PFA Switchmax® Sensor Connectivity by Jennifer Creative

SENSOR CONNECTIVITY PLUG & WIRING PLAY LED LIGHAND TS

WE TAKE SENSOR INTEGRATION TO A NEW LEVEL OF PERFORMANCE UPGRADE MACHINE PERFORMANCE & PROFITABILITY! UPGRADE TO PFA!

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Located just North of Milwaukee, Wisconsin, PFA is an ISO 9001 Registered leader in the design and manufacture of Quick Die Change Systems (QDC), Specialty Injection Mold Components, Specialty Industrial Cylinders, Quick Mold Change Systems (QMC), Multi-Slide Die Casting Solutions, and Robotic Automation End-Effectors. • KOR-LOK™ Side-Action Systems and DIE-LOK™ Multislide Systems for pre-loading and locking moveable cores on injection molds and die cast dies, provide improved part quality, speed and performance over traditional cam pin and toggle methods. • Robotic Automation End Effectors. Modular products allow the coupling of Grippers, Gripper Pads (GP), Compliance Devices (RCC) and Crash Protection (OPD) into a simple and integrated robotic end-effector solution.

N118 W18251 Bunsen Drive Germantown, WI 53022 (262) 250-4410 • Fax (262) 250-4409 switchmax@pfa-inc.com www.pfa-inc.com

• Quick Die Change Systems provide easily customized solutions for stamping die “quick change”. Bolster extensions, die rails/lifters, check valve and locking clamps, and electronic 5,000 psi pump controllers are just a few of the options available. • Hydra-Jaws™ Quick Mold Change and HydraLatch™ Quick Knockout Systems provide consistent clamping and support rapid mold changes for a wide range of mold sizes in a single machine. Clamps move to fit the mold! • Self-Locking and Braking Cylinders hold large loads many times that of standard cylinders, even with pressure removed, making them ideal for a wide variety of industrial applications, where large load capacity or loss of air scenarios demand greater performance and simplicity. Our staff is committed to providing you with the best possible products and service. PFA offers a wide array of standard products plus custom solutions for especially challenging applications. Contact us with your needs. We will be glad to serve you!

2 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

KOR-LOK® Eliminates Core Face Backup! (Traditional system backup may be .020” or more!)

CONTENTS Why Switchmax® Connectivity? . . . . . . . . . . . . . . . 4 Choosing a System

Perfect Part Quality from all your Core-Pull Side-Actions.

SWITCHMAX® Components. . . . . . . . . . . . . . . 6

Kor-loK siDe-action systeMs

Accessories & Wiring

Sensor Dongles. . . . . . . . . . . . . . . . . . . . . . . . 10 Field Wireable Connectors. . . . . . . . . . . . . . . . 10 Double Ended DC Connectivity Cables – M12 with 5 pins. . . . . . . . . . . . . . . . . . . . . . . . 11 Single Ended DC Connectivity Cables – M12 with 5 pins. . . . . . . . . . . . . . . . . . . . . . . . 11 Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . 12 XLT AND XHT PFA Dry Contact/ Relay Sensors. . . . . . . . . . . . . . . . . . . . . . . . . 13

switchMax

sensor connectivity

vS.

PNP Low Profile PFA Proximity Sensors . . . . . 14 Troubleshooting Installation with Mechanical Switches (XLT/XHT/SPDT). . . . . . . . . . . . . . . . . . . . . . . 16 Installation with Solid State Sensors (PNP). . . 20 Schematics I.B. Two KOR-LOK System . . . . . . . . . . . . . . . 24

TRadiTiOnaL Side-acTiOn SySTemS

II.B. Two Cylinder System - PNP Sensor. . . . . 28

Accessories & Wiring

KOR-LOK™ Side-acTiOn SySTemS

• We take Moveable Slides and Cores to a New Level of Performance. •Upgrade Machine Performanc & Profitability • Upgrade to PFA!

Choosing a System

Z er o MoveMcore D ur e n t injectiing on

now with

Why Switchmax®?

Zero Flash Zero DeFect Parts

Mold OPEN Core Out Mold CLOSEd Core OUt

CAN’T DO IT!

Mold CLOSEd Core IN

Troubleshooting

Core PRE-LOAdEd Against FULL Injection Pressure

CAN’T DO IT!

learn More online!

• How It Works Animations • Complete Product Specs/FAQs • Online Articles • Online Design Center N118 W18251 Bunsen Drive • 3D CAD downloads Germantown, WI 53022 • Online Quotes

pfa-inc.com Designed & Made in USA

(262) 250-4410 Fax (262) 250-4409

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SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 3

WHY SWITCHMAX CONNECTIVITY?

Do you need multiple sensor signals to a single controller input with light indications to show positions? SWITCHMAX solves it! ®

SWITCHMAX® connectivity continues to evolve to cover a wide variety of interfaces, options, and applications. With design roots in the molding industry, mold sensor connectivity is still an excellent example of SWITCHMAX® success - connecting multiple sensors to a single input – multiple core position sensors to the single set and single pull input on an injection molding machine. Not surprisingly, the need to integrate multiple sensors only becomes more common as the ever-increasing automation demands intersect with IO limited designs and legacy systems.

Can we plug in a “gizmo” that easily lets us put on more sensors and interface easily with the limited machine control? YES! The “gizmo” is SWITCHMAX®… While not often considered, integration with a simple control system interface requires combining many position switch and sensor “on” signals into a single input signal. The need for simple signal integration is everywhere. Fundamentally, the machine “needs to know” when all the appropriate indications are “made” for the next step in the process. The control’s single input is the place where that will be “made known” to the machine. Integrating different sensors and switches While the terms are often used interchangeably, switch often refers to devices with mechanical actions and sensor to devices that use “electronics only”. Many mechanical switches look mechanical, while a few have the shape of a solid-state device. Regardless of outward appearances, mechanical switches and proximity sensors, employ differing technologies not easily linked together. Proximity sensors require power and individual connections to inputs on the PLC. Each sensor has an individually supplied

voltage (+ and -) and a separate signal path to the control. The PLC/control software programming integrates senor signals for proper machine indication, offering smaller sizes at a relatively low cost. Mechanical sensors (switches) pass signals through a twowire contact and do not require power to operate. Limited to signals only, switches easily combine in series to pass a signal to the control. Mechanical switches are often large, relatively more expensive, and commonly added to products for ease of wiring. SWITCHMAX® integrates both proximity and mechanical sensors into a common system, providing the necessary single channel outputs, allowing more freedom to select products with sensors, and supporting upgrades to inputlimited and legacy systems. Adding Light indication and modular simplicity For any system, this goal is often defeated in swappable subsystem arrangements where sensor quantities vary. Routing sensor inputs independently to the machine would require specific programming for each subsystem. In injection molding for example, molds are the subsystem. Each mold has differing quantities and styles of sensors. As the Injection Molding Machine (IMM) limits the input to the control to one signal, mechanical switch sensors are easy to connect in series, and proximity sensors have complex power needs and connectivity, the use of mechanical switches for injection molds is popular. However, while series connections allow for simple wiring and connection to single input controllers, they do not show individual switch positions or track continuity. Also, many new products operate exclusively with proximity sensors, making the addition of mechanical

4 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

SWITCHMAX CONNECTIVITY IS THE IDEAL SOLUTION: ®

SWITCHMAX INTEGRATES… ®

Multiple Sensor Styles – Combines Plunger and Rocker (SPDT) style and Solid-state (PNP) sensors.

