MTS Sensors Temposonics Powerlink V2 R Series User manual

R-Series Powerlink V2
Operation Manual
Temposonics®
Magnetostrictive Linear Position Sensors

Temposonics® R-Series Powerlink V2
Operation Manual
Table of contents
1. Introduction ..................................................................................................................................................... 3
1.1 Purpose and use of this manual ................................................................................................................................................................ 3
1.2 Used symbols and warnings ..................................................................................................................................................................... 3
2. Safety instructions ............................................................................................................................................. 3
2.1 Intended use.............................................................................................................................................................................................. 3
2.2 Forseeable misuse..................................................................................................................................................................................... 3
2.3 Installation, commissioning and operation................................................................................................................................................ 4
2.4 Safety instructions for use in explosion-hazardous areas.......................................................................................................................... 4
2.5 Warranty.................................................................................................................................................................................................... 4
2.6 Return ....................................................................................................................................................................................................... 4
3. Identification.................................................................................................................................................... 5
3.1 Order code of Temposonics®RP ............................................................................................................................................................... 5
3.2 Order code of Temposonics®RH............................................................................................................................................................... 6
3.3 Order code of Temposonics®RD4............................................................................................................................................................. 7
3.4 Order code of Temposonics®RF................................................................................................................................................................ 8
3.5 Nameplate ................................................................................................................................................................................................. 9
3.6 Approvals .................................................................................................................................................................................................. 9
3.7 Scope of delivery....................................................................................................................................................................................... 9
4. Product description and commissioning ................................................................................................................... 9
4.1 Functionality and system design ............................................................................................................................................................... 9
4.2 Styles and installation of Temposonics®RP ............................................................................................................................................ 10
4.3 Styles and installation of Temposonics®RH............................................................................................................................................ 11
4.4 Styles and installation of Temposonics®RD4.......................................................................................................................................... 14
4.4.1 Installation of RD4 with threaded flange............................................................................................................................................ 16
4.4.2 Installation of RD4 with pressure fit flange ....................................................................................................................................... 17
4.4.3 Installation of RD4's sensor electronic housing ................................................................................................................................ 17
4.5 Styles and installation of Temposonics®RF............................................................................................................................................. 19
4.6 Magnet installation .................................................................................................................................................................................. 22
4.7 Replacement of sensor............................................................................................................................................................................ 25
4.8 Electrical connections.............................................................................................................................................................................. 26
4.9 Frequently ordered accessories............................................................................................................................................................... 27
5. Operation.......................................................................................................................................................30
5.1 Getting started......................................................................................................................................................................................... 30
6. Node ID configuration ........................................................................................................................................30
6.1 Introduction of “MTS Powerlink Configurator”........................................................................................................................................ 30
6.2 Introduction of “Automation Studio”....................................................................................................................................................... 34
7. Integration in Automation Studio ........................................................................................................................... 38
7.1 Programming and configuration ............................................................................................................................................................. 38
7.2 Communication Segement ..................................................................................................................................................................... 40
8. Set the LossSoC threshold for a R-Series Powerlink sensor ........................................................................................... 43
8.1 Hardware setup ....................................................................................................................................................................................... 43
8.2 Defined data types................................................................................................................................................................................... 43
8.3 Used variables......................................................................................................................................................................................... 44
8.4 Program executed by PLC once after start-up......................................................................................................................................... 44
8.5 Program executed by PLC cyclically........................................................................................................................................................ 45
8.6 Variable watch after successful execution of the implemented state machine......................................................................................... 46
9. Maintenance and troubleshooting .........................................................................................................................46
9.1 Error conditions, troubleshooting............................................................................................................................................................ 46
9.2 Maintenance............................................................................................................................................................................................ 46
9.3 Repair...................................................................................................................................................................................................... 46
9.4 List of spare parts ................................................................................................................................................................................... 46
9.5 Transport and storage ............................................................................................................................................................................. 46
10. Removal from service / dismantling .....................................................................................................................46
11. Technical data ...............................................................................................................................................47
12. Appendix ......................................................................................................................................................51

Temposonics® R-Series Powerlink V2
Operation Manual
I 3 I
1. Introduction
1.1 Purpose and use of this manual
Before starting the operation of Temposonics®position sensors,
read this documentation thoroughly and follow the safety
information. Keep the manual for future reference!
Symbol Meaning
NOTICE
This symbol is used to point to situations
that may lead to material damage, but not
to personal injury.
1/ The term qualified technical personnel characterizes persons who:
• are familiar with the safety concepts of automation technology applicable
to the particular project,
• are competent in the field of electromagnetic compatibility (EMC),
• have received adequate training for commissioning and service operations
• are familiar with the operation of the device and know the information required
for correct operation provided in the product documentation.
2. Safety instructions
2.1 Intended use
This product may be used only for the applications defined under item
1 and only in conjunction with the third-party devices and components
recommended or approved by MTS Sensors. As a prerequsite of
proper and safe operation the product requires correct transport,
storage, mounting and commissioning and must be operated with
utmost care.
1. The sensor systems of all Temposonics®series are intended
exclusively for measurement tasks encountered in industrial,
commercial and laboratory applications. The sensors are
considered as system accessories and must be connected
to suitable evaluation electronics, e.g. a PLC, IPC, indicator
or other electronic control unit.
Forseeable misuse Consequence
Wrong sensor connection The sensor will not work
properly or will be destroyed
Operate the sensor out of the
operating temperature range
No signal output
The sensor can be damaged
Power supply is out of the
defined range
Signal output is wrong /
no signal output /
the sensor will be damaged
Position measurement is
influenced by an external
magnetic field
Signal output is wrong
Cables are damaged
Short circuit – the sensor can
be destroyed / sensor does not
respond
Spacers are missing /
are installed in a wrong order Error in position measurement
Wrong connection
of ground / shield
Signal output is disturbed
The electronics can be damaged
Use of a magnet that is not
certified by MTS Sensors Error in position measurement
Do not reprocess the sensor afterwards.
 The sensor might be damaged.
Do not step on the sensor.
 The sensor might be damaged.
2.2 Forseeable misuse
The content of this technical documentation and of its appendix
is intended to provide information on mounting, installation and
commissioning by qualified automation personnel 1or instructed
service technicians who are familiar with the project planning and
dealing with Temposonics®sensors.
1.2 Used symbols and warnings
Warnings are intended for your personal safety and for avoidance
of damage to the described product or connected devices. In this
documentation, safety information and warnings to avoid danger
that might affect the life and health of operating or service personnel
or cause material damage are highlighted by the preceding pictogram
which is defined below.

