine accessories, at:

autosen.com/standard-class

Art. no. Mounting Sensing range /

frequency

AI006 Flush 20 mm / 100 Hz Normally open Cubic M12

AI007 Non-flush 35 mm / 80 Hz Normally open Cubic M12

AI008 Flush 20 mm / 100 Hz Antivalent Cubic M12

AI009 Non-flush 40 mm / 60 Hz Antivalent Cubic M12

AI050 Flush 2 mm / 5000 Hz Normally open M8 thread M8

AI051 Non-flush 4 mm / 5000 Hz Normally open M8 thread M8

AI052 Flush 2 mm / 5000 Hz Normally closed M8 thread M8

AI053 Non-flush 4 mm / 5000 Hz Normally closed M8 thread M8

AI054 Flush 4 mm / 2000 Hz Normally open M12 thread M12

AI055 Non-flush 8 mm / 2000 Hz Normally open M12 thread M12

AI056 Flush 4 mm / 2000 Hz Normally closed M12 thread M12

AI057 Non-flush 8 mm / 2000 Hz Normally closed M12 thread M12

AI058 Flush 8 mm / 2500 Hz Normally open M18 thread M12

AI059 Non-flush 12 mm / 2000 Hz Normally open M18 thread M12

AI060 Flush 8 mm / 2500 Hz Normally closed M18 thread M12

AI061 Non-flush 12 mm / 2000 Hz Normally closed M18 thread M12

AI062 Flush 15 mm / 200 Hz Normally open M30 thread M12

AI063 Non-flush 20 mm / 200 Hz Normally open M30 thread M12

AI064 Flush 15 mm / 200 Hz Normally closed M30 thread M12

AI065 Non-flush 20 mm / 200 Hz Normally closed M30 thread M12

Switching

output

Structural

shape

Connectors

Art. no. Mounting Sensing range /

frequency

AI901 Flush 2 mm / 5 kHz Normally open M8 thread 5 m cable

AI902 Non-flush 4 mm / 5 kHz Normally open M8 thread 5 m cable

AI903 Flush 2 mm / 5 kHz Normally closed M8 thread 5 m cable

AI904 Non-flush 4 mm / 5 kHz Normally closed M8 thread 5 m cable

AI905 Flush 4 mm / 5 kHz Normally open M12 thread 5 m cable

AI906 Non-flush 8 mm / 5 kHz Normally open M12 thread 5 m cable

AI907 Flush 4 mm / 5 kHz Normally closed M12 thread 5 m cable

AI908 Non-flush 8 mm / 5 kHz Normally closed M12 thread 5 m cable

Switching

output

Structural shape Cable

autosen inductive sensors - high resistance class

Can be used in machine tool manufacture, resistant to oils & coolants.

Find a wealth of technical information, incl. engineering data and suitable genuine accessories, at:

autosen.com/high-resistance

Art. no. Mounting

AI001 Flush 2 mm / 800 Hz Normally open M8 thread M8

AI002 Flush 2 mm / 800 Hz Normally open M8 thread M12

AI003 Flush 4 mm / 700 Hz Normally open M12 thread M12

AI004 Flush 8 mm / 400 Hz Normally open M18 thread M12

AI005 Flush 15 mm / 100 Hz Normally open M30 thread M12

AI024 Flush 2 mm / 1300 Hz Normally closed M8 thread M8

AI025 Flush 4 mm / 700 Hz Normally closed M12 thread M12

AI026 Flush 8 mm / 400 Hz Normally closed M18 thread M12

AI027 Flush 15 mm / 100 Hz Normally closed M30 thread M12

AI034 Flush 2 mm / 800 Hz Normally open Ø 6.5mm, smooth M8

AI035 Non-flush 4 mm / 700 Hz Normally open Ø 6.5mm, smooth M8

AI038 Flush 4 mm / 700 Hz Normally open M12 thread M12

Sensing range /

frequency

Switching

output

Structural shape Connectors

10

Art. no. Mounting

AI039 Non-flush 7 mm / 700 Hz Normally open M12 thread M12

AI040 Flush 4 mm / 700 Hz Normally closed M12 thread M12

AI041 Non-flush 7 mm / 700 Hz Normally closed M12 thread M12

AI042 Flush 8 mm / 400 Hz Normally open M18 thread M12

AI043 Non-flush 12 mm / 300 Hz Normally open M18 thread M12

AI044 Flush 8 mm / 400 Hz Normally closed M18 thread M12

AI045 Non-flush 12 mm / 300 Hz Normally closed M18 thread M12

AI046 Flush 15 mm / 100 Hz Normally open M30 thread M12

AI047 Non-flush 22 mm / 100 Hz Normally open M30 thread M12

AI048 Flush 15 mm / 100 Hz Normally closed M30 thread M12

AI049 Non-flush 22 mm / 100 Hz Normally closed M30 thread M12

Sensing range /

frequency

Switching

output

Structural shape Connectors

autosen inductive sensors - full-metal housing

Have protection rating IP 67, IP 68, IP 69 K and are up to 100 °C and 100 bar temperature & pressure
resistant.