Sensor Connectors – Field Wireable Connectors Many sensors in common usage have terminal connections or bare wires. Field wireable Connector (FWC) plug ends and short wired plug dongles are available to add standard plugs to sensors for easy linking to other SWITCHMAX® components. Converting hand-wired equipment to standard connectors provides easy replacement when parts are damaged. It eliminates the need to understand schematics, as the new equipment matches the old and the wireable plugs are easily replaced. Multiple Input Controller Adaptability Relay Sensor Adapters (SM-RSA) and Relay Power Adapters (SM-RPA) provide interfaces that ensure easy connectivity between the sensors and downstream control inputs. Relay Sensor Adapters can be placed on sensor side installations to bring together complex hubs of different sensor/switch groups and connect them to sourcing or sinking single input controls. Relay Power Adapters are machine side solutions, often providing an independent power supply and neutral wire where none is available or converting the machine to a more desirable electric configuration.

SWITCHMAX SHOWS… ®

Junction Box/Hub with LED lights Multiple sensor locations route to a SWITCHMAX®integration hub (Junction Box), which can be located for maximum visibility and ease of access. LED light indication of sensor status is clearly visible and lights are connected in series to aid in troubleshooting position sensing issues or unexpected readings. If a sensor/switch is out of position, the signal will not continue onward to the next sensor, allowing personnel to easily see the out of position location and check the machinery and switch for positioning or electrical issues.

pfa-inc.com Plunger, Rocker, and other Dry Contact/Relay Switches (Form C SPDT) can be combined with 3 wire DC proximity Sensors (PNP) to allow for connecting sensors and switches from a variety of manufactures. Some applications require legacy and alternative control inputs, including AC power and zero voltage DC (sinking) inputs. SWITCHMAX® can

SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 5

Troubleshooting

Multiple Sensor Inputs – Combines single “on” sensors or “two position” sensors to single inputs. Applications may have single position output sensors (on/off) or may have multiple output switches (forward/back). Specific yet common cables are used to integrate a variety of sensors together, so that regardless of which cable you need, the cable is selectable from common stocks, plug and play ready, and easily swapped out.

SWITCHMAX MODULARIZES…

Accessories & Wiring

The ideal solution would be an off the shelf system providing replaceable “plug and play” components, light indications for all sensors/switches, which also covers all possible situations, integrates easily with standard sensor technology already in use, and is simple for users to implement, troubleshoot, and repair quickly with minimal effort. SWITCHMAX® connectivity is the ideal solution.

Redundant Sensor Inclusion. Backup sensors for reading specific equipment position, such as direct core measurement on injection molds, is easily integrated with other sensors. Many backup systems are single indication and need to combine with two-position indication main indicators. Common cables and modular connectors provide this function.

Choosing a System

To control this randomness, some standardization on specific components such as sensors and machine interface plugs is helpful. However, standard components are often combined with connections using custom layouts, complex documentation, unique drawings, unexpected wire colors, and undocumented multiple point methods such as terminal blocks or wire nuts. When these wiring networks, often described as spaghetti networks, stop working, they continue to be the source of daily intractable problems that erode productivity and profitability.

accommodate those needs with standardized adapters.

Why Switchmax®?

switches costly. In all cases, troubleshooting out of position components or sensor/switch failures is extremely difficult for larger systems, even for those familiar with the wiring scheme. Troubleshooting for those unfamiliar with the wiring plan, may be overwhelming.

BUILDING A SYSTEM FROM PARTS OR SELECTING A PACKAGE IS EASY!

CHOOSING A SYSTEM SWITCHMAX® features the typical combining of multiple two-position signals into one two-positon output signal, while simultaneously providing light indication of sensor positions in an easily visible location. Applications using only one position indications and applications with a mixture of single input and two position indictations are easily configured.

signals can be adapted to work within the SWITCHMAX® framework. Three wire PNP (voltage output high) sold state sensors with typical DC power ratings are also easily integrated. Off the shelf modular components and connectors are available to expand the system to cover an unlimited number of mechanical switches or up to 24 PNP two channel (48 sensor) configurations.

Applications commonly consist of two to eight, twoposition actions (4 to 16 switches/sensors). SWITCHMAX® features an 8 port (16 switch/sensor) junction box, with modular cables and components. Many combinations of components are possible, including connection of other “contact style” limit switches and mixing PNP sensors with contact switches. Almost any mechanical “dry contact” switch designed for use with typical 10-60 Volt DC control

Dedicated mechanical switch cables connect directly with PFA’s KOR-LOK™ Side-Action System switches and other common PNP (output high) sensors. A variety of modular adapters are also available to accommodate unique and legacy installations. For further assistance in selecting a system, please contact a PFA applications specialist.

SM-DCH-E5FN-240 HOME RUN CABLE

SPLITTER CABLE SET

BROWN - POWER (SET) WHITE - SIGNAL (SET) BLACK - POWER (PULL) BLUE - SIGNAL (PULL) GREY - NEUTRAL

SLIDE #2

SLIDE #4

2 A

PWR

1 SLIDE #3

RELAY SENSOR ADAPTER BOX SM-RSACOM-1A

PULL

SPLITTER CABLE

SLIDE #1

SLIDE #6

4 3 SLIDE #5

6 A

B 7

SLIDE #7

SM-RJB-8A JUNCTION BOX

SLIDE #8

WIRE TO PLUG TO INJECTION MOLDING MACHINE

SET

SLIDE #2 ACTION

SM-JPR

PULL

SENSOR/ SWITCH

SM-FWCE5MS

SLIDE #1 ACTION

6 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

WIRE TO PLUG TO INJECTION MOLDING MACHINE BROWN - +VDC WHITE - SIGNAL (SET) BLACK - COMMON BLUE - SIGNAL (PULL) GREY - (-)

SWITCHMAX COMPONENTS ®

Why Switchmax®?

A variety of SWITCHMAX® components are available. Major components are shown below, some more customized cables and connection plugs for specific sensors are not included. Please see the accessories section for a variety of additional items or contact a PFA specialist for details on options for specific sensors and applications.