Temposonics® R-Series Powerlink V2
Operation Manual
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2.3 Installation, commissioning and operation
The position sensors must be used only in technically safe condition.
To maintain this condition and to ensure safe operation, installation,
connection and service, work may be performed only by qualified
technical personnel.
If danger of injury to persons or of damage to operating equipment
is caused by sensor failure or malfunction, additional safety measures
such as plausibility checks, limit switches, EMERGENCY STOP
systems, protective devices etc. are required. In the event of trouble,
shut down the sensor and protect it against accidental operation.
Safety instructions for commissioning
To maintain the sensor operability, it is mandatory to follow
the instructions given below.
1. Protect the sensor's against mechanical damage during
installation and operation.
2. Do not open or dismantle the sensor.
3. Connect the sensor very carefully and pay attention to the
polarity of connections and power supply.
4. Use only approved power supplies.
5. It is indispensable to ensure that the specified permissible
limit values of the sensor for operating voltage,
environmental conditions, etc. are met.
6. Check the function of the sensor regularly and provide
documentation of the checks.
7. Before applying power, ensure that nobody’s safety
is jeopardized by starting machines.
2.4 Safety instructions for use in explosion-hazardous areas
The sensor is not suitable for operation in explosion-hazardous areas.
2/ See also applicable MTS Sensors terms of sales and delivery on:
www.mtssensors.com
2.5 Warranty
MTS Sensors grants a warranty period for the Temposonics®
position sensors and supplied accessories relating to material
defects and faults that occur despite correct use in accordance with
the intended application 2. The MTS Sensors obligation is limited to
repair or replacement of any defective part of the unit. No warranty
can be provided for defects that are due to improper use or above
average stress of the product, as well as for wear parts. Under no
circumstances will MTS Sensors accept liability in the event of offense
against the warranty rules, no matter if these have been assured or
expected, even in case of fault or negligence of the company.
MTS Sensors explicitly excludes any further warranties. Neither
the company’s representatives, agents, dealers nor employees are
authorized to increase or change the scope of warranty.
2.6 Return
For diagnostic purposes, the sensor can be returned to MTS Sensors.
Any shipment cost is the responsibility of the sender 2.
For a corresponding form, see chapter "12. Appendix" on page 51.

Temposonics® R-Series Powerlink V2
Operation Manual
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3.1 Order code of Temposonics® RP
*/ Non standard stroke lengths are available; must be encoded in 5 mm / 0.1 in. increments
3/ Note: Specify magnet number for your sensing application and order separately
a Sensor model
R P Profile
b Design
GMagnet slider, joint on top, backslash free (part no. 253 421)
MU-magnet, OD33 (part no. 251 416-2)
SMagnet slider, joint on top (part no. 252 182)
VMagnet slider, joint at front (part no. 252 184)
Optional:
g Magnet number for multi-position measurement 3
Z 0 2 2 magnets
Z 0 3 3 magnets
Z 0 4 4 magnets
d Connection type
D 5 6 2 × M12 female connectors (4 pin),
1 × M8 male connector (4 pin)
e Operating voltage
1+24 VDC (−15 / +20 %)
f Output
U 3 0 1 Powerlink V2
c Stroke length
X X X X M 0025…5080 mm
Standard stroke length (mm)* Ordering steps
25…500 mm 25 mm
500…2500 mm 50 mm
2500…5080 mm 100 mm
X X X X U001.0…200.0 in.
Standard stroke length (in.)* Ordering steps
1…20 in. 1 in.
2…100 in. 2 in.
100…200 in. 4 in.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
R P D 5 6 1U 3 0 1
a b c d e fg
optional
3. Identification

Temposonics® R-Series Powerlink V2
Operation Manual
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3.2 Order code of Temposonics® RH
*/ Non standard stroke lengths are available; must be encoded in 5 mm / 0.1 in. increments
4/ Note: Specify magnet number for your sensing application and order separately
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
R H D 5 6 1U 3 0 1
a b c d e fg
optional
a Sensor model
R H Rod
b Design
BBase unit
DThreaded flange M18×1.5-6g (bushing on rod end)
HThreaded flange ¾"-16 UNF-3A (with fluoroelastomer housing-seal)
JThreaded flange M22×1.5-6g (rod Ø 12.7 mm, 800 bar)
MThreaded flange M18×1.5-6g (standard)
RThreaded flange M18×1.5-6g (thread M4 at rod end)
SThreaded flange ¾"-16 UNF-3A (standard)
TThreaded flange ¾"-16 UNF-3A (with raised-face)
UThreaded flange ¾"-16 UNF-3A (with raised-face &
fluoroelastomer housing-seal)
VThreaded flange M18×1.5-6g (with fluoroelastomer housing-seal)
Optional:
g Magnet number for multi-position measurement 4
Z 0 2 2 magnets
Z 0 3 3 magnets
Z 0 4 4 magnets
e Operating voltage
1+24 VDC (−15 / +20 %)
f Output
U 3 0 1 Powerlink V2
d Connection type
D 5 6 2 × M12 female connectors (4 pin),
1 × M8 male connector (4 pin)
c Stroke length
X X X X M 0025…7620 mm
Standard stroke length (mm)* Ordering steps
25…500 mm 5 mm
500…750 mm 10 mm
750…1000 mm 25 mm
1000…2500 mm 50 mm
2500…5000 mm 100 mm
5000…7620 mm 250 mm
X X X X U001.0…300.0 in.
Standard stroke length (in.)* Ordering steps
1…20 in. 0.2 in.
20…30 in. 0.4 in.
30…40 in. 1.0 in.
40…100 in. 2.0 in.
100…200 in. 4.0 in.
200…300 in. 10.0 in.
.

