Q: When is a magnetostrictive sensor (POSICHRON) the right choice over a cable extension (POSIWIRE) or steel-tape extension (POSITAPE)?

Decision rule: accuracy, lifetime, and mounting form. Choose POSICHRON (magnetostrictive) when: • Contactless, wear-free is critical — high-cycle applications requiring millions of cycles (presses, injection moulding, production lines). • High accuracy required — ±0.02% f.s. linearity and 10 µm resolution. 5-10× better than cable extension. • Integrated inside hydraulic cylinder piston (rod-style PCST models) — sensor is protected inside the cylinder body, no external impact. • Underwater / high pressure — PCST27 pressure-proof up to 15 bar, cable extension can't survive this pressure. • Tight space — PCFP25's 8 mm flat profile fits where cable extension's spool doesn't. Choose POSIWIRE (cable extension) when: • Budget critical — POSICHRON typically 3-5× more expensive. • Low-medium cycle — a few strokes per hour, no need for millions of cycles. • Long stroke (above 5m) — POSICHRON max 5750 mm, POSIWIRE up to 50 metres. Choose POSITAPE (steel-tape extension) when: • Outdoor + dirt/ice/oil + medium cycle. • Mid-range stroke (max 20m). • Middle ground — more durable than POSIWIRE, more economical than POSICHRON. Rule of thumb: Hydraulic cylinder integration + high accuracy + high cycle → POSICHRON . Budget + long stroke → POSIWIRE . Outdoor + medium cycle → POSITAPE .

Question 1

When is a magnetostrictive sensor (POSICHRON) the right choice over a cable extension (POSIWIRE) or steel-tape extension (POSITAPE)?

Accepted Answer

Decision rule: accuracy, lifetime, and mounting form.

Choose POSICHRON (magnetostrictive) when:
• Contactless, wear-free is critical — high-cycle applications requiring millions of cycles (presses, injection moulding, production lines).
• High accuracy required — ±0.02% f.s. linearity and 10 µm resolution. 5-10× better than cable extension.
• Integrated inside hydraulic cylinder piston (rod-style PCST models) — sensor is protected inside the cylinder body, no external impact.
• Underwater / high pressure — PCST27 pressure-proof up to 15 bar, cable extension can't survive this pressure.
• Tight space — PCFP25's 8 mm flat profile fits where cable extension's spool doesn't.

Choose POSIWIRE (cable extension) when:
• Budget critical — POSICHRON typically 3-5× more expensive.
• Low-medium cycle — a few strokes per hour, no need for millions of cycles.
• Long stroke (above 5m) — POSICHRON max 5750 mm, POSIWIRE up to 50 metres.

Choose POSITAPE (steel-tape extension) when:
• Outdoor + dirt/ice/oil + medium cycle.
• Mid-range stroke (max 20m).
• Middle ground — more durable than POSIWIRE, more economical than POSICHRON.

Rule of thumb: Hydraulic cylinder integration + high accuracy + high cycle → POSICHRON. Budget + long stroke → POSIWIRE. Outdoor + medium cycle → POSITAPE.

Question 2

Profile selection: Square (PCQA), Round (PCRP), Flat (PCFP), Rod (PCST) — which goes where?

Accepted Answer

POSICHRON is offered in 4 form factors — selection follows mounting space + application type.

Square Profile (PCQA — Quadratisches Aluminium):
• Standard industrial mounting — externally mounted next to the machine.
• Assumes wide mounting area, rugged aluminum housing.
• PCQA22 (IP64): enclosed indoor, economical.
• PCQA24 (IP67/IP69): outdoor, wash-down compatible.
• Guided magnet option — magnet mechanically aligned to the profile.

Round Profile (PCRP):
• Round mounting area (e.g., beside cylinder body, on pipe).
• PCRP21 (IP64): standard industry, compact round.
• PCRP32 (IP68/IP69): continuous underwater operation, subsea.
• Aluminum/stainless steel combination.

Flat Profile (PCFP):
• Tight mounting space — narrow machine cavities where a high profile doesn't fit.
• PCFP23 (IP64, standard height): economical flat profile.
• PCFP24 (12 mm height, IP67/IP69): mid-thin, wash-down compatible.
• PCFP25 (8 mm height, IP67): the thinnest in class, plastic injection moulds + ultra-narrow OEM.

Rod-Style (PCST — Stab):
• Integrated inside hydraulic or pneumatic cylinder piston.
• Cylinder body protects the sensor; magnet travels inside the piston.
• PCST24/25 (IP67/IP69): standard hydraulic cylinder, dry environment.
• PCST27 (IP68/IP69, 15 bar): underwater + high-pressure hydraulic.