SM-RJB-8A 8 port modular connection hub for combining single position or two position information from 8 locations. Ports are 5 pin female M12 (E5F) connections. The 5 pin male M12 (E5M) home run port at bottom provides for incoming voltage and neutral connections as well as two output wires. One for each channel. Set and Pull or forward and back are typical uses for hydraulic cylinder or slide position indications.

JUMPER PLUG FOR RELAY JUNCTION BOX Sealed plug to fill in empty ports on the Relay Junction Box. Plugs contain internal wiring to provide continuity to serial connections and to extend the signals to the output.

DC HOMERUN CABLE – RJB OUTPUT CABLE Routes power to and signals from the RJB. 240 inch long (20ft/6m) cable with 5 pin male M12 ninety degree (E5FN) plug end and flying leads (no plug) on the far end to allow terminating with a field wireable connector (FWC) or application specific plug.

pfa-inc.com SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 7

Troubleshooting

SM-DCH-E5FN-240

Accessories & Wiring

SM-JPR

Choosing a System

RELAY JUNCTION BOX (PLAIN NO JUMPERS)

SM-KLS-2A KL SPLITTER CABLE WITH STRAIGHT END (AT RJB) Connects switches to RJB. Commonly used to plug directly into the two KOR-LOK Side-Action System mechanical sensors (XLT and XHT styles) – set and pull. The splitter junction in the cable combines these two sensors signals into a single cable to the RJB plug end (E5MS). Split also provides cross checking of sensor inputs to ensure mechanical sensors are not out of position. General use of the cable is for two position cylinders or indicators with mechanical SPDT configurations. The 3 pin female ninety degree (M3FN) plugs often connect to short dongle plugs from mechanic switches with the SPDT terminals or short cables with a matching field wireable connector installed (M3MS).

SM-PNP-2A PNP SPLITTER CABLE WITH STRAIGHT END (AT RJB) Connects Sensors to the RJB. Commonly used to plug directly into the two KOR-LOK Side-Action System PNP style sensors – set and pull. The splitter junction in the cable combines these two sensors signals into a single cable to the RJB plug end (E5MS). General use of the cable is for two position cylinders or indicators with 3 wire PNP sensors (voltage signal output high when reading target). The M12 female straight (E5FS) plugs often connect to short dongle plugs from solid state proximity sensors (PNP voltage high outputs) or short cables with a matching field wireable connector (FWC) installed (E5MS).

SM-RSACOM-1A, -2A, -3A RELAY SENSOR ADAPTOR – UNIVERSAL SWITCH HIGH OR 0 VDC Univeral machine interface. Provides machine controller with signal voltage needed to operate. Allows system to be switched between machines with different controller voltage parameters – O VDC inputs or 24 VDC inputs. Also available in -2A, and -3A options to integrate multiple Junction boxes together on installations with 16 and 32 inputs (up to 32 and 48 sensors).

8 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

SWITCHMAX® PACKAGED SYSTEMS – DC - PFA MECHANICAL SWITCHES

KL-SM-DC8PKG – 2S

Two KOR-LOK™ Side-Action SWITCHMAX® Package [1 RJB with 6 JPR installed – 2 ports open, 2 KLS-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

KL-SM-DC8PKG – 3S

Three KOR-LOK™ Side-Action SWITCHMAX® Package [1 RJB with 5 JPR installed – 3 ports open, 3 KLS-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

KL-SM-DC8PKG – 4S

Four KOR-LOK™ Side-Action – SWITCHMAX® Package [1 RJB with 4 JPR installed – 4 ports open, 4 KLS-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

KL-SM-DC8PKG – 5S

Five KOR-LOK™ Side-Action - SWITCHMAX® Package [1 RJB with 3 JPR installed – 5 port open, 5 KLS-2A Splitter Cable, and 1 DCH 240” (6m) DC Homerun Cable]

KL-SM-DC8PKG – 6S

Six KOR-LOK™ Side-Action SWITCHMAX® Package [1 RJB with 2 JPR installed – 6 ports open, 6 KLS-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

KL-SM-DC8PKG – 7S

Seven KOR-LOK™ Side-Action SWITCHMAX® Package [1 RJB with 1 JPR installed – 7 ports open, 7 KLS-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

KL-SM-DC8PKG – 8S

Eight KOR-LOK™ Side-Action – SWITCHMAX® Package [1 RJB with No JPR installed – 8 ports open, 8 KLS-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

Choosing a System

One KOR-LOK™ Side-Action - SWITCHMAX® Package [1 RJB with 7 JPR installed – 1 port open, 1 KLS-2A Splitter Cable, and 1 DCH 240” (6m) DC Homerun Cable]

Why Switchmax®?

KL-SM-DC8PKG – 1S

SWITCHMAX® PACKAGED SYSTEMS – DC – PFA PNP SENSORS

SM-PNP-DC8PKG – 2S

Two Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with 6 JPR installed – 2 ports open, 2 PNP-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

SM-PNP-DC8PKG – 3S

Three Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with 5 JPR installed – 3 ports open, 3 PNP-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

SM-PNP-DC8PKG – 4S

Four Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with 4 JPR installed – 4 ports open, 4 PNP-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

SM-PNP-DC8PKG – 5S

Five Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with 3 JPR installed – 5 port open, 5 PNP-2A Splitter Cable, and 1 DCH 240” (6m) DC Homerun Cable]

SM-PNP-DC8PKG – 6S

Six Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with 2 JPR installed – 6 ports open, 6 PNP-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

SM-PNP-DC8PKG – 7S

Seven Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with 1 JPR installed – 7 ports open, 7 PNP-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable] Eight Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with No JPR installed – 8 ports open, 8 PNP-2A Splitter Cables, and 1 DCH 240” (6m) DC Homerun Cable]

pfa-inc.com SM-PNP-DC8PKG – 8S

SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 9

Troubleshooting

One Cylinder PNP Sensors - SWITCHMAX® Package [1 RJB with 7 JPR installed – 1 port open, 1 PNP-2A Splitter Cable, and 1 DCH 240” (6m) DC Homerun Cable]

Accessories & Wiring

SM-PNP-DC8PKG – 1S

SENSORS, DONGLES, AND FIELD WIREABLE CONNECTORS BRING IT ALL TOGETHER FOR MODULARITY

ACCESSORIES & WIRING SENSOR DONGLES SM-SEN-E5MS

SENSOR (PNP OR 2 POSITION SWITCH) DONGLES Five Pin E style cable plug with sensor side flying leads for adding a short cable with plug to a sensor with terminal lug connections

SM-SEN-M3MS SENSOR (SPTD OR MECHANICAL) DONGLES Three PIn M style cable plug with sensor side flying leads for adding a short cable with plug to a sensor with terminal lug connections

FIELD WIREABLE CONNECTORS SM-FWC-E5MS SENSOR (PNP OR 2 POSITION SWITCH) DONGLES Five Pin E style cable Field Wireable Connector. Connect to sensors with wires or use to shorten cables with E5MS plugs. Commonly used to create custom length cables from the sensors to the Relay Junction Box (RJB).

