Machine tools are the backbone of modern manufacturing. They have always stood for precision and high efficiency, because without them high-volume produced, high-quality products are impossible. Balluff began as early as the 1950's to lend value to the world of machine tool building – from the classic manually operated machine to the complex, automated multi-axis machining center of today. Our solution portfolio has developed out of long years of partnership with the innovation drivers of metalworking. We work with machine and systems builders as well as the aircraft and automobile industries and their suppliers. Whether it is the production of transmissions, engines and drivetrains or the bodywork, we drive innovations ahead and secure a technological lead.

1. Automation in Metalworking
Applications and solutions

2. 2
As a leading sensor specialist and system provider with a compa-
ny tradition of over 90 years, Balluff GmbH has been a recognized
partner for factory automation and industrial hydraulics for decades.
The global player has a strong presence with 61 sales branches and
representative offices as well as nine production sites on all conti-
nents. The corporate headquarters in Neuhausen a.d.F. is located
near Stuttgart.
Balluff offers a wide array of products with varied operating princi-
ples: high-quality sensors and systems for position measurement
and identification, as well as sensors to detect objects and measure
fluids. The full-range assortment includes optimal network and
connection technology and a comprehensive line of accessories.
We offer innovative, first-class products tested in our own accredited
laboratory and maintain certified quality management in accordance
with DIN EN ISO 9001:2015. Our technology speaks for itself in
international applications. since it also meets regional standards.
Balluff stands for application-specific customer solutions, com-
prehensive services, individual consultation and prompt service.
Our staff of more than 3000 employees is committed to providing
outstanding service worldwide.

3. 3www.balluff.com
Balluff Sets Benchmarks
for the Standards of Tomorrow
On the pulse of customers and key industries
Applications for metalworking
Turning 4
Milling 6
Stamping 8
Applications in assemblies
Spindles, chucks, rotary and swivel tables 10
Handling, transport and process monitoring 12
Tool ID
Tool identification 14
Products
The Heartbeat of Industry 4.0 16
Controlling, regardless of frequency and environment 18
IO-Link simplifies assemblies and machine tools 20
Intelligent connectivity with IO-Link devices 22
Machine safety 24
Product selector 26
Machine tools are the backbone of modern manufacturing. They
have always stood for precision and high efficiency, because without
them high-volume produced, high-quality products are impossible.
Balluff began as early as the 1950's to lend value to the world of
machine tool building – from the classic manually operated machine
to the complex, automated multi-axis machining center of today.
Our solution portfolio has developed out of long years of partnership
with the innovation drivers of metalworking. We work with machine
and systems builders as well as the aircraft and automobile indus-
tries and their suppliers. Whether it is the production of transmis-
sions, engines and drivetrains or the bodywork, we drive innovations
ahead and secure a technological lead.
Balluff was one of the pioneers in the development of inductive sen-
sors. Over 30 years ago we were the very first to turn this technology
into RFID for tool identification. RFID enabled CIM (Computer Inte-
grated Manufacturing) as the precursor to Industry 4.0 on the factory
level. The path for Industry 4.0 was cleared through digitizing with
fieldbus links, system solutions, process sensing and monitoring.
Our full offering reflects this evolution: classic position limit switches
for end-of-travel sensing, all types of machine motion detection
as well as sophisticated technology for measuring, managing and
identifying parts and tools. And with IO-Link data transmission and
communication down to the last meter becomes a reality. What will
the future bring? Just keep challenging us!

4. 4
Turning
Produce reliably and with precision –
from single parts to high volume
You deal with them every day – fittings, valves, fastening elements
as well as motor and transmission parts in automobile engines,
industrial machines and household appliances. But how do you
manufacture such high-volume metal components economically? By
clamping them in a lathe and constructing them rotation-symmetri-
cal. This is especially true of parts which are produced in a clamping
process where they are automatically fed and removed. Sensors play
a decisive role in monitoring these processes with a short cycle and
a high level of automation.
You will find such products on page 26
Tailstock positioning
BTL magnetostrictive position sensors
enable reliable and cost-effective tailstock
positioning, such as with a hydraulic or
a simple motor-driven axis. A second
measuring system can be installed for
the fine-positioning.
Steady rest alignment
Steady rests assist the machining process
for long or heavy turning parts. Here a rod-
style BTL magnetostrictive position sensor
monitors the piston position. For both
compact and precise steady rest positioning
the actuator and sensor are integrated.
Bar loader monitoring
Feeding of the bar material is monitored by
BES inductive sensors at multiple locations.
Good for achieving a seamless production
process with optimal machine utilization as
well as the ability to implement unmanned
shifts.

5. 5www.balluff.com
Checking workpiece clamping
Only if a workpiece is securely chucked,
it can be machined correctly – with consis-
tent quality. In addition to sensors with a
switching output, BIP inductive positioning
systems are increasingly taking over this
task. Our wide range of measuring
systems – from just a few millimeters long
up to 130 mm – ensures the greatest
precision for varying dimensions.
Detecting the turret position
Detecting whether the tool turret has
reached its correct index position after
a rotational move is accomplished using
BES inductive sensors. They detect not
only the turret position but also the locking.
Monitoring drive belts
Machine tools often use drive belts for trans-
ferring rotary motion. Depending on the drive
belt design, either BCS capacitive sensors or
BES inductive sensors monitor its presence
and function. They initiate stopping of the
drive in cases of a fault or error.