Decision table:
• Wide area + external mount → PCQA (square) or PCRP (round)
• Narrow horizontal area, thin profile → PCFP (flat)
• Inside hydraulic/pneumatic cylinder → PCST (rod)
• Underwater / high pressure → PCST27 or PCRP32

Question 3

Hydraulic cylinder piston integration: what's the difference between PCST24 and PCST25?

Accepted Answer

Both are rod-style (Stab) form factor, designed to be integrated inside a hydraulic cylinder piston. The difference is in connection type:

PCST24:
• M12 8-pin connector standard (cable option also available).
• CANopen version: 0.3 m cable + M12 5-pin connector.
• Higher maintenance convenience — sensor swap means disconnecting the connector, no cable change.
• Typical use: standard hydraulic cylinders, equipment with periodic maintenance.

PCST25:
• 2 m standard cable output (connectorless, permanent).
• CANopen: 0.3 m cable + M12 5-pin connector (separate for CAN).
• More economical installation (no connector cost).
• Typical use: embedded installation, applications where sensor swap is rare.

Decision:
• Maintenance convenience, frequent swaps → PCST24
• Budget, permanent installation → PCST25

Shared features:
• Range: 100-5750 mm (in 10 mm increments)
• Sensor rod: 316L stainless steel (AISI 316L)
• Head: AIMgSi (Aluminum/Magnesium/Silicon alloy)
• IP: IP67/IP69
• Accuracy: ±0.02% f.s.
• Output: 0-10 V · 0.5-10 V · 0.5-4.5 V · 4-20 mA (3-wire) · PMU programmable · SSI · CANopen
• Shock: 50 g (100 shocks)

Whichever is chosen, integration inside the cylinder piston is mechanically the same — only the external wiring differs.

Question 4

Ultra-thin flat profile: how do I decide between PCFP24 (12 mm) and PCFP25 (8 mm)?

Accepted Answer

Both are POSICHRON's flat profile models for tight spaces. Decision follows height criticality + IP requirements.

PCFP24 (12 mm height):
• IP67/IP69 — usable in wash-down and washing environments.
• 12 mm height — for medium-thin tight spaces.
• Typical use: plastic injection mould cover position, compact OEM devices, food-processing lines.
• Standard in ASM lineups since 2010.

PCFP25 (8 mm height — thinnest in class):
• IP67 (no IP69 — flat profile structure at 8 mm can't tolerate high-pressure wash-down).
• Only 8 mm height — the thinnest magnetostrictive sensor in the industry.
• Introduced by ASM in 2010 — launched for ultra-narrow mounting areas.
• Typical use: microelectronics manufacturing equipment, pharma line narrow mechanism, robotic small-arm position measurement.
• Limitation: cable output (connectorless) — due to limited access in tight spaces.

Decision:
• 12 mm available + wash-down required → PCFP24 (IP67/IP69)
• Less than 8 mm + standard IP sufficient → PCFP25 (IP67, cable output)
• Standard flat profile sufficient + budget → PCFP23 (IP64 standard flat)

Shared features:
• Range 100-5750 mm
• Same output interfaces (Voltage / 4-20 mA / SSI / CANopen)
• Accuracy ±0.02% f.s., resolution 10 µm
• Magnet slides on profile — contactless, zero wear

Question 5

Underwater / high-pressure applications: when is PCST27 (15 bar) mandatory?

Accepted Answer

PCST27 is the pressure-rated specialised model in the POSICHRON family. Standard PCST24/25 provide IP67/IP69 in oily environments but are not designed for continuous operation in pressurised fluid. PCST27 differs by:

1) 15 bar pressure resistance:
The sensor body withstands continuous 15 bar hydraulic pressure. This equates to 150 m depth subsea. A standard hydraulic cylinder may have up to 200 bar internally — but that pressure is inside the piston; the sensor rod itself, which shares the cylinder body, does not see this pressure directly.

2) Water-proof cable seal:
The cable entry at the sensor head is specifically sealed. A standard cable gland delivers IP67/IP69 but may leak over time under continuous 0.5-1 m water immersion. The PCST27 sealed cable entry guarantees permanent underwater operation.

3) IP68/IP69 combination:
IP68 = continuous immersion (depth model-dependent). IP69 = high-pressure hot-water jet (wash-down standard). PCST27 provides both.

Typical PCST27 applications:
• Subsea hydraulic cylinders — ship bilge pumps, bilge level measurement, marine platform position control.
• High-pressure tank level — chemical tanks, pressurised water reservoirs, hydraulic accumulators.
• Mining shaft lift — continuous moisture + dust + pressure exposure.
• Food-processing high-pressure cleaning — facilities with pressure above standard wash-down levels.