Temposonics® R-Series Powerlink V2
Operation Manual
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3.3 Order code of Temposonics® RD4
*/ Non standard stroke lengths are available; must be encoded in 5 mm / 0.1 in. increments
5/ Note: Specify magnet number for your sensing application and order separately
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
R D 4 D 5 6 U 3 0 1
a b c d e fg
optional
b Design
CThreaded flange M18×1.5-6g, A/F 46
DThreaded flange ¾"-16 UNF-3A, A/F 46
GThreaded flange M18×1.5-6g, A/F 24
MThreaded flange M18×1.5-6g, A/F 23
SPressure fit flange Ø 26.9 mm f6
TThreaded flange ¾"-16 UNF-3A, A/F 23
a Sensor model
R D 4Detached sensor electronics
c Integral cable of sensor rod
For side cable entry on sensor electronics housing
D 1 SPUR cable with M16 connector, length 250 mm (9.8 in.)
D 2 SPUR cable with M16 connector, length 400 mm (15.7 in.)
D 3 SPUR cable with M16 connector, length 600 mm (23.6 in.)
For bottom cable entry on sensor electronics housing
R 2 BPUR cable / wires with flat connector, length 65 mm (2.6 in.)
R 4 BPUR cable / wires with flat connector, length 170 mm (6.7 in.)
R 5 BPUR cable / wires with flat connector length 230 mm (9.1 in.)
R 6 BPUR cable / wires with flat connector, length 350 mm (13.8 in.)
Optional:
g Magnet number for multi-position measurement 5
Z 0 2 2 magnets
Z 0 3 3 magnets
Z 0 4 4 magnets
f Output
U 3 0 1 Powerlink V2
Operating voltage
+24 VDC (−15 / +20 %); Standard, not indicated in order code
e Connection type
D 5 6 2 × M12 female connectors (4 pin),
1 × M8 male connector (4 pin)
d Stroke length
X X X X M Flange »C«, »D«, »G«, »M«, »T«:
0025…5080 mm
Flange »S«: 0025…2540 mm
Standard stroke length (mm)* Ordering steps
25…500 mm 5 mm
500…750 mm 10 mm
750…1000 mm 25 mm
1000…2500 mm 50 mm
2500…5080 mm 100 mm
X X X X U Flange »C«, »D«, »G«, »M«, »T«:
001.0…200.0 in.
Flange »S«: 001.0…100.0 in.
Standard stroke length (in.)* Ordering steps
1…20 in. 0.2 in.
20…30 in. 0.4 in.
30…40 in. 1.0 in.
40…100 in. 2.0 in.
100…200 in. 4.0 in.
200…300 in. 10.0 in.
.

Temposonics® R-Series Powerlink V2
Operation Manual
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3.4 Order code of Temposonics® RF
*/ Non standard stroke lengths are available; must be encoded in 5 mm / 0.1 in. increments
6/ Note: Specify magnet number for your sensing application and order separately
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R F D 5 6 1U 3 0 1
a b c d e fg
optional
a Sensor model
R F Flexible sensor rod
b Design
CBase unit
MThreaded flange M18×1.5-6g
SThreaded flange ¾"-16 UNF-3A
e Operating voltage
1+24 VDC (−15 / +20 %)
Optional:
g Magnet number for multi-position measurement 6
Z 0 2 2 magnets
Z 0 3 3 magnets
Z 0 4 4 magnets
f Output
U 3 0 1 Powerlink V2
d Connection type
D 5 6 2 × M12 female connectors (4 pin),
1 × M8 male connector (4 pin)
c Stroke length (Longer strokes are available. Contact applications engineering for details.)
X X X X X M 00150…10060 mm
Standard stroke length (mm)* Ordering steps
150…1000 mm 50 mm
1000…5000 mm 100 mm
5000…10,060 mm 250 mm
X X X X X U0006.0…0396.0 in.
Standard stroke length (in.)* Ordering steps
6…40 in. 2 in.
40…197 in. 4 in.
197…396 in. 10 in.
.

Temposonics® R-Series Powerlink V2
Operation Manual
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3.5 Nameplate
RPS0200M D561 U301
MAC ID: 00-03-CA-00-2B-7F
S/N: 90550176
GRD: 9.2337 µS/In | 2750.79 m/s
Sensor model
Measuring range (e.g. 200 mm)
Connection type
Output version
Order code
MAC adress
Gradient
Serial number
Fig. 1: Example of nameplate of an R-Series RP sensor
3.6 Approvals
• certified (RP / RH / RF)
• UL/cUL certified (RP / RH)
• GOST certified
• Ethernet POWERLINK Standardization Group (EPSG) certified
3.7 Scope of delivery
RP (profile sensor):
• Sensor
• Position magnet
• 2 mounting clamps up to 1250 mm (50 in.) stroke length +
1 mounting clamp for each 500 mm (20 in.) additional stroke length
RH (rod sensor):
• RH-B: Base unit, 2 socket screws M4
• RH-D / -H / -J / -M / -R / -S / -T / -U / -V: Sensor, O-ring
RD4 (detached sensor electronics):
• RD4-C / -D / -G / -M / -T: Sensor, O-ring
• RD4-S: Sensor, O-ring, back-up ring
RF (flexible sensor rod):
• RF-C: Base unit
• RF-M / -S: Sensor, O-ring
4. Product description and commissioning
4.1 Functionality and system design
Product designation
• Position sensor Temposonics®R-Series
Sensor model
• Temposonics®RP (profile sensor)
• Temposonics®RH (rod sensor)
• Temposonics®RD4 (detached sensor electronics)
•Temposonics®RF (flexible sensor rod)
Stroke length
•RP 25… 5080 mm (1…200 in.)
• RH 25… 7620 mm (1…300 in.)
• RD4 25… 5080 mm (1…200 in.)
• RF 150…10060 mm (6…396 in.)
Output signal
• Powerlink V2
Application
The Temposonics®position sensors are used for measurement and
conversion of the length (position) variable in the fields of automated
systems and mechanical engineering.
Principle of operation and system construction
The absolute, linear position sensors provided by MTS Sensors
rely on the company’s proprietary Temposonics®magnetostrictive
technology, which can determine position with a high level of precision
and robustness. Each Temposonics®position sensor consists of a
ferromagnetic waveguide, a position magnet, a strain pulse converter
and supporting electronics. The magnet, connected to the object in
motion in the application, generates a magnetic field at its location on
the waveguide. A short current pulse is applied to the waveguide.
This creates a momentary radial magnetic field and torsional strain
on the waveguide. The momentary interaction of the magnetic
fields releases a torsional strain pulse that propagates the length
of the waveguide. When the ultrasonic wave reaches the end of the
waveguide it is converted into an electrical signal. Since the speed
of the ultrasonic wave in the waveguide is precisely known, the time
required to receive the return signal can be converted into a linear
position measurement with both high accuracy and repeatability.
5
Sensing element
(Waveguide)
Position magnet (Magnetic field) Torsional strain
pulse converter
4
Current pulse
generates
magnetic field
Interaction with
position magnet
field generates
torsional strain
pulse Torsional strain
pulse propagates
Strain pulse
detected by
converter
Time-of-flight converted
into position
1
2
3
Fig. 2: Time-based magnetostrictive position sensing principle
Modular mechanical and electronic construction
• The sensor rod or profile protects the inner sensor element.
• The sensor electronics housing, a rugged aluminum construction,
contains the complete electronic interface with active signal
conditioning.
• Double shielding ensures high safety of operation and optimum
EMC (Electromagnetic Compatibility).
• The external position magnet is a permanent magnet. Mounted on
the mobile machine part, it travels along the sensor rod or profile
and triggers the measurement through the sensor rod wall.
• The sensor can be connected directly to a control system.
Its electronics generates a strictly position-proportional signal
output between start and end position.