6. 6
Milling
Broad range of solutions for individual
and high-dynamic applications
Thanks to their flexibility, milling machines and machining centers
are among the most commonly found machine tools. They range
from simple 3-axis systems to complex multi-axis machining centers
to hybrid machines which combine for example milling and laser
machining. The main prerequisite for machining block-shaped
workpieces: correct positioning and exact tool guidance at high
speed. These requirements present a challenge for the controlling of
measuring systems. Because the degree of automation is continually
increasing – especially when linked machines are used more and
more for the production of high-volume parts.
You will find such products on page 27
Monitoring tool clamping
BIP inductive positioning systems provide
information about the correct clamping of
the tool: unclamped, clamped with tool,
and clamped without tool. Combined with
BSP pressure sensors, a second channel
can also check the plausibility of the sensor
signals in hydraulic clamping systems.
Decentralizing installation technology
Compared with traditional wiring topologies,
fieldbus blocks make startup of the machine
control much simpler and more cost-effec-
tive. Designed for all commonly used fieldbus
systems, they enable the use of many con-
troller types using the same connector topol-
ogy. And with IO-Link they are also enabled
for the exchange of process, parameter and
diagnostic data for Industry 4.0.
Monitoring end positions
If you need to monitor the travel path of
machine axes, there are two options: tradi-
tionally using BNS mechanical position limit
switches with series-wired NC switches,
or using non-contact BES inductive sensors.
With the BML magnetic encoders in many
cases the sensor signals are also used for
the homing move.

7. 7www.balluff.com
Detecting the rotation angle on the C-axis
To determine the rotation along the Z-axis,
rotary axis angles (A-, B-, C-) are increasingly
used in addition to the main axes (X-,Y-,Z-).
The BML magnetic encoder is used for
high-precision detection of the rotary angle.
Its measuring principle enables generous
leeway in the center of the axis, so that
there is more room there for media such as
coolants as well as the power supply and
signal lines.
Identifying tools in the magazine
Industrial RFID systems BIS C operating
at LF (Low frequency) or BIS M at HF
(High Frequency) ensure that the CNC
controller in milling machines and machin-
ing centers always have the correct tool
data available (number, diameter, length,
number of cuts, etc.). Reliably identified and
trans­mitted, these parameters also form the
basis for high-quality tool asset management
including service life monitoring.
Matching and tracking workpieces
Pallet systems with automated external
loading and unloading reduce internal setup
times to virtually zero, so that the machine
can continue to produce without interrup-
tion. The BIS M 13.56 MHz HF system has
established itself as the standard for reliable
matching and tracking. It can read and write
two-side coded corner tags or databolt
attached directly to the pallet or workpiece.

8. 8
Stamping
Ensuring system up-time and
continually protecting investments
Mechanical presses are indispensable tools for metal forming. The
tools used, which are of particularly high quality and precision, are
most often designed for high production quantities. And no one
can afford long downtimes. Every minute is valuable and any lengthy
production delay costs a lot of money, especially when damage to
the expensive assets makes their replacement or repair necessary.
To detect the exact position during operation cycles, sensor
solutions are used in many locations. These allow malfunctions to be
immediately detected and consequential damage prevented, since a
press so equipped can be shut off safety.
You will find such products on page 28
Shut height monitoring
Hydraulic presses achieve their rated force
over the entire stroke travel. BTL magne-
tostrictive position sensors handle position
monitoring. The magnetic position marker is
attached to the slide or ram, and the profile
style housing fixed to a location on the press
along the axis. Insensitive to mechanical
shock, the high measurement precision
and update rate enables optimal machine
utilization.
Switching eccentric presses
For presses with short strokes and high
stroke counts the BSW rotary cam switches.
Available in mechanical and inductive
switching versions, have proven themselves
for decades. Mechanically adjustable cams
allow them to determine multiple on- and
off-points for the controller, depending on the
rotational angle of the eccentric cam shaft.
Depending on the press type and require-
ments, rotary cam switches are offered with
our without safety regulations.
Changing die sets
To protect expensive press tools sensors
often need to be attached to the tool itself.
The BIC inductive couplers can power for
die protection sensors as well as transmit
the data they receive between the tool and
the press controller. Thus the non-con-
tacting system permits quick changing of
tools without the need for mechanical plug
connections.

9. 9www.balluff.com
Monitoring press forces
BSP pressure sensors allow press forces
to be simply determined using the hydraulic
pressure which is in effect. This provides
users of hydraulic presses a high-value tool
for dynamic monitoring of the press forces.
Monitoring sheet metal thicknesses
BAW inductive distance sensors prevent
improper loading of sheet material. They can
be used to detect whether sheets have been
double fed and the thickness of the sheet.
This is indicated by a continuous analog
signal (e.g. 0...10 V) or IO-Link interface.
Depending on the application, accuracy re-
quirements and holding method for the sheet
metal, one or two sensors may be used.
Checking metal strip sag
BUS ultrasonic distance sensors with a
continuous output signal assist in automated
feeding of metal strips, whereby the speed
is matched to the cycle rate of the press.
The distance between the sheet metal and
the sensor is provided as a signal for con-
trolling the feed motor speed.

10. 10
For applications with a rotational component, traditional applications
become more difficult. Confined spaces and access to the axis of
rotation make size, weight and form-factory very important aspects
to consider. Monitoring on spindles and chucks can be used to en-
sure proper clamping or even measurement of the fixed component.
Rotary and swivel tables with continuous turning can cause trouble
for cables and connectivity. Solutions to connect the automation
to the controller across the axis of rotation are innovating automation
across the industry.
You will find such products on page 29
Monitoring clamping distances
with binary sensors
Tools are typically clamped using tapered
geometries. Using three inductive sensors
from the BES family three conditions can
be checked non-contact and wear-free:
unclamped, clamped without a tool, and
clamped with a tool. Since the sensors
are installed at a defined distance from
each other, this type of clamping distance
monitoring is especially useful for larger
strokes.
Monitoring clamping distances
with positioning system
Using linear position measurement clamping
distance monitoring can be implemented
even when the clamping mechanism rotates.
The BIP inductive positioning system detects
the position of a metal cam which passes by
the sensor from the side. Measuring systems
for various travel distances are available
depending on the requirements.
Monitoring clamping distances
with a distance sensor
If there is a tapered geometry on the tool
holder, movement transverse to the sensor
axis can also be detected using a BAW
inductive distance sensor. Such an arrange-
ment is considered the classic solution for
continuously monitoring measured clamping
distance.
Spindles, Chucks,
Rotary and Swivel Tables
Innovating automation in 360 degrees

11. 11www.balluff.com
Determining travel on rotary tables
The BML magnetic encoder is ideal for pre-
cise rotary angle detection. It meets require-
ments for compactness and thanks to its
compatibility with all standard encoder inputs
is simple to integrate into the application.
Sending signals and data on swivel tables
If sensors and actuators need to be attached
to the swivel table, BIC inductive couplers
can provide connectorless transmission of
power and signals. As hermetically sealed
"non-contact slip ring transmitters", they
work very reliably and are especially rugged.
Detecting piston position
in clamping cylinders
To monitor the clamping position of the
hydraulic piston on swing clamps, high-
pressure-rated inductive sensors are used.
These rugged versions, with a large variety
of models, use their inductive measuring
principle to reliably detect the position in
block cylinders.