Alternative: PCRP32:
Round profile, designed for underwater operation. IP68/IP69, continuous immersion. But pressure rating lower than PCST27 (see datasheet for exact value). Different profile — PCRP32 is externally mounted, PCST27 integrates inside the cylinder.

Decision:
• Inside cylinder + pressurised fluid → PCST27 only option
• External mount + continuous immersion → PCRP32
• Dry hydraulic cylinder + standard oil pressure → PCST24/25 sufficient

Question 6

Position magnet selection: when is a guided magnet required?

Accepted Answer

In the POSICHRON family, the moving part the sensor reads is called the position magnet. The magnet travels along the sensor profile; the sensor reads its position contactlessly.

Two magnet types exist:

1) Floating Magnet (Standard):
Attached to the moving part, travels freely above the profile. Up to 19 mm gap between magnet and profile is tolerated (model + profile dependent).

• Advantage: No contact between magnet and profile, zero mechanical wear.
• Advantage: Flexible mechanical tolerance for the moving part.
• Limit: Drift beyond 19 mm causes magnetic signal loss (false reading).

2) Guided Magnet:
Magnet is mechanically aligned with the sensor profile — slides in a track attached to the profile. Distance is fixed, no drift possible.

• Advantage: Maximum accuracy guaranteed (magnet always at the same distance).
• Advantage: In high-vibration environments, magnet doesn't rub against the profile.
• Limit: Mechanical contact exists (magnet in track) — continuous friction may eventually wear the profile surface, but this doesn't affect sensor electronics.

When is a guided magnet required?
• Moving part has tight mechanical tolerance — magnet drifts laterally/vertically, may exceed the 19 mm gap limit.
• Maximum accuracy needed — precision position control, measurement equipment, quality control.
• High-vibration environment — presses, hammers; a free magnet may fly off due to vibration.

When is a floating magnet sufficient?
• Moving part travels straight, the gap to the profile stays fixed.
• Mechanical tolerance is 5-10 mm, well within 19 mm.
• Cost-critical (guided magnet is more expensive).

Which models offer guided magnet?
PCQA22, PCQA24, PCRP21, PCFP23, PCFP24, PCFP25 — all profile-style models. Rod-style (PCST) models integrate the magnet inside the piston, so the "guided" concept doesn't apply.

For site-specific magnet selection, contact IMB Electric engineering support.

Question 7

POSICHRON output interfaces: what's the difference between PMU programmable analog and SSI digital?

Accepted Answer

The POSICHRON family supports a wide output range meeting modern industrial standards — more options than POSIWIRE, because magnetostrictive technology naturally supports high-accuracy digital outputs.

Analog Outputs:

0-10 V Voltage: Standard analog. Accuracy depends on PLC card quality. Short-medium distance (≤100 m).

0.5-10 V or 0.5-4.5 V Voltage: Automotive standard. Easy fault detection on PLC (0 V indicates error). Common in mobile machinery controllers.

4-20 mA Current (3-wire): Most robust analog option. Noise-immune up to 1000 m. Industry-standard default.

PMU — Programmable Analog (PMUV / PMUI):
Voltage or current output, user-programmable upper/lower limits. Example: PCQA24's 100-5750 mm physical range, if only 500-2000 mm is used, can be PMU-mapped to 0-10 V output. The sensor utilises full dynamic range, accuracy increases.
• Advantage: Maximum resolution + flexibility. Same sensor adapts to different stroke ranges across applications.
• Limit: Requires initial PMU software programming (USB or CAN).

Digital Outputs:

SSI 12/14/16 bit: Synchronous Serial Interface. Accuracy 16 bit = 65,536 steps. Requires PLC SSI input card (Siemens, Allen-Bradley, ABB available). Zero noise, highest accuracy.
• POSICHRON SSI resolution: 5, 10, 20, 50 or 100 µm selectable.
• Typical use: high-end CNC, robotics, precision press applications.

CANopen: Automotive industry standard. 127 sensors per bus. Available on PCQA22/24, PCRP21, PCFP series, PCST24/25 and specials.
• POSICHRON CANopen resolution: 50 µm (fixed).

SAE J1939: Heavy-vehicle standard (truck, tractor, off-highway).

Decision table:
• Standard factory interior → 4-20 mA
• High accuracy, PLC has SSI card → SSI 16 bit
• Mobile machinery → CANopen or J1939
• Same sensor across different strokes → PMU programmable
• Automotive 0.5-4.5 V compatibility → 0.5-4.5 V

Question 8

What are the POSICHRON warranty, calibration, and IMB Electric regional support conditions?