SM-FWC-M3MS SENSOR (SPTD OR MECHANICAL) DONGLES Three Pin M style cable Field Wireable Connector. Connect to sensors with wires or use to shorten cables with E3MS plugs.

10 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

SM-RTB-1A RELAY TEST BOX

DOUBLE ENDED DC CONNECTIVITY CABLES – M12 WITH 5 PINS

Why Switchmax®?

Relay Test Box is used for testing sensors and powering RJB Box for short duration testing. (not designed for long term testing due to limited battery capacity)

Typically used for connections from Sensor with installed Field Wireable Connector (FWC) or molded cable to the Relay Junction Box or from a Relay Junction Box (RJB) Home Run port to an Adapter Box (RSA/RPA). Various cable lengths may be available.

SM – DCA – E5FN-40-E5MS

DC Adaptor Cable 40” – Female90 to Male Straight (1m)

SM – DCA – E5FN-80-E5MS

DC Adaptor Cable 80” – Female 90 to Male Straight (2m)

SM – DCA – E5FN-…-E5MS

DC Adaptor Cable (length)” - Female 90 to Male Straight (varies)

Choosing a System

90 DEGREE TO STRAIGHT

STRAIGHT TO STRAIGHT

DC Adaptor Cable 40” – Female Straight to Male Straight (1m)

SM – DCA – E5FS-80-E5MS

DC Adaptor Cable 80” – Female Straight to Male Straight (2m)

SM – DCA – E5FS-??-E5MS

DC Adaptor Cable (length)”– Female Straight to Male Straight (varies)

SINGLE ENDED DC CONNECTIVITY CABLES – M12 WITH 5 PINS

Accessories & Wiring

SM – DCA – E5FS-40-E5MS

Typically used for connections from Sensor with installed FWC or molded cable to the Relay Junction Box or from a Relay Junction Box (RJB) Home Run port to an Adapter Box (RSA/RPA) where the customer also desires to use a Field Wireable Connector (FWC) to set the desired length. (SAME AS SM-DCH-XXX HOME RUN CABLES)

SM – DCA – E5FS-40

DC Adaptor Cable 40” (1m)– Female Straight plug end to wire strands – no plug

SM – DCA – E5FS-80

DC Adaptor Cable 80” (2m)– Female Straight plug end to wire strands – no plug

SM – DCA – E5FS-200

DC Adaptor Cable 200” (5m)– Female Straight plug end to wire strands – no plug

SM – DCA – E5FS-240

DC Adaptor Cable 240” (6m) – Female Straight plug end to wire strands – no plug

pfa-inc.com SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 11

Troubleshooting

S T R A I G H T T O F LY I N G L E A D S ( F L )

WIRING EXAMPLES MECHANICAL SENSOR (XLT) KOR-LOK® SIDE ACTION SET EXAMPLE

PULL

SET

SM-KLS-2A BROWN - POWER (SET) WHITE - SIGNAL (SET) BLACK - POWER (PULL) BLUE - SIGNAL (PULL) GREY - NEUTRAL

SM-JPR

XLT SWITCH

SLIDE #2

SLIDE #4

2 A

1 SLIDE #3

SLIDE #1

PWR

SLIDE #6

4 B 3 SLIDE #5

Relay Sensor Adapter Box SM-RSACOM-1A Switches Common to Set and Pull Signal Wires

PULL

SET

SM-KLS-2A

6 A

B 7

SLIDE #7

SM-RJB-8A

SLIDE #8

Add Customer Plug to Injection Molding Machine

SM-JPR

XLT SWITCH

BROWN - +VDC WHITE - SIGNAL (SET) BLACK - COMMON BLUE - SIGNAL (PULL) GREY - (-)

SM-FWC-E5MS Available to Shorten Cables

PNP SENSOR (3 WIRE) EXAMPLE

BROWN - POWER (SET) WHITE - SIGNAL (SET) BLACK - POWER (PULL) BLUE - SIGNAL (PULL) GREY - NEUTRAL

SET

SM-PNP-2A SM-JPR

PULL

PNP SENSOR

SLIDE #2

2 A 1

SM-JPR

SM-FWC-E5MS Available to Shorten Cables

12 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

PWR

A SLIDE #3

PULL

SET

SM-PNP-2A

SLIDE #1

SLIDE #4

SLIDE #6

3 SLIDE #5

SLIDE #7

8 B 7

SM-RJB-8A

SLIDE #8

Add Customer Plug to Injection Molding Machine

Relay Sensor Adapter Box SM-RSACOM-1A Switches Common to Set and Pull Signal Wires

BROWN - +VDC WHITE - SIGNAL (SET) BLACK - COMMON BLUE - SIGNAL (PULL) GREY - (-)

XLT AND XHT PFA DRY CONTACT/RELAY SENSORS RED w/WHITERED Stripe w/WHITE Stripe to presssignal to press or Temp BLUE if signal High Temp or BLUE if High

– to press set– to press set (RED w/WHITE(RED or BLUE) w/WHITEsignal or BLUE) wire signal wire

N/O

N/C

– typically used – typically used

(RED w/BLACK (RED or RED) w/BLACK or RED) with SWITCHMAX® with SWITCHMAX® only only

– to press set– to press set FROM FROM COMMONCOMMON signal wire signalPRESS wire FRONT (SET) FRONT SENSOR (SET) SENSOR (GREEN or BLACK) (GREEN or BLACK) PRESS

SET SENSOR SET #1 SENSOR #1

GREEN or BLACK GREEN or BLACK

SET WIRE

Why Switchmax®?

SENSOR WIRING AND REPLACEMENT INSTRUCTIONS Standard EE 70194/CT70300 (assembly) and High Temperature EE70199/CT705XX (Assemblies)

Stripe or BLUE RED w/WHITERED w/WHITE Stripe or BLUE

GREEN or BLACK signal from press signal from press SET SENSOR SET #2 SENSOR #2 GREEN or BLACK if High Temp if High Temp

Fig. 2 - Multiple Sensor Wiring (Series)

PFA Relay-style SPDT Form C sensors (CT70300 assembly CT70520/21/22... High Temperature Assembly) typically function as a true dry contact switch. In normal usage, when the target comes “in range” of the sensor, the magnet inside the switch closes the normally open (NO) contact.

Relay-style switches offer many benefits to the user. They have no voltage drop when closed nor do they have leakage current when open. In most applications the Normally Open (N/O) connection is used so that when the cores reach set or pull, the relay contacts close to give that indication to the press. In most cases, the Normally Closed (N/C) connection is not used, but is available for use as part of PFA’s SWITCHMAX® Mold Wiring solution.