12. 12
Linked production systems consist of standard machines which
are connected to each other by means of intralogistic fixtures and
continuous conveyors. An especially economical concept, with low
costs and few modifications to the system, both high-volume parts
and lower volume part variants can be produced. At the same time
the so-called "small process technology" needs to be state-of-the-
art in order to reliably monitor loaders, ensure coolant and lubricant
provision and keep an eye on levels in the hydraulic units. And
the ever shorter product development times and associated layout
changes need to be easily accommodated.
You will find such products on page 30
Controlling positioning of the linear drives
Freely selectable target positions increase
the flexibility of linear drives with integrated
displacement measurement. The BML
magnetic encoder is all that is needed to
upgrade positioning drives including the
position-controlled axis.
Monitoring grippers on gantry loaders
Pneumatically actuated grippers are often
equipped with pistons and magnets for
position detection of the gripper jaws. When
this is the case, the gripping actions can
be simply monitored using BMF magnetic
cylinder sensors. Here's how it works: Insert
sensors into the mounting slot. Slide to set
the desired switching point. Screw in place.
Done.
Detecting end positions on gantry loaders
BES inductive sensors are used to detect
end positions on overhead loading systems.
All that is needed is to attach a metal target
at the desired position. This is detected by
the sensors without contact to provide the
controller with the correct switching signal.
Handling, Transport
and Process Monitoring
Flexibly meet changing requirements

13. 13www.balluff.com
Checking levels on
the hydraulic power unit
Detecting the level of hydraulic fluid can be
done with magnetostrictive level sensors
and floats. They are fully encapsulated for
ruggedness, precise and designed for
high sampling rates. Both analog signals
(0...10 V or 4...20 mA) and IO-Link can be
used as interfaces.
Detect process fluids and
levels continuously or switching
Depending on the version BUS ultrasonic
level sensors can be used for 2-point
switching or for continuous level control.
Leak detection
Installing BCS capacitive sensors on a
spacer attached to the catch tank floor is
the most elegant solution to leak detection.
These will register even the slightest fluid
losses with absolute reliability.

14. 14
Tool presetting
The tool presetter with built-in RFID read/
write head uses the tool number to automat-
ically know which tool has been inserted.
It then writes the measured actual tool
parameters to the RFID tag embedded in the
tool holder.
Documenting tool data
Having the unique documentation of all the
parameters on the RFID tag in the tool
holder is of great value. In this way the tool
can remain in storage for any length of time
without its data getting lost. And when need-
ed, it is immediately ready to use.
Communicating with the CNC controller
Before or when the tool is introduced into the
spindle, the actual tool parameters on the
tag are read out. Alternately the data can be
read when tools are placed in the tool store,
chain or magazine. In both cases the CNC
controller gets all the current tool data in real
time.
Tool Identification
The right tool at the right time
at the right place
Industrial RFID for automated tool identification brings numerous
advantages. Transmitting the tool parameters (tool number, tool
diameter, tool length, number of cuts, ...) to the CNC controller
ensures optimal tool utilization and high machine up-time. By adding
tool life monitoring and asset management concepts, unproductive
idle time, mismatches and missing or unsharpened tools become a
thing of the past.
Tool ID solutions read the current data directly from the tool, docu-
ment all the data and thus provide predictive information for future
use. Highly beneficial for users, since this not only increases the
quality and efficiency of the production process, but also reduces
costs and improves profitability. Many companies take advantage
of the opportunity to retrofit and upgrade. Or they decide on the
purchase of new equipment and solicit bids from those machine
builders who have already integrated such technologies. Making
them well-positioned for Industry 4.0.
Do you have more questions?
Contact us at tool-id@balluff.de for immediate and comprehensive
assistance.

15. 15www.balluff.com
Organizing data mapping
The advantage of decentralized data retention on the RFID tag is
that tool parameters are available continuously and independent of
the central server. The user can define to what extent this data is
stored entirely according to his specific requirements. Also import-
ant: so-called data mapping, i.e. organization of memory addresses
coordinated between the presetter, inventory management and
machine tool.
Different ways of mapping are available depending on the manufac-
turer. If needed you can also use the Balluff mapping system.
Would you like to learn more? Contact us at: tool-id@balluff.de.

16. 16
The Heartbeat of Industry 4.0
In metalworking and throughout the entire workflow
The basis of Industry 4.0 is the availability of all relevant data in
real-time as well as the ability to create the optimal value creation
flow from this data at any point in time. Combined with our networ-
king and connectivity technology, Balluff sensors and identification
systems provide all the prerequisites. Data are acquired, transported
and provided as basic information for interpretation and sending
to higher level systems such as controllers or the cloud. This is our
core competency as a pacesetter for Industry 4.0 solutions.