Accepted Answer

Warranty: ASM Sensor offers a 2-year manufacturer warranty on all POSICHRON models. Out-of-warranty cases:
• Use outside datasheet limits (temperature, pressure, IP)
• Mechanical impact damaging the sensor rod
• Floating magnet used where guided was needed, rubbing the sensor profile
• Unauthorised opening or repair
• Pressure above 15 bar on the PCST27 model

Calibration: POSICHRON is based on magnetostrictive technology — no mechanical wear, so calibration intervals are long. Typically 5-10 years. For field verification:
• Sensor signals measured at full range (max stroke) and 0 position.
• Must remain within ±0.02% f.s. linearity.
• IMB Electric provides accredited calibration services in Türkiye (TÜRKAK scope).

Sensor replacement: POSICHRON is contactless — no wear, no self-degradation. Failure mode is typically external impact (rod breakage) or over-temperature (outside datasheet limit).

Magnet life: Standard position magnet (neodymium/ceramic) is long-life — magnetism doesn't fade. Only limit is high temperature (>150°C demagnetises neodymium) — in such cases, high-temperature magnet (samarium-cobalt) is preferred.

IMB Electric Regional Support:
IMB Electric is listed for Türkiye on ASM Sensor's official global distribution network, with authorisation extending to Türkiye + the Middle East + North Africa + Western Asia.

Regional services:
• Stock delivery (İstanbul İkitelli OSB)
• Fast quotation (24-48 hours)
• Accredited calibration and repair (TÜRKAK scope)
• Application-based engineering support — sensor selection, hydraulic cylinder integration assistance, magnet selection, certification documentation
• Local management of warranty processes
• Turkish + English + Arabic (for the Middle East) technical documentation
• Field training (on request)

Contact: info@imbelectric.com · +90 212 544 59 59 · imbelectric.com

Question 9

How do I use a POSICHRON sensor with a slider element (linear slider)? What is a push rod?

Accepted Answer

POSICHRON magnetostrictive sensors operate on the principle of a position magnet moving along the sensor rod. In some applications, the moving part cannot directly reach the magnet — in this case, a push rod (slider element) bridges the gap.

How Push Rod Solution Works:

POSICHRON sensor rod is mounted next to/under the equipment.
Position magnet slides along the sensor rod (unguided or guided).
PCGS push rod connects the magnet to the moving part — works like a push bar.
PCGK link at the push rod end joins to the moving part — articulated connection.
When the moving part rotates or translates, the push rod carries the magnet along the sensor rod.

PCGS Push Rod Sizes:

Length 75-499 mm — short stroke applications
Length 500-1249 mm — medium stroke
Length 1250-2000 mm — long stroke
Each size includes the PCGK link.

Typical Push Rod Applications:

Hydraulic cylinder position: POSICHRON sensor next to the cylinder body, piston tip moves — push rod carries magnet to piston position.
Press table slider: Press table moves, sensor beside the table — push rod connection.
Valve position feedback: External position measurement of valve body — push rod pulls magnet from valve stem.
Lift door position: Sensor beside door + push rod linked to door motion.

Push Rod vs Direct Mounting — Decision:

Moving part passes directly beside the sensor rod → Position magnet directly mounted (push rod not needed, economical)
Moving part on a separate axis from the sensor rod → Push rod solution needed
Travel distance exceeds 2 metres → Push rod not mechanically suitable, use alternative technology (POSIWIRE or POSITAPE)

Advantages:

Adapts to complex-geometry applications
Tolerance for angular misalignment between sensor and moving part
Isolates moving-part vibration/shock from sensor

Disadvantages:

Push rod length can reduce measurement accuracy (mechanical oscillation)
Extra mechanical component → additional maintenance point
Cost increase (push rod + link)

IMB Electric engineering team provides push rod selection + installation consulting.

About the POSICHRON® — Magnetostrictive Position Sensors series

01When is a magnetostrictive sensor (POSICHRON) the right choice over a cable extension (POSIWIRE) or steel-tape extension (POSITAPE)?

02Profile selection: Square (PCQA), Round (PCRP), Flat (PCFP), Rod (PCST) — which goes where?

03Hydraulic cylinder piston integration: what's the difference between PCST24 and PCST25?

04Ultra-thin flat profile: how do I decide between PCFP24 (12 mm) and PCFP25 (8 mm)?

05Underwater / high-pressure applications: when is PCST27 (15 bar) mandatory?

06Position magnet selection: when is a guided magnet required?

07POSICHRON output interfaces: what's the difference between PMU programmable analog and SSI digital?

08What are the POSICHRON warranty, calibration, and IMB Electric regional support conditions?

09How do I use a POSICHRON sensor with a slider element (linear slider)? What is a push rod?