Sensor Applications
Application Note
January 2008
New Information
The sensor applications on the
following pages range from basic
problems to complex problems that
can be solved only with specific CutlerHammer
®
sensors from Eaton’s
electrical business.
The solution is summarized along with
the Catalog Numbers of suggested
models to be used. Note that many
sensors are interchangeable; slight
differences in the application may
dictate the choice of one sensor over
another. When full Catalog Numbers
are listed, that specific model is
suggested. Where no Suffix is given
1451B ) or only one family is
(e.g.
listed, the choice of a specific model
within the suggested type would be
determined by operating voltage,
sensing range, choice of cable or
connector base, etc.
1. Broken Tool Detection
Description Catalog
E58 Perfect Prox Sensor E58-30DP or
Number
E58-18DP
Sensor
An E58 Harsh Duty Perfect Prox sensor
is used to sense for the presence of the
bit on a mill. The high sensing power
and background rejection of the
Perfect Prox allows reliable detection
through high levels of cutting fluids,
while ignoring objects just beyond the
bit. The rugged harsh duty sensor
survives constant exposure to
lubricants, cutting fluids and flying
metal chips.
2. Broken Bit Detection
Description Catalog
Tubular Inductive Proximity
Sensor
Fine Spot Comet Perfect Prox 13105
Number
E57 Product
Family or
iProx
3. Machining Processes
Description Catalog
Tubular Inductive Proximity
Sensor
Number
E57 Product
Family or
iProx
A ferrous only sensor is used in a
process where aluminum is being
machined. The ferrous only sensor
ignores the aluminum (non-ferrous)
chips from the machining process and
only detects the ferrous target.
4. Tool Position
Description Catalog
Tubular Inductive Proximity
Sensor
Number
E57 Product
Family or
iProx
A tubular E57 proximity sensor is used
to detect the position of a tool chuck.
A tubular E57 proximity sensor is used
to detect the presence of a drill bit —
should the drill bit be broken the
sensor would signal a controller. For
very small tools, a fine spot Comet
Perfect Prox will reject the background
while detecting a broken drill bit.
AP05300001E For more information visit: www.eaton.com
For assistance with these or other applications,
contact us at
1-800-426-9184
.
Application Note
Page 2
5. Bottle Filling Detection
Description Catalog
E65 Clear Object Sensor
A clear object sensor is used to sense
the presence of bottles at a filling
operation. The sensor offers high
reliability in sensing clear bottles of
different colors and thicknesses.
6. Process Control
Description Catalog
Tubular Capacitive Proximity
Sensor
A capacitive proximity sensor used to
verify fill level of bottled water on a
filling process line.
Effective: January 2008
Number
E66CBL1C or
E65VBL1C
Number
E53 Product
Family
Sensor Applications
7. Jam Detection
Description Catalog
50 Series Reflex Sensor
Time Delay Logic Module
Plug-In Relay Output Device 8532B
3" Diameter Retroreflector 6200A-6501
A reflex control with a time delay
module set for “delay dark” ignores
momentary beam breaks. If the beam
is blocked longer than the delay
period, the output energizes to sound
an alarm or stop the conveyor.
8. Conveyor System Control
Description Catalog
Tubular Inductive Proximity
Sensor
A tubular inductive proximity sensor is
used to detect the presence of metal
carriers holding parts to be machined.
Number
1450B
8251B
Number
E57 Product
Family or
iProx
9. Stack Height Control
Description Catalog
Comet Series Thru-Beam
Source
Comet Series Thru-Beam
Detector
Number
11155A
11255B
A set of thru-beam sensors determines
the height of a scissor lift. For
example, when the control is set for
“dark-to-light” energize, the lift rises
after a layer has been removed and
stops when the next layer breaks the
beam again.
10. Carton Fill-Level Detection
Description Catalog
Comet Visible-Beam Reflex
Sensor
Comet 9 Inch Perfect Prox
Sensor
3" Diameter Retroreflector 6200A-6501
E67 Long Range Perfect Prox
(preset 3 – 8 ft.)
Number
14102A
13103A
E67-LRDP
Two sensors work together to inspect
the fill level in cartons on a conveyor.
A reflex sensor senses the position of
the carton and energizes the Perfect
Prox sensor located over the contents.
If the Perfect Prox sensor does not
“see” the fill level, the carton does not
pass inspection.
For assistance with these or other applications,
contact us at 1-800-426-9184 .
For more information visit: www.eaton.com
AP05300001E
11. Box Counting
Description Catalog
Number
Prism Polarized Reflex Sensor 14151R
3" Diameter Retroreflector 6200A-6501
A Prism right-angle reflex sensor
detects boxes anywhere on a four foot
wide conveyor. Interfacing the control
with a programmable controller
provides totals at specific time
intervals. Polarized reflex optics
prevent false triggering on shiny
objects, while the high optical power
burns through box dust and
contamination.
