Introduction to CELESCO PT801-0005-611-1212
Product Description
The CELESCO PT801-0005-611-1212 is a high-precision string potentiometer (draw-wire sensor) designed for linear position measurement in industrial environments. Renowned for its rugged construction and reliable performance, this sensor is widely used in applications such as hydraulic cylinder positioning, material handling systems, robotics, and structural health monitoring across industries including aerospace, automotive, and heavy machinery.
This sensor operates on the draw-wire principle: a stainless-steel cable extends from a spring-loaded spool, with its free end attached to the moving object. As the object moves, the cable unwinds or retracts, rotating the spool and converting linear displacement into a proportional electrical signal via an integrated encoder. The PT801-0005-611-1212 combines durability (resistant to shock, vibration, and environmental contaminants) with high accuracy, making it suitable for harsh operating conditions where precise position feedback is critical for control and safety.
Technical Parameters
- Measurement Range: 5 inches (127 mm) full scale
- Output Signal: 4-20 mA analog current loop (two-wire)
- Accuracy: ±0.1% of full scale (including linearity, hysteresis, and repeatability)
- Resolution: Infinite (analog output); effectively limited by signal conditioning (typically 0.01% of range)
- Operating Temperature Range: -40°C to +85°C (-40°F to +185°F)
- Cable Specifications: 0.018-inch diameter stainless steel cable; maximum extension speed 10 ft/s (3 m/s)
- Spring Return Torque: 1.5 oz-in (1.06 N-cm) at full extension
- Electrical Connections: 12-pin MIL-C-5015 connector ( mating part required)
- Power Supply: 10-30 V DC (typically 24 V DC)
- Current Consumption: ≤ 25 mA (including load)
- Environmental Protection: IP67 (cable exit and housing); NEMA 6
- Shock Resistance: 1000 g peak (11 ms duration, half-sine)
- Vibration Resistance: 20 g (10-2000 Hz)
- Weight: Approximately 1.2 lbs (0.54 kg)
- Mounting: Two M5 threaded holes (recommended torque 8 in-lbs)
Usage Methods
- Installation:
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- Mount the sensor securely to a fixed structure using the provided M5 mounting holes, ensuring alignment with the moving object’s path to prevent cable side loading.
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- Attach the cable’s free end (fitted with a swivel connector) to the moving target, maintaining a straight line between the sensor and the attachment point to avoid cable abrasion.
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- Allow 1-2% cable slack to prevent tension when the object is at its minimum position.
- Wiring:
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- Connect the 12-pin MIL-C-5015 connector to a compatible mating connector (e.g., MS3102A 12S-3P).
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- Wire the 4-20 mA output to a PLC, DCS, or data acquisition system: connect the positive lead to the controller’s analog input and the negative lead to the controller’s common (0 V).
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- Apply 10-30 V DC power to the sensor, ensuring correct polarity to avoid damage.
- Calibration:
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- Verify the output signal at the minimum and maximum positions: 4 mA (0% range) and 20 mA (100% range) respectively.
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- Use the controller’s calibration tools to adjust for any offset or gain errors, if necessary.
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- Perform a full-range movement test to confirm linearity across the measurement range.
- Maintenance:
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- Inspect the cable quarterly for fraying, kinks, or corrosion; replace immediately if damaged.
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- Clean the cable with a dry cloth to remove debris that could cause wear.
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- Check the mounting hardware annually for tightness, especially in high-vibration environments.
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- Avoid exposing the sensor to temperatures beyond -40°C to +85°C to prevent damage to internal components.
System Introduction
The CELESCO PT801-0005-611-1212 functions as a critical position feedback device in closed-loop control systems, integrating with three key components:
- Mechanical Interface: The draw-wire assembly physically connects to the moving object, translating linear motion into rotational motion of the spool.
- Sensing Layer: An encoder converts the spool’s rotation into an electrical signal (4-20 mA), with the current proportional to the displacement (4 mA = 0 inches, 20 mA = 5 inches).
- Control System Integration: The analog output is transmitted to a controller (PLC/DCS), which uses the position data to adjust actuators (e.g., valves, motors) and maintain desired operating parameters.
In a typical application—such as monitoring the extension of a hydraulic cylinder in a press machine—the PT801-0005-611-1212 provides real-time feedback on piston position. The 4-20 mA signal is sent to a PLC, which adjusts hydraulic pressure to control the cylinder’s speed and stopping point, ensuring precise part forming and preventing overtravel.
Related Models in the Series
- PT801-0010-611-1212: 10-inch (254 mm) measurement range, identical output and specifications, suitable for longer displacement applications.
- PT801-0005-613-1212: 5-inch range with 0-10 V DC analog output, compatible with systems requiring voltage-based feedback.
- PT801-0005-621-1212: 5-inch range with RS485 (Modbus RTU) digital output, ideal for networked control systems.
- PT850-0005-611-1212: Heavy-duty variant with enhanced shock resistance (2000 g) and IP68 protection, designed for extreme environments (e.g., off-road vehicles).
- PT801-0005-611-2424: 5-inch range with 24-inch cable and extended temperature range (-55°C to +125°C), suitable for aerospace applications.
- RT900-0005-611-1212: Compact rotary potentiometer version, measuring angular displacement (0-360°) with the same electrical characteristics.
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