Temposonics® R-Series Powerlink V2
Operation Manual
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4.2 Styles and installation of Temposonics® RP
Fig. 3: Temposonics®RP-M with U-magnet
RP
Magnet
18
(0.71)
50
(1.97)
68
(2.68)
35.6
(1.4)
2
(0.08)
45
(1.77)
Dead zone
66 / 71*
(2.6 / 2.8*)
14.5
(0.57)
Adjustable mounting clamp
28
(1.1)
Sensor electronics housing
129
(5.07)
Null zone
28
(1.1)
Stroke length
25…5080
(1…200)
49
(1.93)
9
(0.36)
M5 or
#10 screw
Ø 5.5
(0.21)
* > 5000 mm (196.9 in.) stroke length
Controlling design dimensions are in millimeters and measurements in ( ) are in inches
Installation of RP
The position sensor can be installed in any position. Normally,
the sensor is firmly installed and the position magnet is fastened
to the mobile machine part. Thus it can travel along the sensor profile.
The sensor is fitted on a flat machine surface using the mounting
clamps (Fig. 4). A length-dependent number of these clamps are
delivered with the sensor and must be distributed over the profile
at regular distances. For fastening use M5×20 screws to DIN 6912 that
should be tightened with a fastening torque of 5 Nm.
Fig. 4: Mounting clamps (part no. 400 802) with cylinder screw M5×20
Fig. 5: T-slot nut M5 (part no. 401 602)
NOTICE
Take care to mount the sensor in an axially parallel position to
avoid damage to magnet and sensor.
≤ 5
(≤
0.2)
M5
Alternative:
If only limited space is available, the profile sensor can be mounted
also via the T-rail in the profile bottom using an T-slot nut M5
(part no. 401 602) or a sliding block (Fig. 5).
Fastening torque: 5 Nm
50
(1.97)
9.5
(0.38)
Bore Ø 5.5
(Ø 0.27)
14.5
(0.57)

Temposonics® R-Series Powerlink V2
Operation Manual
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4.3 Styles and installation of Temposonics® RH
Controlling design dimensions are in millimeters and measurements in ( ) are in inches
Fig. 6: Temposonics®RH with ring magnet part 1
RH-H / -M / -S / -V
18
(0.71)
Null zone
51
(2.01)
10
(0.4)
Dead zone
63.5 / 66*
(2.5 / 2.6* )
Stroke length
25…7620
(1…300)
Sensor electronics housing
133
(5.24)
A/F 46
Ø 10 ±0.13
(Ø 0.39 ±0.01)
46
(1.81)
53
(2.09)
25
(0.98)
Flange »M« / »V«: M18×1.5-6g
Flange »S« / »H«: ¾"-16 UNF-3A
Magnet
* Stroke length > 5000 mm (196.9 in.)
RH-D
Dead zone
63.5 / 66*
(2.5 / 2.6*)
22
(0.87)
15
(0.59)
3
(0.12)
8
(0.31)
Ø 12.8 ±0.1
(Ø 0.5 ±0.004)
A/F 46
Ø 10
(Ø 0.39)
Flange: »D«
M18×1.5-6g
Magnet
* Stroke length > 5000 mm (196.9 in.)
RH-T / -U
Magnet
Flange »T« / »U«:
¾"-16 UNF-3A
Null zone
51
(2.01)
7.11
(0.28)
9.65
(0.38)
Dead zone
63.5 / 66*
(2.5 / 2.6* )
Stroke length
25…7620
(1…300)
A/F 44.5
Ø 10 ±0.13
(Ø 0.39 ±0.01)
44.5
(1.75)
51.3
(2.02)
* Stroke length > 5000 mm (196.9 in.)
Ø 25.4
(Ø 1)
RH-R
Dead zone
70 / 72.5*
(2.76 / 2.85*)
3.5
(0.14)
6
(0.24)
M4 thread
A/F 46
Ø 10 ±0.13
(Ø 0.39 ±0.01)
Flange: »R«
M18×1.5-6g
Magnet
* Stroke length > 5000 mm (196.9 in.)