Sensor Applications
13. Cookie Motion Detection
Description Catalog
50 Series Fiber Optic Sensor 1550B
One-Shot Logic Module
(In Retrigger Mode)
Fiber Optic Thru-Beam Cable
(2 Required)
Plug-In Relay Output Device 8532B
High temperature environments are
accommodated by the use of fiber
optics. Here conveyor motion in a
450°F cookie oven is detected. If the
motion stops, the one-shot logic
module detects light or dark for too
long, and the output device shuts the
oven down.
Number
8252A
6221B
Application Note
Effective: January 2008 Page 3
15. Tollbooth Control
Description Catalog
Number
20 Series Thru-Beam Source 1141D-6501
20 Series Thru-Beam Detector 1241D-6501
DPDT Relay Output Device 8526A-6501
E67 Long Range Perfect Prox E67-LRDP
Thru-beam source/detector or the long
range polarized reflex controls are
used to time the toll gate. To eliminate
toll cheating, the gate lowers the
instant the rear of the paid car passes
the control. The E67 Long Range
Perfect Prox allows you to mount the
sensor on one side, instead of both.
Plus with Perfect Prox, the E67 will
detect cars with different colors and
finishes while ignoring all other
background objects. The rugged
control handles harsh weather, abuse
and 24-hour operation.
12. Log Diverter
Description Catalog
Number
E51 Extended Range Sensor E51CNP4
Single-Shot Logic Module E51MSS
E67 Long Range Perfect Prox E67-LRDP
The log is detected by an extendedrange diffuse reflective control with a
single-shot logic module or a high
power E67 Long Range Perfect Prox.
The hydraulic system is energized and
the log is pushed onto a lateral
conveyor. The logic module (used with
the E51) allows for control of output
pulse timing and duration. The E67
reliably senses logs of different colors
and shapes while ignoring objects in
the background.
14. Lid Detection
Description Catalog
Tubular Inductive Proximity
Sensor
Number
E57 Product
Family or
iProx
A pair of tubular proximity sensors
used to, a) detect the presence of a can
on a conveying line, and b) check for
presence of a lid.
16. Garage Door Control
Description Catalog
80 Series High Current
Control Unit (2 Required)
Number
8880C-6501
A safe and secure garage is achieved
through the use of thru-beam controls
interfaced to the door controller. The
door shuts automatically after a car
leaves, and if the beam is broken while
the door is lowering, the motor
reverses direction and raises the door
again.
AP05300001E For more information visit: www.eaton.com
For assistance with these or other applications,
contact us at 1-800-426-9184 .
Application Note
Page 4
17. Cut-Off Saw Control
Description Catalog
E51 Thru-Beam Source
E51 Thru-Beam Detector
NOTE: All products listed are required
for each two-foot increment.
An array of thru-beam controls detect
the length of the log in standard twofoot increments. The correct saw is
then activated to cut the log at its
longest standard length. High optical
performance is a must in this dusty
and dirty environment.
18. Liquid Level Detection
Description Catalog
Tubular Capacitive Proximity
Sensor
A pair of E53 capacitive proximity
sensors are used to sense high and
low liquid levels in a tank through a
sight glass. This arrangement starts a
pump to fill the tank when the lower
sensor is energized and shuts the
pump off when the top sensor is
energized.
Effective: January 2008
Number
E51ELA
E51CLC1
Number
E53 Product
Family
Sensor Applications
19. Bulk Material Detection
Description Catalog
Tubular Capacitive Proximity
Sensor
A capacitive proximity is used to
control fill level of solids such as
plastic pellets in a hopper or bin.
20. Hopper Fill Level Control
Description Catalog
80 Series High Current
Control Unit
80 Series 18 Inch Diffuse
Reflective Sensor
Time Delay Logic Module
The fill level on this machine hopper is
controlled by a diffuse reflective
control with a time delay module. The
control must detect the level for a
certain time interval before it energizes
the shut-off mechanism. This
eliminates false “full” indications
caused by extraneous material
momentarily passing by the control.
Number
E57 Product
Family
Number
8880C-6501
1381B
8280A
21. Web Loop Control
Description Catalog
70 Series Analog Control Unit 8172A
70 Series Reflex Curtain-ofLight Sensor
Analog Isolation Module
Strip Retroreflector
Number
1471A
8272A
6210A
A sensor that generates a “curtain-oflight” detects the length of a loop on a
web drive system by measuring the
amount of light returned from an array
of retroreflectors. With this
information, the analog control unit
instructs a motor controller to speed
up or slow down the web drive.