17. 17www.balluff.com

18. 18
Controlling, Regardless of
Frequency and Environment
How tool identification, material flow and
handling tasks are quickly and easily combined
(1)
IRT-capable by looping through the signals from other slaves
(2)
BIS C only possible using BCC0FCK adapter
Application for BIS M (13.56 MHz) n n
BIS L (125 kHz) n n
BIS C (70/455 kHz) n
Profibus BIS00T3 BIS012E
EtherCAT BIS00U9 BIS0147
CC-Link BIS010P BIS014E
Ethernet/IP Power, 5-pin BIS012F BIS014C
Power, 4-pin BIS0122 BIS0146
Profinet (1)
BIS013U BIS013W
Read/write head ports 4 × BIS VM and BIS VL 4 × BIS C (2)
(BIS VM and BIS VL can also be
connected)
Power supply 24 V DC ±10% LPS Class 2 24 V DC ±10% LPS Class 2
Power supply ≤ 2 A ≤ 2 A
Operating/storage temperature 0...+60 °C 0...+60 °C
Degree of protection per IEC 60529 IP65 IP 65
IO-Link master Version 1.1, max. 0.5 A Version 1.1, max. 0.5 A
Max. cable length (read/write heads) 50 m 10 m for BIS C, 50 m for BIS M/BIS L
Read/write heads BIS M (13.56 MHz)
BIS013H
BIS0140
BIS0132
BIS0131
BIS012Z
BIS M tags
BIS004A 7 5.5
BIS00PT 7.5 22
BIS0043 28
BIS00NZ 25 57
BIS00P3 60 100
Read/write distances in mm
Read/write heads BIS C (70/455 kHz)
BIS005Z
BIS006F
BIS00PH
BIS0067
BIS C tags
BIS0011 2.5 2.5 2.5
BIS0009 3.5 3.5 5
BIS0019 8 3.5
BIS002P 3.5 3.5 10
Read/write heads BIS L (125 kHz)
BIS00UL
BIS00U6
BIS00UF
BIS00UH
BIS L tags
BIS00KJ 17 13 13
BIS00KK 21 18 16
BIS003E 32 18 22
BIS0036 40 55 25 65
BIS0039 55 70 30 85
The following combinations of tags and read/write heads are possible (examples):
RFID systems with different frequency ranges – often mixed –
are being increasingly used in modern production and assembly
systems. Whereas low-frequency (LF) systems prove to be
especially rugged and reliable particularly in metal surroundings.
High-frequency (HF) systems score high with their high speed
and greater read/write distance.
The BIS V processor unit is the first to permit frequency-indepen-
dent use of a controller. It allows up to four HF (13.56 MHz) and LF
(70...455 kHz) read/write heads per processor unit to be operated at
the same time. So that now just one version is needed to automati-
cally track and control the entire material flow without interruption.

19. 19www.balluff.com

20. 20
IO-Link Simplifies Assemblies
and Machine Tools
Ideal for process parameterization and control
Pressure monitoring directly where the action is
Without secure holding of the workpiece and tool on a lathe,
high-quality results cannot be guaranteed. Pressure sensors for
clamping force monitoring verify secure holding and are also
ideal for monitoring process media such as coolants, lubricants,
hydraulic fluids and pneumatic components.
The special feature of IO-Link pressure sensors: they continuously
relay their measured values and data to the controller, let it provide
precise readjustment when necessary, and ensure the greatest
possible machine up-time. Sensor replacement is just a matter of
plug-and-play. Because the current data are automatically loaded by
the IO-Link master.
BSP pressure sensors with IO-Link
Pressure sensors –1...2 bar BSP00AM BSP00JE
0...10 bar BSP00AT BSP00JK
0...250 bar BSP00AZ BSP00JP
0...400 bar BSP00C0 BSP00JR
0...600 bar BSP00C1 BSP00JT
Output signals PNP, one programmable switching point
and analog output 0...10 V DC
PNP, analog output 0...10 V DC
Ambient/media temperature –40…+85 °C/–40...+125 °C –40…+85 °C/–40...+125 °C
Connection Plug connector M12 connector, 4-pin M12 connector, 4-pin
Process connection Internal thread G1/4" per DIN EN 3852 * G1/4"
with display
* Please order adapter for G1/4" process fitting
separately using order code BAM01KP
no display

21. 21www.balluff.com
Clamping distance monitoring in a machining center
The BIP inductive positioning system with IO-Link was designed
especially for position monitoring and fits easily into tight mounting
spaces. It features an optimum ratio of useful to physical length as
well as a calibrated measuring range, which makes it ideal for series
production applications.
BIP inductive positioning systems with IO-Link
This compact performer uses an absolute measuring principle
and uses an additional Out-of-Range bit to tell the controller if the
target has left the measuring range. A welcome side-effect: its
digital IO-Link signal is guaranteed to be noise immune even with
unshielded cable. And an analog input card can also be eliminated.
Inductive positioning systems BIP0007 BIP0004
Measuring range 1...14 mm 1...40 mm
Linearity ±250 µm ±400 µm
Repeat accuracy ±80 µm ±100 µm
Distance to tape, position encoder, target 0.5...2 mm 1...3 mm
Target/position encoder metal n n
IO-Link interface n n

22. 22
Intelligent Connectivity with
IO-Link Devices
Maximum flexibility in handling with
minimal installation effort
Technologies that think along and ahead
IO-Link solutions are implemented using traditional cabling. Balluff
IO-Link blocks make any controller ready for Industry 4.0: from
Profibus and Profinet to CC-Link and Devicenet all the way to
Ethernet/IP and EtherCAT. And that's not all. We make many tech-
nologies IO-Link capable.
Now even the most complex challenges can be met simply and
with the greatest possible handling flexibility. For instance, the
universal IO-Link interface integrates intelligent devices, such as
the BVS vision sensor, into the controller. And any standard analog
sensor can be integrated there with equal ease using the IO-Link
analog converter.
A Balluff IO-Link sensor hub can bundle the signals from up
to 16 sensors or actuators. If these hubs are connected to our
8 × IO-Link module, then a it can transmit up to 136 inputs/outputs.
Even actuators like valve terminals can be controlled via Balluff
IO-Link by the master. Full functionality requires only connecting
the valve terminal to the IO-Link module using a standard cable
with valve terminal plug.
IO-Link module