Temposonics® R-Series Powerlink V2
Operation Manual
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Hydraulics sealing
There are two ways to seal the flange contact surface (Fig. 10):
1. A sealing by using an O-ring (e.g. 22.4 × 2.65 mm (0.88 × 0.1 in.),
25.07 × 2.62 mm (0.99 × 0.1 in.)) in a cylinder bottom groove.
2. A sealing by using an O-ring in the undercut.
For threaded flange (¾"-16 UNF-3A) »H« / »S« / »T« / »U«:
O-ring 16.4 × 2.2 mm (0.65 × 0.09 in.) (part no. 560315)
For threaded flange (M18×1.5-6g) »D« / »M« / »R«/ »V«:
O-ring 15.3 × 2.2 mm (0.60 × 0.09 in.) (part no. 401133)
For threaded flange (M22×1.5-6g) »J«:
O-ring 19.2 × 2.2 mm (0.76 × 0.09 in.) (part no. 561337)
Installation of RH with threaded flange »D«, »H«, »J«, »M«, »R«, »S«,
»T«, »U« & »V«
Fix the sensor rod via threaded flange M18×1.5-6g, M22×1.5-6g or
¾"-16 UNF-3A.
In the event of servicing, the sensor rod
with flange remains in the cylinder
Position magnet
Base unit
The sensor electronics housing
with sensing element can be replaced
Fig. 7: Mounting example of threaded flange »D«, »H«, »J«, »M«, »R«, »S«, »T«, »U« & »V«
Fastening torque:
RH-D/-H /-M / -R /-S / -T / -U / -V: 50 Nm
RH-J: 125 Nm
Fig. 8: Sensor in cylinder
Installation of a rod-style sensor in a fluid cylinder
The rod-style version has been developed for direct stroke
measurement in a fluid cylinder. Mount the sensor via threaded flange
or a hex nut.
• Mounted on the face of the piston, the position magnet travels
over the rod without touching it and indicates the exact position
through the rod wall – independent of the hydraulic fluid.
• The pressure resistant sensor rod is installed into a bore in the
piston rod.
• The base unit is mounted by means of only two screws. It is the
only part that needs to be replaced if servicing is required, i.e. the
hydraulic circuit remains closed. For more information see chapter
"4.7 Replacement of sensor" on page 25.
R-Series RH-J
Null zone
51
(2.01)
Dead zone
73.6
(2.9)
Ø 12.7 ±0.13
(Ø 0.5 ±0.01)
4.6
(0.18)
6.2
(0.24)
Stroke length
25…7620
(1…300)
A/F 46
Flange: »J«
M22×1.5-6g
Magnet
R-Series RH-B
** Stroke length 25…1575 (1…62): 52 (2.05) dead zone
Stroke length 1576…5000 (62.05…196.9): 54 (2.13) dead zone
Stroke length 5001…7620 (196.9…300): 57 (2.24) dead zone
Null zone
61
(2.4)
Dead zone
52 / 54 / 57**
(2.05 / 2.13 / 2.24)
Stroke length
25…7620
(1…300)
Sensor electronics housing
123
(4.84)
Ø 6.8 ±0.13
(Ø 0.27 ±0.01)
43.7
(1.72)
49
(1.93)
Magnet
Fig. 9: Temposonics®RH with ring magnet part 2
Controlling design dimensions are in millimeters and measurements in ( ) are in inches

Temposonics® R-Series Powerlink V2
Operation Manual
I 13 I
In the case of threaded flange M18×1.5-6g or M22×1.5-6g, provide
a screw hole based on ISO 6149-1 (Fig. 11).
See ISO 6149-1 for further information.
Controlling design dimensions are in millimeters
Sealing via O-ring
in the flange undercut
Sealing via O-ring
in cylinder end cap groove
Notice for metric threaded flanges
Thread
(d1×P)
d2d3d4d5
+0.1
0
L1
+0.4
0
L2L3L4Z°
±1°
RH-M / -R / -V
M18×1.5-6g 55 ≥ 13 24.5 19.8 2.4 28.5 2 26 15°
RH-D
M18×1.5-6g 55 ≥ 16 24.5 19.8 2.4 28.5 2 26 15°
RH-J
M22×1.5-6g 55 ≥ 16 27.5 23.8 2.4 28.5 2 26 15°
Ød
5
Ra 3.2
Ra 3.2
Pitch diameter
A
A
Thread (d
1
× P)
Ød
3
(Reference)
A
Ød
2
Ød
4
(Gauging)
This dimension applies when
tap drill cannot pass through
entire boss.
≤ R0.4
R0.3
R0.1
Z°
4
5
°
±
5
°
L
3
L
1
L
2
L
4
A0.1 A0.2
• Note the fastening torque of:
RH-D/-H /-M / -R /-S / -T / -U / -V: 50 Nm
RH-J: 125 Nm
• Seat the flange contact surface completely on the cylinder mounting
surface.
• The cylinder manufacturer determines the pressure-resistant gasket
(copper gasket, O-ring, etc.).
• The position magnet should not grind on the sensor rod.
•The piston rod drilling
(RH-H/-M/-R/-S/-T/-U/-V: rod Ø 10 mm: ≥ Ø 13 mm (≥ Ø 0.51 in.);
RH-D: rod Ø 10 mm: ≥ Ø 16 mm (≥ Ø 0.63 in.); RH-J: rod Ø 12.7 mm:
≥ Ø 16 mm (≥ Ø 0.63 in.)) depends on the pressure and piston speed.
• Adhere to the information relating to operating pressure.
•Protect the sensor rod against wear.
Fig. 10: Possibilities of sealing
Fig. 11: Notice for metric threaded flange M18×1.5-6g / M22×1.5-6g based on DIN ISO 6149-1

Temposonics® R-Series Powerlink V2
Operation Manual
I 14 I
4.4 Styles and installation of Temposonics® RD4
Controlling design dimensions are in millimeters and measurements in ( ) are in inches
Fig. 12: Temposonics®RD4 sensor electronics housings
Sensor electronics housing with bottom cable entry
45
(1.77)
2
(0.08)
Mounting block
45
(1.77)
Sensor electronics housing
123
(4.84)
Sensor electronics
housing
18
(0.71)
24.7
(0.97)
26.5
(1.04)
7.7
(0.3)
Ø 6.2
(Ø 0.24)
Ø 19
(Ø 0.75)
49
(1.93)
25
(0.98)
41
(1.61)
50
(1.97)
38
(1.5)
Recommendation:
Use M6×45 (ISO 4762)
screws for sensor fastening.
Fastening torque: 6 Nm.
Sensor electronics housing with side cable entry
5
(0.2)
Mounting block
45
(1.77)
Sensor electronics housing
123
(4.84) 18
(0.71)
24.7
(0.97)
24.7
(0.97)
8.2
(0.32)
7.7
(0.39
Ø 6.2
(Ø 0.24)
49
(1.93)
41
(1.61)
45
(1.77)
Ø 18
(Ø 0.71)
45
(1.77)
38
(1.5)
Sensor electronics
housing
Recommendation:
Use M6×45 (ISO 4762)
screws for sensor fastening.
Fastening torque: 6 Nm.