CT70300 ASSEMBLY SPECIFICATIONS Part No. on Sensor: EE70194 / EE70194B Cylinder Designation: -XLT SPDT (Single-Pole, Double Throw)

Contact Rating:

2 Amps @ 12OVAC 1 Amp @ 240VAC 1 Amp @ 24VDC

Temperature:

-40˚F (-40˚C) to 257˚F (125˚C)

Pressure:

3000 psi max.

Install Torque Max.:

50 in-lbs. max.

CT70520/21/22... ASSEMBLY SPECIFICATIONS Part No. on Sensor: 72-16222-F4 / EE70199 Cylinder Designation: -XHT SPDT (Single-Pole, Double Throw)

Contact Rating:

4 Amps @ 12OVAC 2 Amp @ 240VAC 3 Amp @ 24VDC

Temperature:

-40˚F (-40˚C) to 400˚F (204˚C)

Pressure:

3000 psi max.

Install Torque Max.:

50 in-lbs. max.

Multiple set sensors may be wired in series to provide a single set indication to the press. Similarly, the pull wires may be connected in series. For situations where a core or other part of the mold may be damaged if opened with cores set, it is recommended that a redundant sensor be placed on the core itself and wired in series with the main unit sensors to ensure the core is retracted prior to mold opening. PFA’s SWITCHMAX® Mold Wiring solution is also available to provide cross checking of sensors to verify proper sequencing and provide operator side LED light indication. For additional information on SWITCHMAX®, please view the information online at www.pfa-inc.com.

pfa-inc.com If target is at sensor (turned on) resistance is low between pins 1 & 3

PIN 3 NORMALLY OPEN (Blue to Sensor / Red with White on Cable)

PIN 2 NORMALLY CLOSED (Red to Sensor / Red with Black on Cable)

PIN 1 COMMON

(Black to Sensor / Green on Cable)

SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 13

Troubleshooting

Contact Type:

Connection between the KOR-LOK® Side-Action System and the press, is as simple as connecting two set sensor wires and two pull sensor wires to the two pair of machine control wires. The order of connection for each pair is not important.

Accessories & Wiring

Contact Type:

Choosing a System

Fig. 1 - Single Sensor Wiring

PNP LOW PROFILE PFA PROXIMITY SENSORS SENSOR WIRING AND REPLACEMENT INSTRUCTIONS EE70600/CT70600 Assembly

Example: Front (Set) Sensor

PFA Low Profile -PNP sensors (EE 70600/CT 70600 assembly with seal) function as typical high pressure proximity sensor, with a solid state device that senses the metal target of the lock or piston and outputs the input voltage to the machine control commonly referred to as 24 volt systems. Actual voltage will range from about 10-30 VDC. CT70600 ASSEMBLY SPECIFICATIONS Part No. on Sensor: PFA-EE70600 Cylinder Designation: -PNP Contact Type:

Solid State PNP/NO

Contact Rating:

100 mAmps @ 24VDC

Supply Voltage:

10-30 VDC

Voltage Drop:

≤2.5 VDC

Temperature:

-13˚F (-25˚C) to 175˚F (80˚C)

Install Torque Max.:

50 in-lbs. max.

3 1

1 = Brown (Power 10-30 VDC) 2 = Blue (Neutral 0 VDC) 3 = Black (Signal)

Low Profile PNP sensors offer benefits to the user when fitting The KOR-LOK unit into demandingly small applications or when Integrating with other actuators using similar PNP sensor logic. PFA’s PNP option has a low voltage drop, typically allowing multiple sensors to be connected together to facilitate a single input to the machine control. Sensor integration is easily accomplished with PFA’s SWITCHMAX® connectivity solution with PNP designated splitter cables. In a generic application the Normally Open Sensor is paired with an individual cable to provide power and route the signal. To use the sensors individually, Power +24VDC (Brown wire) and Neutral 0 VDC (Blue wire) is required, as well as some method of integrating the sensor signal (Black wire) to the press. Various schemes are used to accomplish this task for molds with multiple cylinders, however, PFA recommends SWITCHMAX® to provide a plug and play serial connection of sensors into single inputs for set and pull, while also providing operator side indication and troubleshooting capability. While proper indication is expected, PFA cautions that for situations where a core or other part of the mold may be damaged if opened with cores set, it is recommended that a redundant sensor be placed on the core itself and wired in series with the main unit sensors to ensure the core is retracted prior to mold opening. For details on SWITCHMAX® options, please view the information online at www.pfa-inc.com.

14 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

Why Switchmax®?

Choosing a System

Accessories & Wiring

Troubleshooting

pfa-inc.com

SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 15

TROUBLESHOOTING INSTALLATION WITH MECHANICAL SWITCHES (XLT/XHT/SPDT)

I.A. TWO (2) KOR-LOK XLT/XHT SYSTEM OR SIMILAR SPDT MECHANICALS 1. CORES SET - NORMAL INDICATION

fashion, and lights the Slide 2 GREEN LED. The signal then continues to the #3 port Jumper, and onward to output to the Press - PULL SIGNAL WIRE. 3. CORES SET OR PULLED - NO LIGHTS

INDICATION: ALL AMBER LED LIGHTS ON OUTPUT: SET SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES SET.

Set Power enters the Home Run port, travels through the Slide 1 splitter port, to the Slide 1 set switch (which is “on” because the cylinder is set & locked), then travels through the pull switch to confirm that it is in the “off” position, then to the Slide 1 AMBER LED. Power continues onward to the Slide 2 splitter port, through the switches in a similar fashion, and lights the Slide 2 AMBER LED. The signal then continues to the #3 port Jumper, and onward to output to the Press - SET SIGNAL WIRE. (See pg. 24) 2. CORES PULLED - NORMAL INDICATION

INDICATION: ALL GREEN LED LIGHTS ON OUTPUT: PULL SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES PULLED

Pull Power enters the Home Run port travels through the Slide 1 splitter port, to the Slide 1 Pull switch (which is “on” because the cylinder is retracted), then travels through the set switch to confirm that it is in the “off” position, then to the Slide 1 GREEN LED. Power continues onward to the Slide 2 splitter port, through the switches in a similar