22. Parts Presence
Description Catalog
Limit Switch Inductive
Proximity Sensor
Comet Perfect Prox
iProx Inductive Proximity
Sensor
Number
E57 Product
Family
1310
E59F
A limit switch style proximity sensor, a
Comet Perfect Prox or the iProx
Sensor may be used to detect the
presence of a part in a pick-and-place
application for inspection. The Comet
will detect any target material, color or
finish while rejecting the background.
The iProx can be programmed to
sense a specific metal target while
rejecting all other metal.
For more information visit: www.eaton.com
For assistance with these or other applications,
contact us at 1-800-426-9184 .
AP05300001E
23. Small Parts Detection
Description Catalog
70 Series High Power Control
Unit
Low Contrast Logic Module 8215A
70 Series Reflex Curtain-ofLight Sensor
Strip Retroreflector
Triac Output Relay or Other
Selection
Number
8171B
1471A
6210A
8572A
Small objects moving through a
“curtain-of-light” are counted by
detecting a change in reflected light. A
low contrast logic module inside the
control unit responds to slight but
abrupt signal variations while ignoring
slow changes such as dust build-up.
Sensor Applications
25. Filter Paper Length Control
Description Catalog
Comet Focused Diffuse
Reflective Sensor
A focused diffuse reflective sensor
interfaces with a programmable
controller to measure a specific length
of corrugated automotive filter paper.
The control detects the presence or
absence of a corrugation. When a
predetermined number of
corrugations has been detected, the
programmable controller directs a
shear to cut the paper.
Number
13102A
Application Note
Effective: January 2008 Page 5
26. Broken Thread Detection
Description Catalog
70 Series High Power Control
Unit
Low Contrast Logic Module 8215A
70 Series 375 Foot Thru-Beam
Source (2 Required)
70 Series 375 Foot Thru-Beam
Detector (2 Required)
DPDT Relay
Mounting Brackets
A pair of remote thru-beam sensors
scan over and under multiple strands
of thread. If a thread breaks and
passes through one of the beams, the
low-contrast logic module detects the
sudden change in signal strength and
energizes the output. Because this
logic module does not react to slow
changes in signal strength, it can
operate in a dusty environment with
little maintenance.
Number
8171B
1173A-100
1273A-100
8530A
6142A
24. Parts Detection
Description Catalog
Comet Series 4 Inch Perfect
Prox Sensor
E67 Long Range Perfect Prox E67-LDRP
Number
13101A
A four inch Perfect Prox sensor detects
parts of various heights from 0.5 to 3
inches passing through a channel,
while ignoring the channel bottom. For
longer range sensing up to 8 ft., use
the E67 Long Range Perfect Prox.
Installation is simple with no cutting or
drilling of the channel required.
AP05300001E For more information visit: www.eaton.com
For assistance with these or other applications,
contact us at 1-800-426-9184 .
Application Note
Page 6
27. Hypodermic Needle Quality Control
Description Catalog
70 Series High Power Control
Unit
70 Series 300 Foot Thru-Beam
Source
70 Series 300 Foot Thru-Beam
Detector
Triac Output Relay
A remote source and detector pair
inspects for passage of light through a
hypodermic needle. Their small design
and waterproof stainless steel housing
are appropriate for crowded
machinery spaces and frequent
washdowns. High signal strength
allows quality inspection with hole
sizes down to 0.007 inch.
Effective: January 2008
Number
8171B
1173A-300
1273A-300
8573A
Sensor Applications
29. Multi-Hole Casting Inspection
Description Catalog
70 Series Modular Control
Unit (4 Required)
70 Series 35 Foot Thru-Beam
Source (4 Required)
70 Series 35 Foot Thru-Beam
Detector (4 Required)
Panel Mount Socket for
Control Unit (4 Required)
Remote sensors inspect for the
presence of holes in a metal casting.
Because each hole has its own
inspection system, accurate defect
information is recorded. Rugged
sensor housing and extremely high
signal strength handle dirt and grease
with minimum maintenance. Using
the modular control unit allows for
dense packaging in small enclosures.
Number
8771A
1173A-300
1273A-300
8905A
31. Over/Underspeed Control
Description Catalog
50 Series Reflex Sensor
Motion Detection Logic
Module
Solid-State Switch Output
Device
3 inch Diameter Retroreflector 6200A-6501
Number
1450B
8253A
8562B
A reflex sensor with a motion
detection module counts the
revolutions of the wheel. Speed is
controlled by a programmable
controller. Provides timing ranges
from 2.4 to 12,000 counts per minute.