Temposonics® R-Series Powerlink V2
Operation Manual
I 15 I
Controlling design dimensions are in millimeters and measurements in ( ) are in inches
Fig. 13: Temposonics RD4 flanges with ring manget
Threaded flange »C« & »D« (for bottom or side entry)
Magnet
Ø 10 ±0.13
(Ø 0.4 ±0.01)
Cable for bottom
cable entry
Cable for side
cable entry
4.5
(0.18)
PUR-cable:
Ø 6 (Ø 0.24)
Bend radius:
> 24 (> 0.94)
Length for bottom cable entry:
65 / 170 / 230 / 350
(2.6 / 6.7 / 9.1 / 13.8)
Length
for side cable entry:
250 / 400 / 600
(9.8 / 15.7 / 23.6)
26.9
(1.1)
Null zone
51
(2.01)
32
(1.36)
Stroke length
25…5080
(1…200)
Dead zone
63.5 / 66*
(2.5 / 2.6)
Flange »C«: M18×1.5-6g
Flange »D«: ¾"-16 UNF-3A
* > 5000 mm (196.85 in.) stroke length
A/F 46
Threaded flange »G« (for bottom or side entry)
Magnet
Ø 10 ±0.13
(Ø 0.4 ±0.01)
4.5
(0.18)
32
(1.36)
Null zone
51
(2.01)
Stroke length
25…5080
(1…200)
Dead zone
63.5 / 66*
(2.5 / 2.6*)
26.9
(1.1)
* > 5000 mm (196.85 in.) stroke length
PUR-cable:
Ø 6 (Ø 0.24)
Bend radius:
> 24 (> 0.94)
Length for bottom cable entry:
65 / 170 / 230 / 350
(2.6 / 6.7 / 9.1 / 13.8)
Length
for side cable entry:
250 / 400 / 600
(9.8 / 15.7 / 23.6)
Flange »G«: M18×1.5-6g
25
(1)
A/F 24
Cable for bottom
cable entry
Cable for side
cable entry
Threaded flange »M« & »T« (for bottom or side entry)
Flange »M«: M18×1.5-6g
Flange »T«: ¾"-16 UNF-3A
Magnet
Ø 10 ±0.13
(Ø 0.4 ±0.01)
25
(1)
Cable for bottom
cable entry
Cable for side
cable entry
4.5
(0.18)
PUR-cable:
Ø 6 (Ø 0.24)
Bend radius:
> 24 (> 0.94)
Length for bottom cable entry:
65 / 170 / 230 / 350
(2.6 / 6.7 / 9.1 / 13.8)
Length
for side cable entry:
250 / 400 / 600
(9.8 / 15.7 / 23.6)
Null zone
51
(2.01)
32
(1.36)
26.9
(1.1)
Stroke length
25…5080
(1…200)
Dead zone
63.5 / 66*
(2.5 / 2.6)
* > 5000 mm (196.85 in.) stroke length
A/F 23
Pressure fit flange »S« (for bottom or side entry)
Magnet
Ø 10 ±0.13
(Ø 0.4 ±0.01)
Null zone
21.4
(0.84)
32
(1.36)
12.7
(0.5)
4.5
(0.18)
Cable for bottom
cable entry
Cable for side
cable entry
Stroke length
25…2540
(1…100)
PUR-cable:
Ø 6 (Ø 0.24)
Bend radius:
> 24 (> 0.94)
Length for bottom cable entry:
65 / 170 / 230 / 350
(2.6 / 6.7 / 9.1 / 13.8)
Length
for side cable entry:
250 / 400 / 600
(9.8 / 15.7 / 23.6)
Dead zone
63.5
(2.5)
26.9 f6
(1.1)