23. 23www.balluff.com
IO-Link blocks BNI003K BNI003P BNI007M BNI005H BNI0092 BNI006C BNI007J
Fieldbus Profibus Profinet
No. of ports/IO-Link ports 8/4 4/4 16/16 8/8 4/4 8/4 8/8
Inputs/outputs max. 16/16 4/4 32/32 16/16 8/8 16/16 16/16
Configurable inputs/outputs 16 32 16 8/8 16
IO-Link version 1.1 1.1 1.1 1.1 1.1 1.1 1.1
IO-Link blocks BNI006A BNI004A BNI005A BNI0001 BNI0040 BNI0049 BNI0077
Fieldbus Ethernet/IP Devicenet CC-Link EtherCAT
No. of ports/IO-Link ports 8/8 8/4 8/4 8/– 8/4 8/8 8/8
Inputs/outputs max. 16/16 16/16 16/16 16/16 16/16 16/16 16/16
Configurable inputs/outputs 16 16 16
IO-Link version 1.1 1.1 1.1 1.1 1.1 1.1
IO-Link devices BNI0035 BNI005U BNI0021 BNI0072 BNI0083 BNI0042 BNI004C
Series Sensor hub SmartLight Analog converter
Special properties M12, metal M12, plastic M8, plastic without sound with sound Voltage variant
No. of ports 8 8 8
Inputs/outputs max. 16/16 16/16 16/–
Configurable inputs/outputs 16 16
Analog in-/output 1/– –/1
IO-Link version 1.0 1.1 1.0 1.1 1.1 1.0 1.0
IO-Link devices BNI004W BNI005M BNI006N BNI000F BNI0067 BNI0073 BNI00AM
Series Valve terminal
interface
Universal
interface
Valve terminal
plug
Unmanaged
Switch
USB master Memory
module
Special properties IP67 IP30
No. of ports 9 8
IO-Link version 1.1 1.1 1.1 1.1 1.1

24. 24
Functional safety for machine tools
Multiple position limit switches with forced opening contacts have
proven themselves for years in end-of-travel monitoring on machine
tools. Rotary cam switches with a BG certificate are classics for
monitoring presses and stamping machines.
E-stop, light curtains and door switches ensure the safety of machine
tools. These are the economical way to meet current specifications.
Machine Safety
In metalworking
Photoelectric
light grid
Subject to modification. Please refer to data sheets.

25. 25www.balluff.com
Safety switch BID0005 BID0004 BID0002 BID0003 BID0001
Guard locking mechanical (closed-
circuit current)
mechanical (closed-
circuit current)
electrical (open-
circuit current)
electrical (open-
circuit current)
Escape release Yes Yes
Door contacts 2 × positive
opening contacts
and 1 × NO
1 × NO 1 × NO 1 × NO 1 × NO
Magnetic contacts 2 × positive
opening contacts
2 × positive
opening contacts
2 × positive
opening contacts
2 × positive
opening contacts
Connection M12 connector,
5-pin
M12 connector,
8-pin
M12 connector,
8-pin
M12 connector,
8-pin
M12 connector,
8-pin
E-Stop BAM02HA
Contacts 2 × positive
opening contacts
Connection M12 connector,
5-pin
Accessories BAM0270 BAM0271 BAM0272
Description Actuator,
angled
Actuator,
swinging doors
handle
Actuator,
sliding doors
handle
Application for Finger protection Hand protection Body protection
Range < 6 m < 19 m < 50 m
Response time 11…50 ms 9…28 ms 14…16 ms
Resolution 14 mm 30 mm > 315 mm
Photoelectric
light grid
150 mm BLG000A BLG000T
300 mm BLG000C BLG000U
450 mm BLG000E BLG000W
515 mm BLG0006
600 mm BLG000F BLG000Y
750 mm BLG000H BLG000Z
815 mm BLG0007
900 mm BLG000J BLG0010
915 mm BLG0008
1050 mm BLG000K BLG0011
1200 mm BLG000L BLG0012
1215 mm BLG0009
1350 mm BLG000R BLG0013
1500 mm BLG000M BLG0014
1650 mm BLG000N BLG0015
1800 mm BLG000P BLG0016
Switching output OSSD OSSD OSSD
PL (EN ISO 13849-1)/SIL CL (EN/IEC 62061) PLe/SIL CL 3 PLe/SIL CL 3 PLe/SIL CL 3
Connection Emitter M12 male, 4-pin M12 male, 4-pin M12 male, 4-pin
Receiver M12 male, 5-pin M12 male, 5-pin M12 male, 5-pin
R
LISTED
4PA1
"ESPE"

26. 26
Product Selector
The right sensor for every application
Application Product family Example Functions, interfaces and properties
Turning
Bar loader monitoring Inductive sensors BES0068 M12 × 1, PNP NO, switching distance
4 mm, flush mountable, M12 connector
BES0055 M12 × 1, NPN NO, switching distance
4 mm, flush mountable, 3 m PUR cable
BES008M M18 × 1, PNP NO, switching distance
8 mm, flush mountable, M12 connector
BES007M M18 × 1, NPN NO, switching distance
8 mm, flush mountable, M12 connector
BES00AH M30 × 1.5, PNP NO, switching distance 15 mm,
flush mountable, M12 connector
Tailstock positioning Magnetostrictive position sensors,
profile series
BTL...-P-... Profile, measuring range max. 7620 mm,
analog interface 0...10 V or 4...20 mA,
SSI, Start/Stop Pulse Interface, CANopen,
Devicenet, Profibus DP, Profinet, EtherCAT
BTL...-PF-... Profile flat, measuring range up to max. 4572 mm,
analog interface 0...10 V or 4...20 mA,
IO-Link
Steady rest alignment Magnetostrictive position sensors,
rod series
BTL...-B-... Rod, measuring range max. 7620 mm,
analog interface 0...10 V or 4...20 mA,
SSI, Start/Stop Pulse Interface, CANopen,
Profibus DP, Profinet, EtherCAT, IO-Link,
mounting flange with M18 × 1.5,
or inch threads in Z-version
BTL...-K-... Compact rod, measuring range max. 7620 mm,
analog interface 0...10 V or 4...20 mA,
SSI, Start/Stop Pulse Interface, CANopen,
mounting flange Ø 18 mm
Checking workpiece clamping Inductive positioning systems BIP0002 Measuring range 40 mm, analog interface 0...10 V,
teachable, M12 connector
BIP0004 Measuring range 40 mm, IO-Link,
teachable, M12 connector
BIP000C Measuring range 70 mm, analog interface 0...10 V
and 4...20 mA, teachable, M8 connector
BIP000R Measuring range 133 mm, analog interface 0...10 V
and 4...20 mA, teachable, M8 connector
Detecting the turret position Inductive sensors BES00FT M5 × 0.5 mm, PNP NO, switching distance 0.8 mm,
flush mountable, 2 m PUR cable, installation length 27 mm
BES00N4 M8 × 1, PNP NO, switching distance 1.5 mm,
flush mountable, 2 m PUR cable, installation length 30 mm
BES00CN M8 × 1, NPN NO, switching distance 1.5 mm,
flush mountable, 2 m PUR cable, installation length 40 mm
BES0060 M12 × 1 PNP NO, switching distance 2 mm,
flush mountable, M12 connector
Monitoring drive belts Capacitive sensors BCS00LL M18 × 1, PNP NO, switching distance
15 mm, non-flush mountable, 2 m PUR cable
BCS00TR 40 × 40 × 10 mm, PNP/NPN and NO/NC select-
able, switching distance 20 mm, flush mountable,
2 m PUR cable
This selection table lists the product families and examples to fit
your application. At www.balluff.de you can enter the product family
or sample product to obtain detailed technical information.