INDICATION: NO LIGHTS EITHER DIRECTION OUTPUT: NONE POSSIBLE CAUSES:

a. POWER NOT CONNECTED or POWER CONNECTION REVERSED Typically during initial mold install in the press, power may be disconnected from the core pull circuit at the machine or at an alternate location from the mold plug. Some molds are set up with a plug that can be put in 180 degrees out of position. b. M ISSING NEUTRAL VOLTAGE – INCORRECT NEUTRAL or GROUND The SWITCHMAX® Junction Box is designed to operate with nominal 24 VDC power and requires a neutral 0 VDC connection relative to the Power Input for LED indication. If only the positive + power and signal wires are connected, it will provide the correct outputs for the press, but the LED’s will not light. Check for the press reading the cores inputs - it is likely that the Neutral wire connection is missing, incorrect – not off controller power. c. INCORRECT POWER – 110 VAC or 0 VDC systems While not particularly common, some presses operate on AC power, 110 VAC or similar. While the PFA XLT and XHT sensors can be operated at this voltage, the SWITCHMAX®

16 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

e. CYLINDER CONTAMINATED WITH METAL New molds may have internal fluid passages with over drilled intersections or have off the shelf manifolds installed, which were not fully clean prior to connecting hydraulic components. Upon startup both Slide #1 sensors may be fouled and prevent any power from reaching the LED’s.

b. SLIDE #1 SET SWITCH FAILED/CONTAMINTATION IN THE “ON” POSITION – STUCK “ON”. If the Side #1 front lock sensor fails to cycle due to being “STUCK” or “FAILED” in the ON position, the pull signal cannot pass as the path uses a common connection. This can be noticed by watching the Slide #1 AMBER LED STAY LIT while cylinders are in the mid stroke position and then going off when slide #1 reaches the pull position (turning the pull sensor on). Check the middle/front/rod end switch (set switch) for contamination or replace the sensor. If contaminated with metal – send the cylinder to PFA for evaluation/repair/cleaning and purge the hydraulic lines and system from contamination. If contaminated on initial mold change out, contamination is likely from contaminated hydraulic lines from previous mold. If upon initial mold tryout or early mold life startup, contamination may be from manifolds or hydraulic passages in the mold base. 5. CORES SET - ABNORMAL INDICATION – NO LIGHTS. CORES PULLED - NORMAL INDICATION

Accessories & Wiring

4. CORES SET - NORMAL INDICATION; CORES PULLED - ABNORMAL INDICATION NO LIGHTS

OUTPUT: SET SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES SET.

OUTPUT: PULL SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES PULLED.

SET SIGNAL WIRE – NOTHING

pfa-inc.com

PULL SIGNAL WIRE – NOTHING

POSSIBLE CAUSES:

a. CORE SLIDE #1 NOT PULLING Both cylinders are reading “LOCKED and SET”, but CORE SLIDE #1 may not be reaching the full retracted position. As

POSSIBLE CAUSES:

a. CORE SLIDE #1 NOT LOCKING/NOT SET Both cylinders are reading “PULLED”, but CORE SLIDE #1 may not be reaching the full extended and locked position. As a result, the sensor does not turn “on” and the signal cannot pass to the AMBER LED and onward in the circuit

SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 17

Troubleshooting

INDICATION: ALL GREEN ON PULL, NO LIGHTS ON SET INDICATION: ALL AMBER ON SET, NO LIGHTS ON PULL

Choosing a System

d. C HECK SLIDES IN MID POSITION – NOT SET OR PULLED Typically during an initial tryout, something could be preventing the cores from reaching the fully pulled condition (in mold stops prevent the cylinder piston from reaching end of stroke) or something preventing the SET and LOCKED condition. For the SET indication, the cylinders must be properly adjusted and extended with adequate pressure to preload and lock for the lock to pass in front of the set switch and turn it “on”. (See pg. 25 for slide #2 out of position example)

a result, the switch does not turn “on” and the signal cannot pass to the GREEN LED and onward in the circuit

Why Switchmax®?

RJB is not designed for AC operation. Some press manufacturers provided zero voltage DC Power and inputs. While the RJB will pass these signals, there is no voltage for LED indication. Contact PFA for adaptors for these types of systems.

b. SLIDE #1 PULL SWITCH FAILED/CONTAMINATION IN THE “ON” POSITION - STUCK “ON”. If the Side #1 back Pull switch fails to cycle due to being “STUCK” or “FAILED” in the ON position, the set signal cannot pass as the path uses a common connection. This can be noticed by watching the Slide #1 GREEN LED STAY LIT while cylinders are in the mid stroke position and then going off when slide #1 reaches the set and locked position (turning the set switch on). Check the back switch (pull switch) for contamination or replace the sensor. If contaminated with metal – send the cylinder to PFA for evaluation/repair/cleaning and purge the hydraulic lines and system from contamination. If contaminated on initial mold change out, contamination is likely from contaminated hydraulic lines from previous mold. If upon initial mold tryout or early mold life startup, contamination may be from manifolds or hydraulic passages in the mold base. 6. CORES SET - NORMAL INDICATION; CORES PULLED - ABNORMAL INDICATION BOTH LIGHTS

INDICATION: ALL AMBER ON SET, SLIDE #1 – BOTH AMBER & GREEN LIGHTS ON PULL OUTPUT: SET SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES SET.

PULL SIGNAL WIRE – NO SIGNAL.

POSSIBLE CAUSES:

SLIDE #2 SET SWITCH FAILED/CONTAMINATION IN THE “ON” POSITION - STUCK “ON”. If the Side #2 front lock switch fails to cycle due to being “STUCK” or “FAILED” in the ON position, the pull signal travels through the SLIDE #1 SWITCHES correctly and lighting the #1 GREEN LED, but the signal while going

through the Slide #2 Pull switch, it cannot pass the Slide #2 SET as the path uses a common connection. The power is routed instead through the stuck path to the Slide #1 AMBER LED resulting in both #1 SLIDE GREEN and AMBER Lights. The cause of the condition could be due to a failed switch or due to steel contamination on the sensor face. Check the middle/front/rod end switch (set switch) for contamination or replace the switch. If contaminated with metal – send the cylinder to PFA for evaluation/repair/cleaning and purge the hydraulic lines and system from contamination. If contaminated on initial mold change out, contamination is likely from contaminated hydraulic lines from previous mold. If upon initial mold tryout or early mold life startup, contamination may be from manifolds or hydraulic passages in the mold base. 7. CORES PULLED - NORMAL INDICATION; CORES SET – ABNORMAL INDICATION – BOTH LIGHTS

INDICATION: ALL GREEN ON PULL, SLIDE #1 – BOTH AMBER & GREEN LIGHTS ON SET OUTPUT: PULL SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES PULLED.

SET SIGNAL WIRE – NO SIGNAL.

POSSIBLE CAUSES:

SLIDE #2 PULL SWITCH FAILED/CONTAMINATION IN THE “ON” POSITION - STUCK “ON”. If the Side #2 Pull switch fails to cycle due to being “STUCK” or “FAILED” in the ON position, the set signal travels through the SLIDE #1 SWITCHES correctly and lighting the #1 AMBER LED, but the signal while going through the Slide #2 Set switch, it cannot pass the Slide #2 PULL as the path uses a common connection. The power is routed instead

18 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

through the stuck path to the Slide #1 GREEN LED resulting in both #1 SLIDE GREEN and AMBER Lights.