Find a wealth of technical information, incl. engineering data and suitable genuine accessories, at:

autosen.com/ganzmetall-sensoren

Art. no. Mounting Sensing range /

frequency

AI016 Flush 3 mm / 100 Hz Normally open M12 thread M12

AI017 Non-flush 6 mm / 500 Hz Normally open M12 thread M12

AI018 Flush 5 mm / 100 Hz Normally open M18 thread M12

AI019 Non-flush 12 mm / 500 Hz Normally open M18 thread M12

AI020 Flush 10 mm / 50 Hz Normally open M30 thread M12

AI021 Non-flush 25 mm / 250 Hz Normally open M30 thread M12

Output Structural shape Connectors

autosen inductive sensors - miniature sensors

Inductive sensors with a short overall length and small diameters up to 3 mm are also used in very
conned conditions. This makes them the ideal solution for robotics, mounting and handling technolo­gy. These sensors achieve switching frequencies of up to 7000 Hz across a high temperature range.

Find a wealth of technical information, incl. engineering data and suitable genuine accessories, at:

autosen.com/miniatursensoren

Art. no. Flush/Non-flush Sensing range /

frequency

AI801 Flush 0.6 mm / 3000 Hz Normally open Ø3mm, smooth 2 m cable

AI802 Non-flush 1 mm / 3000 Hz Normally open Ø3mm, smooth 2 m cable

AI803 Flush 0.6 mm / 3000 Hz Normally closed Ø3mm, smooth 2 m cable

AI804 Non-flush 1 mm / 3000 Hz Normally closed Ø3mm, smooth 2 m cable

AI805 Flush 0.8 mm / 5000 Hz Normally open Ø4mm, smooth 2 m cable

AI806 Non-flush 1.5 mm / 5000 Hz Normally open Ø4mm, smooth 2 m cable

AI807 Flush 0.8 mm / 5000 Hz Normally closed Ø4mm, smooth 2 m cable

AI808 Non-flush 1.5 mm / 5000 Hz Normally closed Ø4mm, smooth 2 m cable

AI809 Flush 0.8 mm / 5000 Hz Normally open M5 thread 2 m cable

AI810 Non-flush 1.5 mm / 5000 Hz Normally open M5 thread 2 m cable

AI811 Flush 0.8 mm / 5000 Hz Normally closed M5 thread 2 m cable

AI812 Non-flush 1.5 mm / 5000 Hz Normally closed M5 thread 2 m cable

AI813 Flush 1.5 mm / 7000 Hz Normally open Ø6.5mm, smooth 2 m cable

AI814 Non-flush 2 mm / 7000 Hz Normally open Ø6.5mm, smooth 2 m cable

AI815 Flush 1.5 mm / 7000 Hz Normally closed Ø6.5mm, smooth 2 m cable

AI816 Non-flush 2 mm / 7000 Hz Normally closed Ø6.5mm, smooth 2 m cable

Output Structural shape Cable

12

autosen inductive sensors - Factor 1

Have protection rating IP 67, IP 68, IP 69 K, are magnetic-eld immune and detect all metals with the
same sensing range (correction factor = 1).

A transmitter and receiver coil system on a circuit board forms a transformer.

Electrically conductive materials in the near eld inuence the coupling factor of the transformer.

The change of the coupling factor is used by downstream electronics for a switching signal.
By omitting the ferrite core, the inductive F1 sensors are less sensitive to interference from strong

magnetic elds.

Find a wealth of technical information, incl. engineering data and suitable genuine accessories, at:

autosen.com/faktor1

1: Connection
2: Housing
3: Downstream electronics
4: Circuit board with transmitter and receiver coil

5: Alternating electromagnetic eld = active face
6: Target = electrically conductive material

Art. no. Flush/Non-flush Sensing range /

frequency

AI028 Flush 4 mm / 2000 Hz Normally open M12 thread M12

AI029 Non-flush 10 mm / 2000 Hz Normally open M12 thread M12

AI030 Flush 8 mm / 2000 Hz Normally open M18 thread M12

AI031 Non-flush 15 mm / 2000 Hz Normally open M18 thread M12

AI032 Flush 15 mm / 2000 Hz Normally open M30 thread M12

AI033 Non-flush 30 mm / 2000 Hz Normally open M30 thread M12

AI036 Flush 3 mm / 2000 Hz Normally open M8 thread M8

AI037 Non-flush 6 mm / 2000 Hz Normally open M8 thread M8

Output Structural

shape

Connectors

autosen inductive sensors with IO-Link

Enable a reliable transmission of the distance as a linearised process value using IO-Link. The normal­ly closed / normally open functions and PNP/NPN can be adjusted via IO-Link.