Temposonics® R-Series Powerlink V2
Operation Manual
I 16 I
Threaded flange »M« / »T«, »G«Threaded flange »C« / »D«
Fastening torque
50 Nm
NOTICE
Mount the sensor as follows:
1. Mount the flange with sensor rod
2. Mount the sensor electronics housing
3. Connect the cable between flange and the sensor electronics
housing
Fig. 14: Conformity of serial numbers
NOTICE
RPS0200M D561 U301
MAC ID: 00-03-CA-00-2B-7F
S/N: 90550176
GRD: 9.2337 µS/In | 2750.79 m/s
RPS0200M D561 U301
MAC ID: 00-03-CA-00-2B-7F
S/N: 90550176
GRD: 9.2337 µS/In | 2750.79 m/s
S/N: 90550176
Note for installation respectively
for replacement
The serial numbers (S/N:) of cable
and sensor electronics housing
must match so that the position
measurement is correct.
Serial number
example
4.4.1 Installation of RD4 with threaded flange
Fix the sensor rod via threaded flange M18×1.5-6g or ¾"-16 UNF-3A.
Sealing via O-ring
e.g. 22.4 × 2.65 (0.88 × 0.1)
in cylinder end cap groove
For threaded flange
»C« / »D«
Sealing via O-ring
16.4 × 2.2 (0.65 × 0.09)
in the flange undercut
For threaded flange
»D« / »T«
Sealing via O-ring
15.3 × 2.2 (0.6 × 0.09)
in the flange undercut
For threaded flange
»C« / »M« & »G«
Fig. 15: Mounting example of threaded flange »C / D«, »M / T« & »G«
Hydraulics sealing
There are the following ways to seal the flange contact
surface (Fig. 16):
For threaded flange »C« / »D«:
1. A sealing by using an O-ring (e.g. 22.4 × 2.65 mm (0.88 × 0.1 in.)
25.07 × 2.62 mm (0.99 × 0.1 in.)) in a cylinder end cap groove.
For threaded flange (¾"-16 UNF-3A) »D« / »T«:
2. A sealing by using an O-ring 16.4 × 2.2 mm (0.65 × 0.09 in.)
(part no. 560315) in the undercut.
For threaded flange (M18×1.5-6g) »C« / »M« & »G«:
3. A sealing by using O-ring 15.3 × 2.2 mm (0.6 × 0.09 in.)
(part no. 401133) in the undercut. In this case a screw hole based
on ISO 6149-1 (Fig. 17) must be provided. See ISO 6149-1 for
further information.
Fig. 16: Possibilities of sealing
Fig. 17: Notice for metric threaded flange M18×1.5-6g based on DIN ISO 6149-1Controlling design dimensions are in millimeters and measurements in ( ) are in inches
• Note the fastening torque of 50 Nm.
• Seat the flange contact surface completely on the cylinder
mounting surface.
• The cylinder manufacturer determines the pressure-resistant
gasket (copper gasket, O-ring, etc.).
• The position magnet should not grind on the sensor rod.
• The piston rod drilling (≥ Ø 13 mm (≥ Ø 0.51 in.))
depends on the pressure and piston speed.
• Adhere to the information relating to operating pressure.
•Protect the sensor rod against wear.
Notice for metric threaded flanges
Thread
(d1×P)
d2d3d4d5
+0.1
0
L1
+0.4
0
L2L3L4Z°
±1°
RD4-C
M18×1.5-6g 55 ≥ 13 24.5 19.8 2.4 28.5 2 26 15°
RD4-G / -M
M18×1.5-6g 30 ≥ 13 24.5 19.8 2.4 28.5 2 26 15°
Ød
5
Ra 3.2
Ra 3.2
Pitch diameter
A
A
Thread (d
1
× P)
Ød
3
(Reference)
A
Ød
2
Ød
4
(Gauging)
This dimension applies when
tap drill cannot pass through
entire boss.
≤ R0.4
R0.3
R0.1
Z°
4
5
°
±
5
°
L
3
L
1
L
2
L
4
A0.1 A0.2
The steps mentioned above will be explained in chapter 4.4.1, chapter
4.4.2 and chapter 4.4.3.
Controlling design dimensions are in millimeters
Installation of a rod-style sensor in a fluid cylinder
The rod-style version has been developed for direct stroke
measurement in a fluid cylinder. Mount the sensor via threaded flange
or a hex nut.
• Mounted on the face of the piston, the position magnet travels over
the rod without touching it and indicates the exact position through
the rod wall – independent of the hydraulic fluid.
• The pressure resistant sensor rod is installed into a bore in the
piston rod.

Temposonics® R-Series Powerlink V2
Operation Manual
I 17 I
4.4.2 Installation of RD4 with pressure fit flange
Cylinder mounting
Install the rod using the pressure fit flange. Seal it off by means of
the O-ring and the back-up ring. Block the pressure fit flange using a
shoulder screw (Fig. 18). For details of the pressure fit flange »S« see
Fig. 19. Also note the mounting examples in Fig. 20 and Fig. 21.
NOTICE
To fulfill the EMC standards for emission and immunity the
following points are necessary:
• The sensor electronics housing has to be connected to machine
ground.
• The cable between the sensor and the electronics must be
integrated into a metallic housing.
32
(1.26)
5
(0.2) 20.3
(0.8)
20
(0.79)
Bore
27 H7
(1.07)
15°
2.5
(0.1)
For side cable entry: Ø 10…20 (Ø 0.39…0.79)
bore for cable to electronics housing
For bottom cably entry: Ø 13…17 (Ø 0.51… 0.67)
to push single wires through
14.7
(0.58)
44.7
(1.76)
4.8
(0.2)
7.1
(0.28)
26.9 +0.03
(1.06 +0.001)
22.9
(0.9)
12.7
(0.5)
4.4
(0.17)
10
(0.4)
5.8
(0.23)
Ø 22.9
(Ø 0.9)
45°
Note for cylinder installation:
• The position magnet should not grind on the sensor rod.
• The piston rod drilling (≥ Ø 13 mm (≥ Ø 0.51 in.))
depends on the pressure and piston speed.
• Adhere to the information relating to operating pressure.
• Protect the sensor rod against wear.
Fig. 18: Example of mounting detail: Shoulder screw 8-M6 (ISO 7379) with internal hexagon
Controlling design dimensions are in millimeters and measurements in ( ) are in inches
4.4.3 Installation of RD4's sensor electronic housing
The following section explains the connection of a RD4 sensor with
bottom cable entry (Fig. 20) and side cable entry (Fig. 21) based on
RD4-S. The sensor electronics of RD4 sensors with threaded flange
are mounted in the same way.
Sensor electronics with bottom cable entry
Connect the rod via the connector to the sensor electronics. Mount the
sensor electronics so that you can lead the cables below the bottom of
the housing. Thus the sensor system including the connection cables is
fully encapsulated and protected against external disturbances (Fig. 20).
Note the bending radius of the cable if you run the cable between sensor
electronics and rod (see Fig. 13).
Non-magnetic
material
Included in delivery:
O-ring 21.9 × 2.6 (part no. 560 705)
Back-up ring (part no. 560 629)
Magnet
O-ring 21.9 × 2.6 (part no. 560 705)
Back-up ring (part no. 560 629)
Magnet
Non-magnetic
material
Connect the flange to the sensor electronics housing via the molex
connectors for bottom cable entry respectively via the 6 pin cable for
side cable entry.
Fig. 19: Pressure fit flange »S« details
Fig. 20: Mounting example of pressure fit flange »S« and sensor electronics with bottom
cable entry
Fig. 21: Mounting example of pressure fit flange »S« and sensor electronics with side
cable entry
Sensor electronics with side cable entry
Connect the rod via the cable to the sensor electronics on the side.
Encapsulate the sensor system including the connection cables
(Fig. 21). Note the bending radius of the cable if you run the cable
between sensor electronics and rod (see Fig. 13).

Temposonics® R-Series Powerlink V2
Operation Manual
I 18 I
Fig. 22: Mounting of RD4‘s sensor electronics housing (example of bottom cable entry)
4 M6×45 (ISO 4762) screws
Fastening torque: 6 Nm
Mounting block
Mounting of sensor electronics housing
Mount the sensor electronics housing with 4 M6×45 (ISO 4762)
screws via the mounting block. Note the fastening torque of 6 Nm.