27. 27www.balluff.com
Application Product family Example Functions, interfaces and properties
Milling
Monitoring tool clamping Inductive positioning systems BIP0001 Measuring range 14 mm, analog interface 0...10 V,
teachable, 2 m PUR cable
BIP0008 Measuring range 14 mm, analog interface 4...20 mA,
teachable, 2 m PUR cable
BIP0007 Measuring range 14 mm, IO-Link,
2 m PUR cable
Decentralizing installation
technology
Fieldbus blocks BNI003K Profibus, metal housing, 8 ports,
16 × in-/outputs, 4 × IO-Link, configurable
BNI005H Profinet, metal housing, 8 ports,
16 × in-/outputs, 8 × IO-Link, configurable
BNI007M Profinet, metal housing, 16 ports,
32 × in-/outputs, 16 × IO-Link, configurable
BNI0040 CC-Link, metal housing, 8 ports,
16 × in-/outputs, 4 × IO-Link, configurable
BNI0077 EtherCAT, metal housing, 8 ports,
16 × in-/outputs, 8 × IO-Link, configurable
Sensor hubs BNI005U 8 × M12 ports, plastic housing,
16 × in-/outputs, configurable
Monitoring end positions Inductive sensors BES01W2 20 × 32 × 8 mm (R01), PNP complementary, switching
distance 7 mm, 0.2 m PUR cable with M12 connector
BES01UZ 20 × 32 × 8 mm (R01), NPN complementary, switching
distance 7 mm, 0.2 m PUR cable with M12 connector
Mechanical position limit switches BNS 813-
D...-100-...
Series 100 multiple position limit switch with
safety switch elements per DIN EN 60204-1
Detecting the rotation angle
on the C-axis
Magnetic encoder BML S1F_-Q... Compact size 25 × 12 × 13 mm, incremental,
RS422 per DIN 66259, resolution 1...10 µm
BML ring Various form factors/polarities on request
Identifying tools in the magazine Industrial RFID systems BIS0011 Data tag Ø 10 × 4,5 mm, standardized per
DIN 69873, BIS C with 455/70 kHz (LF), 511 bytes
BIS004A Data tag Ø 10 × 4.5 mm, standardized per
DIN 69873, BIS C with 13.56 kHz (LF), 2000 bytes
BIS005Z Read/write head Ø 14.5 mm, BIS C with
455/70 kHz (LF), 5 m PUR cable with M12 female,
please order adapter BCC0FCK separately
BIS013Z Read/write head Ø 14.5 mm, BIS M with
13.56 MHz (HF), 0.3 m cable with M12 connector
BIS V...-C1... BIS V processor unit for BIS M, BIS L and BIS C,
various fieldbus versions on page 18
Matching and tracking
workpieces
Industrial RFID systems BIS00NZ Data tag 24 × 24 × 21 mm, rod antenna, BIS M with
13.56 MHz (HF), 2000 bytes, corner style
BIS00PT Data tag Ø 22 mm /M6, round antenna, BIS M with
13.56 MHz (HF), 2000 bytes, data screw
BIS0131 Read/write head 105 × 40 × 15 mm, BIS M with
13.56 MHz (HF), 0.3 m PUR cable with M12 connector
BIS0132 Read/write head M30 × 1.5, round antenna,
BIS M with 13.56 MHz (HF), M12 connector
BIS V...-C0... BIS V processor unit for BIS M and BIS L,
various fieldbus versions on page 18