Representation of the process value with measuring range and adjustment range for
frontal damping

1

8184

3800

4095

3500

3000

2500

2

2000

1500

1000

400

500

3

4

-8184

6

7

Process data value

① ⑤

Adjustment range PDV (ProcessDataVariable)

② ⑥

Near range

③ ⑦
④

Adjustment range

14

5

[mm]

Distance to sensing face

LED IO-Link

LED SIO (on delivery)

Switch point denition IO-Link

Single point mode (presence detection) to smart sensor prole 2

Normally open (switch point logic = 0)

SSC

0

ON OFF

Normally closed (switch point logic = 1)

SSC

0

SP1

teach

SP1

teach

H

SP1

SP1

SP1+H

H

SP1+H

ONOFF

PDV
4095

PDV
4095

SP1

SP1 + H

Switch-on point

Switch-off point

SP1

SP1 + H

Switch-off point

Switch-on point

Window mode (presence detection) to smart sensor prole 2

Normally open (switch point logic = 0)

0

SP1

SP1 + H

0

SSC

SP2-H

OFF

Switch-on point

Switch-off point

SSC

SP2-H

ON

teach

H

SP1

H

teach

SP2

SP2

SP1

ON

SP2

SP2 - H

Normally closed (switch point logic = 1)

teach

H

SP1

H

teach

SP2

SP2

SP1

OFF

SP1+H

OFF

Switch-on point

Switch-off point

SP1+H

ON

PDV
4095

PDV
4095

SP1

SP1 + H

16

Switch-off point

Switch-on point

SP2

SP2 - H

Switch-off point

Switch-on point

Two point mode (presence detection) to smart sensor prole 2

Normally open (switch point logic = 0)

teach

teach

SP2

SP2

H

SP1

OFF

SP1

H

SP1

NOFFO

SP1

PDV
4095

PDV
4095

SSC

0

SP1

SP2

0

SP1

SP2

Condition:
SP1 > SP2 + 3% and SP1 between 400 and 3800 and SP2 between 388 and 3686

SP2

ON

Switch-off point

Switch-on point

Normally closed (switch point logic = 1)

SSC

SP2

Switch-on point

Switch-off point

Switch point

SP

Hysteresis

H

Switching signal channel

SSC

Process data variable

PDV

autosen inductive sensors with IO-Link

Inductive sensors with IO-Link interface and protection rating IP 65; IP 66; IP 67; IP 68; IP 69K.
Find a wealth of technical information, incl. engineering data and suitable genuine accessories, at:

autosen.com/induktive-IO-Link

Art. no. Flush/

Non-flush

AI401 Flush 0.375...3.75 mm / 600 Hz NO/NC prog. M12 M12 thread

AI402 Non-flush 0.7...7 mm / 600 Hz NO/NC prog. M12 M12 thread

AI403 Flush 0.75...7.5 mm / 300 Hz NO/NC prog. M12 M18 thread

AI404 Non-flush 1.3...13 mm / 300 Hz NO/NC prog. M12 M18 thread

AI405 Flush 1.3...13 mm / 100 Hz NO/NC prog. M12 M30 thread

AI406 Non-flush 2.3...23 mm / 100 Hz NO/NC prog. M12 M30 thread

AI407 Flush 2.1...21 mm / 100 Hz NO/NC prog. M12 cubic design

AI408 Non-flush 2.6...26 mm / 100 Hz NO/NC prog. M12 cubic design

Sensing range /

frequency

Output Connec-

tors

Structural shape

18

10. General information on connection systems

3-wire technology

(negative or positive

switching)

4-wire technology

(positive switching, normally closed

and normally open)

Series connection (AND) Parallel connection (OR)

3-wire series connection
Max. 4 units Power-on delay times, voltage
drops and current consumption add up. UB
min (sensor) and UHIGH min (load) must
remain unchanged.

2. negative switching / 3. positive switching / 4. sensor 1 / 5. sensor n

3-wire parallel connection
The current consumption of all non-switched
units adds up. The units can be used in
combination with mechanical switches.

11. Conguration of cables and connectors

Colour coding:
BK: black, BN brown, BU: blue, WH: white

Technical data and further information at:

20

www.autosen.com

We reserve the right to make technical changes without prior notice.