Temposonics® R-Series Powerlink V2
Operation Manual
I 19 I
4.5 Styles and installation of Temposonics® RF
Note the following information when mounting a RF sensor:
1. Always insert the flexible sensor rod in a support tube
(e.g. pressure rod HD / HL / HP or HFP profile). The support
tube with an inside diameter of 9.4 mm (0.37 in.) consists of
non-magnetic material. The support tube can be straight or
bent (note the bending radius in Fig. 25).
2. Use non-magnetic material for mounting support.
3. Do never bend beyond the minimum bending radius of
250 mm (9.84 in.)
4. Note the minimum distance to a spatial limitation of 300 mm
(11.81 in.), when mounting / dismounting the sensor (Fig. 25).
5. Note that the first 107 mm (4.21 in.) (for RF-C) respectively
97 mm (3.82 in.) (for RF-M) of the sensor rod are not flexible.
Fig. 23: Temposonics®RF base unit with ring magnet (top) and RF with threaded flange with ring magnet (bottom)
RF-C
Stroke length
150…10060
(6…396)
Total length
Dead zone
see table
18
(0.71)
43.7
(1.72)
49
(1.93)
34.6
(1.36)
Sensor electronics housing
123
(4.84) 7
(0.28)
Null zone
61
(2.4)
11.5
(0.45)
Magnet
Ø
8 ± 0.23
(
Ø
0.31 ± 0.01)
Not flexible
107
(4.21)
Stroke length
Up to 7620 mm (300.00 in.)
Up to 10,000 mm (393.70 in.)
Up to 15,000 mm (590.55 in.)
Up to 20,000 mm (787.00 in.)
Tolerance of total length
+8 mm (0.31 in.) / −5 mm (0.20 in.)
+15 mm (0.59 in.) / −15 mm (0.59 in.)
+15 mm (0.59 in.) / −30 mm (1.18 in.)
+15 mm (0.59 in.) / −45 mm (1.77 in.)
Dead zone
94 mm (3.70 in.)
100 mm (3.94 in.)
120 mm (4.72 in.)
140 mm (5.51 in.)
Note: Tolerance of total length has no influence on the stroke length.
RF-M / -S
Null zone
51
(2.01)
Stroke length
150…10060
(6…396)
Total length
Dead zone
see table
Sensor electronics housing
133
(5.24)
46
(1.81)
18
(0.71)
53
(2.09)
Magnet
Ø
8 ± 0.23
(
Ø
0.31 ± 0.01)
Not flexible
97
(3.82)
25
(0.98)
Flange »M«: M18×1.5-6g
Flange »S«: ¾"-16 UNF-3A
A/F 46
Stroke length
Up to 7620 mm (300.00 in.)
Up to 10,000 mm (393.70 in.)
Up to 15,000 mm (590.55 in.)
Up to 20,000 mm (787.00 in.)
Tolerance of total length
+8 mm (0.31 in.) / −5 mm (0.20 in.)
+15 mm (0.59 in.) / −15 mm (0.59 in.)
+15 mm (0.59 in.) / −30 mm (1.18 in.)
+15 mm (0.59 in.) / −45 mm (1.77 in.)
Dead zone
94 mm (3.70 in.)
100 mm (3.94 in.)
120 mm (4.72 in.)
140 mm (5.51 in.)
Note: Tolerance of total length has no influence on the stroke length.
Position magnet
Non-magnetic support tube, inner-Ø 9.4 (0.37)
Fig. 24: Linear measurement
Controlling design dimensions are in millimeters and measurements in ( ) are in inches

Temposonics® R-Series Powerlink V2
Operation Manual
I 20 I
NOTICE
Connect the sensor electronics housing to machine ground to fulfill
the EMC standards for emission and immunity.
Installation of a RF sensor with pressure rod HD / HL / HP in a fluid
cylinder:
The rod-style version has been developed for direct stroke measurement
in a fluid cylinder. Mount the sensor via threaded flange or a hex nut.
• Mounted on the face of the piston, the position magnet travels over
the rod without touching it and indicates the exact position through
the rod wall – independent of the hydraulic fluid.
• The pressure resistant sensor rod is installed into a bore in the
piston rod.
• The base unit is mounted by means of only two screws. It is the
only part that needs to be replaced if servicing is required, i.e. the
hydraulic circuit remains closed. For more information see chapter
"4.7 Replacement of sensor" on page 25.
Fastening torque
50 Nm
Sensor design Mounting
RF-C • Insert the flexible sensor rod in
a support tube.
• Mount the sensor electronics housing
by means of two non-magnetic socket
head screws M4×90.
Fastening torque: 2 Nm (see Fig. 26)
Recommendation:
Seal the sensor via flange.
RF-C with pressure
rod HD / HL / HP
or HFP profile
(see accessories)
Advantage: The flexible sensor rod is
inserted in a support tube.
• Mount the sensor electronics housing
by means of two non-magnetic socket
head screws M4×59.
Fastening torque: 2 Nm (see Fig. 26)
RF-M / RF-S • Insert the flexible sensor rod in
a support tube.
• Mount the sensor via flange.
Installation of RF with threaded flange »M«, »S« respectively with
pressure rod HD / HL / HP
Fix the sensor rod via threaded flange M18×1.5-6g or ¾"-16 UNF-3A
This is the way you mount the RF sensors:
Socket head screw
M4×90
Fastening torque of socket head screw M4×90: 2 Nm
NOTICE
Smaller radiuses cause damage to the flexible sensor rod.
500 (20) recommended
≥ 300 (≥ 11.81) Magnet
10
(0.4)
AF46
Flange
M18×1.5-6g
¾"×16 UNF-3A
Customized support tube
required, e.g. Ø 12.7 ×
1.65
(Ø 0.5 × 0.65),
inside Ø 9.4 (Ø 0.37),
non-magnetic
R > 250
(R > 9.84)
Fig. 25: Clearances for installation
Fig. 26: Mounting with socket head screws M4×90
Fig. 27: Mounting example of threaded flange »M« / »S« or with pressure rod
HD / HL / HP