28. 28
This selection table lists the product families and examples to fit
your application. At www.balluff.de you can enter the product family
or sample product to obtain detailed technical information.
Product Selector
The right sensor for every application
Application Product family Example Functions, interfaces and properties
Stamping
Switching eccentric presses Mechanical rotary cam switches BSW0040 259 × 190 × 140 mm, six switch positions
with forced opening contacts, BG certificate
BSW003N 199 × 190 × 140 mm, three switch positions
with forced opening contacts
Controlling hydraulic presses Magnetostrictive linear
position sensors, profile series
BTL...-P-... Profile, measuring range max. 7620 mm,
analog interface 0...10 V or 4...20 mA,
SSI, Start/Stop Pulse Interface, CANopen,
Devicenet, Profibus DP, Profinet, EtherCAT
BTL...-PF-... Profile flat, measuring range up to max. 4572 mm,
analog interface 0...10 V or 4...20 mA, IO-Link
Changing press tools Inductive couplers BIC005C,
BIC005A
40 × 40 mm, unidirectional version,
working range 1...5 mm, IO-Link
BIC0072,
BIC0071
40 × 40 mm, unidirectional version,
working range 1...5 mm, IO-Link
Sensor hubs BNI003T Metal version, 8 ports, 16 × inputs, unidirectional,
coding for tool identification
BNI005U Plastic version, 8 ports,
16 × in-/outputs, configurable, bidirectional,
coding for tool identification
Monitoring sheet metal
thicknesses
Inductive distance sensors BAW0056 M12 × 1, measuring range 0.2...7 mm, IO-Link
BAW0026 M18 × 1, measuring range 1...5 mm, flush mount-
able, analog interface 0...10 V, temperature output
Checking metal strip sag Ultrasonic distance sensors BUS005K M30 × 1.5, analog interface 0...10 V or 4...20 mA,
measuring range 65...350 mm, straight version
BUS004Z M18 × 1, distance and switching state via IO-Link,
straight version
BUS004Y M18 × 1, distance and switching state via IO-Link,
angled version
Monitoring press forces Pressure sensors without display BSP00JP 0...250 bar, 0...10 V, G1/4" external thread
BSP00JR 0...400 bar, 0...10 V, G1/4" external thread
BSP00JT 0...600 bar, 0...10 V, G1/4" external thread
BSP00PU 0...250 bar, PNP, IO-Link, G1/4" external thread
BSP00PW 0...400 bar, PNP, IO-Link, G1/4" external thread
BSP00PY 0...600 bar, PNP, IO-Link, G1/4" external thread
BSP00TW 0...250 bar, NPN, IO-Link, NPT1/4" external thread
BSP00TY 0...400 bar, NPN, IO-Link, NPT1/4" external thread
BSP00TZ 0...600 bar, NPN, IO-Link, NPT1/4" external thread
Pressure sensors with display BSP0011 0...250 bar, 0...10 V analog, PNP switching output
BSP0012 0...400 bar, 0...10 V analog, PNP switching output
BSP0013 0...600 bar, 0...10 V analog, PNP switching output
BSP001A 0...250 bar, 4...20 mA analog, PNP switching output
BSP001C 0...400 bar, 4...20 mA analog, PNP switching output
BSP001E 0...600 bar, 4...20 mA analog, PNP switching output
BSP001T 0...250 bar, 0...10 V analog, NPN switching output
BSP003T 0...400 bar, 0...10 V analog, NPN switching output
BSP003U 0...600 bar, 0...10 V analog, NPN switching output
Adapters for pressure sensors
with display
BAM01KP Process side G1/4" external thread
BAM01KT Process side NPT1/4" external thread

29. 29www.balluff.com
Application Product family Example Functions, interfaces and properties
Spindles, chucks, rotary and swivel tables
Monitoring tool clamping
distances
Inductive sensors BES013N M8 × 1, PNP NO, switching distance 1.5 mm,
flush mountable, M8 connector
BES01C8 M12 × 1, PNP NO, switching distance
2 mm, flush mountable, M12 connector
Inductive distance sensors BAW003E 14 × 38.5 × 17 mm, measuring range 1...5 mm,
analog interface 0...10 V, temperature output,
2 m PUR cable
BAW003A 14 × 38.5 × 17 mm, measuring range 1...5 mm,
IO-Link, temperature output, 2 m PUR cable
Inductive positioning systems BIP0001 Measuring range 14 mm, analog interface 0...10 V,
2 m PUR cable
BIP0007 Measuring range 14 mm, IO-Link,
2 m PUR cable
BIP0004 Measuring range 40 mm, IO-Link,
teachable, M12 connector
BIP000M Measuring range 48 mm, analog interface 0...10 V
and 4...20 mA, teachable, M8 connector
BIP000N Measuring range 70 mm, analog interface 0...10 V
and 4...20 mA, teachable, M12 connector
BIP000U Measuring range 103 mm, analog interface 0...10 V
and 4...20 mA, teachable, M12 connector
BIP000R Measuring range 133 mm, analog interface 0...10 V
and 4...20 mA, teachable, M12 connector
Sending signals and data
on swivel tables
Inductive couplers BIC0078,
BIC0077
M12 × 1, unidirectional version,
working range 0...2 mm, 50 mA power,
2 × PNP signals
BIC0054,
BIC0053
M30 × 1.5 mm, unidirectional version,
working range 0...5 mm, IO-Link interface
4 x analog
Sensor hubs BNI0008 Plastic version, 8 ports, 4 × analog 0...10 V,
8 × inputs, IO-Link interface to BIC
BNI0007 Plastic version, 8 ports, 4 × analog 4...20 mA,
8 × inputs, IO-Link interface to BIC
Determining travel
on rotary tables
Magnetic encoder BML-S1G... 97 × 17.4 × 18.5 mm, absolute,
interface BiSS C or SSI
BML-M02-
A55-...
Magnetic tape absolute,
10 mm wide, for angles < 360°
Detecting piston position
in clamping cylinders
High-pressure-rated
inductive Sensors
BHS0054 M8 × 1, pressure rated to 500 bar, PNP NO, switching
distance 1.5 mm, M8 connector, installation length 45 mm
BHS002Y M12 × 1, pressure rated to 500 bar, PNP NO, switching
distance 1.5 mm, M12 connector, installation length 56 mm
High-pressure-rated
inductive distance sensors
BAW0040 M12 × 1, pressure rated to 500 bar, analog 0...10 V, measuring
range 0.5...2 mm, M12 connector, installation length 78 mm
Magnetic cylinder sensors BMF008E Various slot styles, M12 connector, aluminum
housing, with clamping holder (order separately)
BMF0076 Two sensors with one plug-in terminal,
slides into the T-slot, PNP NO,
0.3 m PUR cable with M12 connector