9. CORES SET - ALL AMBER AND GREEN (OR) CORES PULLED – ALL GREEN AND AMBER

Why Switchmax®?

The cause of the condition could be due to a failed switch or due to steel contamination on the sensor face. Check the back end switch (pull sensor) for contamination or replace the switch. If contaminated with metal – send the cylinder to PFA for evaluation/repair/cleaning and purge the hydraulic lines and system from contamination. If contaminated on initial mold change out, contamination is likely from contaminated hydraulic lines from previous mold, manifolds or hydraulic passages in the mold base. (See pg. 26)

INDICATION: ALL AMBER + GREEN (OR) ALL GREEN + AMBER OUTPUT: SET SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES SET WHEN SET PULL SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES PULL WHEN PULLED

Choosing a System

8. CORES SET - ALL AMBER + ANY GREEN (OR) CORES PULLED - ALL GREEN + ANY AMBER

POSSIBLE CAUSES:

INDICATION: ALL AMBER + ANY GREEN (OR) ALL GREEN + ANY AMBER OUTPUT: SET SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES SET WHEN SET PULL SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES PULL WHEN PULLED POSSIBLE CAUSES:

THIS CONDITION MAY LOOK SIMILAR TO THE SHORT SCENARIO, but is EASY TO IDENTIFY AS IT HAPPENS WHEN THE MOLD IS INITIALLY INSTALLED.

If the Normally Open (NO) and Normally Closed (NC) wires contact the COMMON wire in any of the components, a 3-WAY short is created sending power signals to multiple locations and LED lights.

pfa-inc.com PFA thus recommends the use of redundant core retract sensing in the event of sensor failures, rod to core separation, or other unexpected circumstances.

SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 19

Troubleshooting

SHORT CONDITION IN SENSOR, RJB, SPLITTER CABLE, OR PLUG ENDS – FIELD WIREABLE CONNECTORS INSTALLED AND WIRES TOUCHING INSIDE MANUAL WIRING TERMINAL LOCATION.

If the plugs used for the SWITCHMAX® RJB connection are split to three separate connections, Neutral, “set plug”, and “pull plug”, it is possible that the Neutral is correct and the Set and Pull plugs or wires are connect opposite of the normal connection. Thus the power wire has the signal connection and the signal wire has power on it, effectively trying to power the RJB backwards.

Accessories & Wiring

POWER IS REVERSED FOR THE SET WIRES AND PULL WIRES ONLY

TROUBLESHOOTING INSTALLATION WITH SOLID STATE SENSORS (PNP) II.A. TWO (2) KOR-LOK PNP SYSTEM OR SIMILAR PNP SENSORS 1. CORES SET - NORMAL INDICATION

continues to the #3 port Jumper, the Expansion port jumper, and to the Press - PULL SIGNAL WIRE. 3. CORES SET OR PULLED - NO LIGHTS

INDICATION: ALL AMBER LED LIGHTS ON OUTPUT: SET SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES SET.

Set Power enters the Home Run port, travels through the Slide 1 splitter port, to the Slide 1 set sensor (which is “on” because the cylinder is set & locked), then travels through the pull sensor to confirm that it is in the “off” position, then to the Slide 1 AMBER LED. Power continues onward to the Slide 2 splitter port, through the sensors in a similar fashion, and lights the Slide 2 AMBER LED. The signal then continues to the #3 port Jumper, and onward to output to the Press - SET SIGNAL WIRE. (See pg. 28) 2. CORES PULLED - NORMAL INDICATION

INDICATION: ALL GREEN LED LIGHTS ON OUTPUT: PULL SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES PULLED

Pull Power enters the Home Run port travels through the Slide 1 splitter port, to the Slide 1 Pull sensor (which is “on” because the cylinder is retracted), then travels through the set sensor to confirm that it is in the “off” position, then to the Slide 1 GREEN LED. Power continues onward to the Slide 2 splitter port, through the sensors in a similar fashion, and lights the Slide 2 GREEN LED. The signal then

INDICATION: NO LIGHTS EITHER DIRECTION OUTPUT: NONE POSSIBLE CAUSES:

a. POWER NOT CONNECTED or POWER CONNECTION REVERSED Typically during initial mold install in the press, power may be disconnected from the core pull circuit at the machine or at an alternate location from the mold plug. Some molds are set up with a plug that can be put in 180 degrees out of position. b. M ISSING NEUTRAL VOLTAGE – INCORRECT NEUTRAL or GROUND The SWITCHMAX® Junction Box is designed to operate with nominal 24VDC power and requires a neutral 0 VDC connection relative to the Power Input for LED indication. IF only the positive + power and signal wires are connected, it will not function, because PNP sensors require a neutral voltage (0 VDC) to operate. Neutral may be missing or not from the control power connector. c. INCORRECT POWER – 110 VAC or 0 VDC systems While not particularly common, some presses operate on AC power, 110 VAC or similar. The SWITCHMAX® RJB is not designed for AC operation. Some press manufacturers provided zero voltage DC Power and inputs. While the RJB will pass these signals, there is no voltage for LED indication. Contact PFA for adaptors for these types of systems.

20 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

5. CORES SET - ABNORMAL INDICATION NO LIGHTS - CORES PULLED - NORMAL INDICATION.

Why Switchmax®?

d. C HECK SLIDES IN MID POSITION – NOT SET OR PULLED Typically during an initial tryout, something could be preventing the cores from reaching the fully pulled condition (in mold stops prevent the cylinder piston from reaching end of stroke) or something preventing the SET and LOCKED condition. For the SET indication, the cylinders must be properly adjusted and extended with adequate pressure to preload and lock for the lock to pass in front of the set sensor and turn it “on”. (See pg. 30 for slide #2 out of position example)

INDICATION: ALL GREEN ON PULL, NO LIGHTS ON SET OUTPUT: PULL SIGNAL WIRE AT POSITIVE VOLTAGE CORES PULLED.

SET SIGNAL WIRE - NOTHING

Choosing a System

4. CORES SET - NORMAL INDICATION; CORES PULLED - ABNORMAL INDICATION NO LIGHTS.

POSSIBLE CAUSES:

INDICATION: ALL AMBER ON SET, NO LIGHTS ON PULL OUTPUT: SET SIGNAL WIRE AT SUPPLY VOLTAGE (24VDC TYPICAL) – CORES SET.

b. S LIDE #1 SET SENSOR DAMAGED If the set sensor is not working for position #1, there will be no light for set.