28. Automotive Body Assembly
Description Catalog
Weld Field Immune Inductive
Proximity Sensor
Number
E57 Product
Family
Automotive body assembly lines use
welders which can cause standard
inductive proximity sensors to
perform erratically. Cutler-Hammer
Weld-Field Immune Sensors from
Eaton’s electrical business are
designed to provide reliable operation
in these environments.
30. Web Flaw Detection
Description Catalog
70 Series High Power Control
Unit
Low Contrast Logic Module 8215A
DPDT Relay
70 Series Reflex Curtain-ofLight Sensor
Strip Retroreflector
Number
8171B
8530A
1471A
6210A
A web passes over an array of
retroreflectors. When light is returned
to the sensor head, the output is
energized and the web shuts down.
Because of the superior response time
of the control unit, high web speeds
can be maintained.
32. Motion Position Detection
Description Catalog
Tubular Inductive Proximity
Sensor
Number
E57 Product
Family or
iProx
A tubular E57 proximity sensor is used
to detect the presence of set screws on
a shaft hub providing a control device
with signals for speed regulation or
detection of rotation.
For more information visit: www.eaton.com
For assistance with these or other applications,
contact us at 1-800-426-9184.
AP05300001E
Sensor Applications
Application Note
Effective: January 2008 Page 7
33. Motion Control
Description Catalog
Tubular Inductive Proximity
Sensor
Number
E57 Product
Family or
iProx
A pair of tubular proximity sensors is
used to determine full open and fully
closed valve position.
34. Clear Plastic Web Break Detection
Description Catalog
80 Series High Current
Control Unit
80 Series 7 Inch Diffuse
Reflective Sensor
Number
8880C-6501
1380B
The clear web is detected by an
extremely sensitive diffuse reflective
sensor. Its short detection range
makes it immune to reflective objects
in the background. The extremely high
excess gain helps it ignore reflection
caused by fluttering of the web.
35. Web Splice Detection
Description Catalog
70 Series Differential Control
Unit
One-Shot Logic Module 8213A
DPDT Relay 8526A
70 Series 30 Foot Thru-Beam
Source (2 Required)
70 Series 30 Foot Thru-Beam
Detector (2 Required)
Number
9072A
1173A-300
1273A-300
When the two thru-beam detectors see
the same signal strength, the output is
zero. When the opacity of the web
changes, as in a splice, the signal
strengths are thrown out of balance
and the output is energized. This
system can be used on webs of
different colors and opacities with no
system reconfiguration.
36. Paper Presence Detection
Description Catalog
Comet Series 2 Inch Right
Angle Perfect Prox Sensor
Number
13104R
Right angle viewing and compact size
allow the sensor to be mounted in the
tight confines of paper handling
systems. High gain and sharp optical
cut-off ensure that background
machinery will be ignored while paper
will be detected regardless of color
and texture.
Comet Sensor
Paper
Rollers
37. Web Guiding
Description Catalog
70 Series Slot Sensor 1372A-6501
70 Series Analog Control Unit 8172A
Number
The 1372A-6501 slot sensor head is
mounted so that the edge of the web
extends into the slot and blocks half of
the source beam. As the web moves
into or out of position, a proportional
signal is provided by the analog
control unit to alert your control
system.
AP05300001E For more information visit: www.eaton.com
For assistance with these or other applications,
contact us at 1-800-426-9184.
Application Note
Page 8 Effective: January 2008
Sensor Applications
38. Damage Warning
Description Catalog
Comet Series 100 Foot ThruBeam Source
Comet Series 100 Foot ThruBeam Detector
Number
11102A
12102A
Source and detector are mounted at
opposite ends of a long warehouse
storage shelf with the beam situated a
safe distance below overhead
obstacles (lighting, conduit, gas lines,
ducts, pipes, etc.). If a forklift operator
interrupts the beam while moving a
load, a siren or flashing light will warn
him to stop before any damage
occurs.
39. Zero Pressure Accumulation Conveyor
Description Catalog
E68 Integral Sensor Valve E68-SVS
200 Series Zero Pressure
Accumulation
Number
14286/14266
E68 Series or 200 Series sensors
detect and control the movement of
boxes on the conveyor, to maximize
throughput and eliminate line
pressure between boxes. The sensor
contains all required logic with no
need for a PLC.
Eaton Corporation
Electrical Group
1000 Cherrington Parkway
Moon Township, PA 15108
United States
877-ETN CARE (877-386-2273)
Eaton.com
For assistance with these or other applications,
contact us at 1-800-426-9184.
© 2008 Eaton Corporation
All Rights Reserved
Printed in USA
Publication No. AP05300001E/CPG
January 2008
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