30. 30
This selection table lists the product families and examples to fit
your application. At www.balluff.de you can enter the product family
or sample product to obtain detailed technical information.
Product Selector
The right sensor for every application
Application Product family Example Functions, interfaces and properties
Handling, transport and process monitoring
Monitoring grippers
on gantry loaders
Magnetic cylinder sensors BMF00C4 Inserted in T-slot from above, PNP NO,
0.3 m PUR cable with M8 connector
BMF00C9 Two sensors with one plug-in terminal,
inserted in T-slot from above, PNP NO,
0.3 m PUR cable with M12 connector
BMF0002 Slides into C-slot (Festo), PNP NO,
0.3 m PUR cable with M8 connector
BMF00A2 Slides into C-slot (SMC), PNP NO,
0.3 m PUR cable with M8 connector
Detecting end positions
on gantry loaders
Inductive sensors BES0028 M8 × 1, PNP NO, switching distance 2 mm,
flush mountable, M12 connector, installation length 65 mm
BES0068 M12 × 1, PNP NO, switching distance 4 mm,
flush mountable, M12 connector, installation length 65 mm
BES008L M18 × 1, PNP NO, switching distance 8 mm,
flush mountable, M12 connector, installation length 65 mm
BES00AF M30 × 1.5, PNP NO, switching distance 15 mm,
flush mountable, M12 connector, installation length 65 mm
Controlling positioning
of the linear drives
Magnetic encoder BML-S1G... 97 × 17.4 × 18.5 mm, absolute,
interface BiSS C or SSI
BML-M02-
A55-...
Magnetic tape absolute, 10 mm wide,
max. 48 m long
Monitoring levels
on the hydraulic power unit
Magnetostrictive linear
position sensor, rod series
BTL...-B-... Rod, analog interface 0...10 V or 4...20 mA,
Start/Stop Pulse Interface, CANopen,
Profibus DP, Profinet, EtherCAT,
flange connection M18 × 1.5,
alternately inch threads style Z
BTL...-K-... Compact rod, analog interface 0...10 V or 4...20 mA,
Start/Stop Pulse interface, CANopen,
flange connection Ø 18 mm
Floats BAM024J Ø 32 × 53 mm, stainless steel
BAM0146 Ø 44 × 49 mm, stainless steel
Detect process fluids and levels
continuously or switching
Ultrasonic distance sensors BUS005Y M30, process connection G1", range 85...350 mm,
analog interface 0...10 V/4...20 mA and PNP,
NO/NC selectable, pressure rated to 6 bar,
M12 connector
BUS005U M30, process connection G1", range 200...1300 mm,
2 × PNP, NO/NC selectable,
pressure rated to 6 bar, M12 connector
BUS005W M30, process connection G1", range 200...1300 mm,
analog interface 0...10 V/4...20 mA and PNP,
NO/NC selectable, pressure rated to 6 bar,
M12 connector
Leak detection Capacitive sensors BCS012T 16 × 34 × 8 mm, PNP NO, 0.3 m PUR cable
with M8 connector, for non-conductive media,
universal holder for leak detection included
BCS012Z 16 × 34 × 8 mm, PNP NO, 0.3 m PUR cable
with M8 connector, for conductive media,
universal holder for leak detection included

31. 31www.balluff.com
Product family Example Functions, interfaces and properties
Accessories
Double-ended cordsets BCC02M9 M8 female straight, 3-pin, 5 m PUR cable,
drag chain compatible
BCC02MJ M8 female right-angle, 3-pin, 5 m PUR cable,
drag chain compatible
BCC032H M12 female straight, 4-pin, 5 m PUR cable,
drag chain compatible
BCC032P M12 female right-angle, 3-pin, 5 m PUR cable,
drag chain compatible
Junction boxes BPI00HJ Plastic, sensor connection 8 ports (M8 female, 3-pin),
controller connection M12 connector, 12-pin
BPI00JY Plastic, sensor connection 8 ports (M12 female, 4-pin),
controller connection M23 connector, 19-pin
Machine Lights BAE00W8 Ø 20 × 250 mm, light field size 170 mm,
white LED with beam angle 120°, M12 connector
BAE00W9 Ø 20 × 358 mm, light field size 278 mm,
white LED with beam angle 120°, M12 connector
BAE00WA Ø 20 × 432 mm, light field size 562 mm,
white LED with beam angle 120°, M12 connector
BAM02ML 35 × 29 × 15 mm, clamp for machine light,
2 pieces included, attached using M6 screw
Fasteners BAM00E0 M12 clamp with positive stop, coated brass,
for thread lengths 30 mm and greater
BAM00CY M12 clamp with positive stop, coated brass,
for thread lengths 40 mm and greater
BAM00FT M18 clamp with positive stop, coated brass,
for thread lengths 30 mm and greater
BAM00FN M18 clamp with positive stop, coated brass,
for thread lengths 50 mm and greater
BAM00J6 M30 clamp with positive stop, coated brass,
for thread lengths 30 mm and greater
BAM00J4 M30 clamp with positive stop, coated brass,
for thread lengths 50 mm and greater
BAM00C4 M12 fastening cuffs without positive stop,
plastic PA 6
BAM00F2 M18 fastening cuffs without positive stop,
plastic PA 6
BAM00HN M30 fastening cuffs without positive stop,
plastic PA 6
Switching Power Supplies BAE00TP IP67 Heartbeat power supply with IO-Link, input 100...240 V AC,
output 24 V DC/3.8 A, 91.2 W power rating
BAE00TL IP67 Heartbeat power supply with IO-Link, input 100...240 V AC,
output 24 V DC/8 A, 192 W power rating
BAE00T4 IP20 Heartbeat power supply with IO-Link, input 115/230...V AC,
output 24 V DC/5 A, 120 W power rating
BAE00M3 IP20 Heartbeat power supply with IO-Link, input 115/230...V AC,
output 24 V DC/20 A, 480 W power rating
BAE00TF IO-Link adapter for IP20 Heartbeat power supply
for controlling and diagnosing the power supply

32. www.balluff.comDoc. No. 930824/Mat. No. 255486 EN
G16; subject to changes.
Please note:
The applications described are examples only.
Always refer to user manuals and data sheets.
Headquarters
Balluff GmbH
Schurwaldstrasse 9
73765 Neuhausen a.d.F.
Germany
Phone +49 7158 173-0
Fax +49 7158 5010
balluff@balluff.de