Accessories & Wiring

a. CORE SLIDE #1 NOT SET - NOT READING Slide #1 may not be reading the fully extended position or locked position. As a result, the sensor does not turn “on” and the signal cannot pass to the AMBER LED and onward in the circuit

c. For locking cylinders (KOR-LOK®) preload may be incorrect. One cylinder not locking - check setup/preload.

PULL SIGNAL WIRE – NOTHING

POSSIBLE CAUSES:

b. S LIDE #1 PULL SENSOR DAMAGED If the pull sensor is not working for position #1, there will be no lights for pull.

pfa-inc.com SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 21

Troubleshooting

a. CORE SLIDE #1 NOT PULLING - NOT READING SLIDE #1 may not be reaching the fully retracted position. As a result, the sensor does not turn “on” and the signal cannot pass to the GREEN LED and onward in the circuit

6. CORES SET - NORMAL INDICATION; CORES PULLED - ABNORMAL INDICATION BOTH LIGHTS

INDICATION: ALL AMBER ON SET, SLIDE #1 – BOTH AMBER & GREEN LIGHTS ON PULL OUTPUT: NORMAL - JUST EXTRA AMBER LIGHT WHEN CORES PULLED. POSSIBLE CAUSES:

Ready target - metal in front of sensor. Damaged sensor - short 7. CORES PULLED - NORMAL INDICATION; CORES SET – ABNORMAL INDICATION – BOTH LIGHTS

INDICATION: ALL AMBER ON SET, SLIDE #1 – BOTH AMBER & GREEN LIGHTS ON PULL OUTPUT: NORMAL - JUST EXTRA GREEN LIGHT WHEN CORES SET. POSSIBLE CAUSES:

Ready target - metal in front of sensor. Damaged sensor - short

22 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

Why Switchmax®?

Choosing a System

Accessories & Wiring

Troubleshooting

pfa-inc.com

SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 23

I.B. TWO (2) KOR-LOK SYSTEM - SCHEMATICS

SM-KLS-2A

TWO (2) KOR-LOK SYSTEM XLT/XHT SENSORS SCHEMATIC

SM-KLS-2A

CORES SET - NORMAL INDICATION

24 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

Why Switchmax®?

SM-KLS-2A

Choosing a System

CORES PULLED - NORMAL INDICATION

Accessories & Wiring

SM-KLS-2A

pfa-inc.com SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 25

Troubleshooting

SLIDE #2 NOT IN PROPER POSITION SIGNAL NOT PASSED ON OUTPUT-NONE

SM-KLS-2A

SLIDE #1 SWITCH STUCK ON, SET & PULL POWER CONNECTED, NO LED’S OUTPUT-NONE

SM-KLS-2A

SLIDE #2 SWITCH STUCK ON, BACKFEEDS SLIDE #1 LED, BOTH LED’S ON SLIDE #1 OUTPUT-NONE

26 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

SM-KLS-2A

Why Switchmax®?

SM-KLS-2A

Choosing a System

3 WAY SHORT-SET-SLIDE #2 SET SWITCH BACKFEEDS SLIDE #2 OTHER LED OUTPUT - SET OUTPUT IF NOT LAST IN SERIES BOTH OUTPUTS IF LAST IN SERIES

Accessories & Wiring

SM-KLS-2A

pfa-inc.com SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 27

Troubleshooting

3 WAY SHORT-SET-SLIDE #2 SET SWITCH BACKFEEDS SLIDE #2 OTHER LED OUTPUT-PULL OUTPUT IF NOT LAST IN SERIES BOTH OUTPUTS IF LAST IN SERIES

II.B. TWO (2) CYLINDER SYSTEM - PNP SENSOR SCHEMATICS SM-PNP-2A JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A

EXPANSION PORT

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

TWO (2) CYLINDER SYSTEM PNP SENSOR SCHEMATIC

SET SENSOR

SM-PNP-2A JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A

EXPANSION PORT

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

SET SENSOR

CORES SET - NORMAL INDICATION OUTPUT ON SET SIGNAL WIRE

28 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

SET SENSOR

JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

SET SENSOR

SLIDE #1 - NOT IN PROPER POSITION SIGNAL NOT PASSED ON NO LEDS ON NO OUTPUT

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

pfa-inc.com SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 29

Troubleshooting

EXPANSION PORT

Accessories & Wiring

SM-PNP-2A

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

CORES PULLED - NORMAL INDICATION OUTPUT ON PULL SIGNAL WIRE

Choosing a System

EXPANSION PORT

Why Switchmax®?

SM-PNP-2A

SM-PNP-2A JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A

EXPANSION PORT

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

SET SENSOR

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

SLIDE #2 - NOT IN PROPER SET POSITION SIGNAL NOT PASSED ON SLIDE #1 SET LED ON NO OUTPUT

SM-PNP-2A JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A

EXPANSION PORT

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

STUCK

SET SENSOR

ABNORMAL SENSOR “ON” CORES PULLED SLIDE #1 - SENSOR SET STUCK ON NORMAL OUTPUTS BUT SENSOR ERROR

30 SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC.

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A STUCK

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

SET SENSOR

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

ABNORMAL SENSOR “ON” CORES SET SLIDE #1 - SENSOR PULL STUCK ON NORMAL OUTPUTS BUT SENSOR ERROR

JUMPER PLUG

5 4 3 2 1

JUMPER PLUG

5 4 3 2 1

5.1K

5 4 3 2 1

5.1K

5 4 3 2

5 4 3 2 AB

5.1K

SLIDE #2

PULL SENSOR

SET SENSOR SM-PNP-2A

SLIDE #3

SLIDE #2

SLIDE #1

PULL SENSOR 5 4 3 2 1 5 4 3 2 1

SET SENSOR

ABNORMAL POWER CONNECTION POWER AND SIGNAL REVERSED MAY DAMAGE SENSORS

1=SET POWER (BN) 2=SET INPUT (WH) 3=PULL INPUT (BU) 4=PULL POWER (BK) 5=GROUND FOR LED (GY)

pfa-inc.com SWITCHMAX® SENSOR CONNECTIVITY BY PFA, INC. 31

Troubleshooting

EXPANSION PORT

Accessories & Wiring

SM-PNP-2A

Choosing a System

EXPANSION PORT

Why Switchmax®?

SM-PNP-2A

N118 W18251 Bunsen Drive Germantown, WI 53022 (262) 250-4410 • Fax (262) 250-4409 switchmax@pfa-inc.com YOUR LOCAL PFA REPRESENTATIVE:

pfa-inc.com Copyright ©2011 PFA, Inc. All rights reserved. Reproduction or use in any manner of editorial or graphic content herein without the express written permission of PFA, Inc. is strictly prohibited. Every effort has been made to ensure the information within this publication is complete and accurate at the time of printing.

S2701 REV A

PFA Switchmax® Sensor Connectivity

Articles inside

Choosing a System

XLT AND XHT PFA Dry Contact/ Relay Sensors