Switchmax® Sensor 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 two-wire 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 input-limited 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 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.

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.

SWITCHMAX® Connectivity is the Ideal Solution:

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.

SWITCHMAX® Integrates…

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.

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

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 accommodate those needs with standardized adapters.

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.

SWITCHMAX® Modularizes…

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.

Building a System From Parts or Selecting a Package is Easy!

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.

Applications commonly consist of two to eight, two-position 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 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.

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.

Switchmax Wiring Diagram - General

Switchmax® Components

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 Relay Junction Box

Relay Junction Box (plain no jumpers)
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.

SM-JPR Jumper Plug

Jumper Plug for Relay Junction Box
SM-JPR

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.

SM-DCH-E5FN-240 DC Homerun Cable – RJB output cable

DC Homerun Cable – RJB Output Cable
SM-DCH-E5FN-240

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.

SM-KLS-2A KL splitter cable with straight end (at RJB)

KL Splitter Cable with Straight End (at RJB)
SM-KLS-2A

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)

PNP Splitter Cable with Straight End (at RJB)
SM-PNP-2A

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

Relay Sensor Adaptor – Universal – Switch High or 0 VDC
SM-RSACOM-1A, -2A, -3A

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).

SWITCHMAX® PACKAGED SYSTEMS – DC – PFA Mechanical Switches
Part Number Description
SM-KL-DC8PKG – 1S 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]
SM-KL-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]
SM-KL-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]
SM-KL-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]
SM-KL-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]
SM-KL-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]
SM-KL-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]
SM-KL-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]
SWITCHMAX® PACKAGED SYSTEMS – DC – PFA PNP Sensors
Part Number Description
SM-PNP-DC8PKG – 1S 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]
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]
SM-PNP-DC8PKG – 8S 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]

Sensors, Dongles, and Field Wireable Connectors Bring it all Together for Modularity

Sensor Dongles

SM-SEN-E5MS Sensor (PNP or 2 Position Switch) Dongles

Sensor (PNP or 2 Position Switch) Dongles
SM-SEN-E5MS

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

Sensor (SPTD or Mechanical) Dongles
SM-SEN-M3MS

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)

Sensor (PNP or 2 Position Switch) Dongles
SM-FWC-E5MS

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

Sensor (SPTD or Mechanical) Dongles
SM-FWC-M3MS

Three Pin M style cable Field Wireable Connector. Connect to sensors with wires or use to shorten cables with E3MS plugs.

SM-RTB-1A Relay Test Box

Relay Test Box
SM-RTB-1A

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)

Double Ended DC Connectivity Cables – M12 with 5 pins

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.

90 degree to Straight
Part Number Description
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)
Straight to Straight
Part Number Description
SM – DCA – E5FS-40-E5MS 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

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.

Straight to Flying leads (FL) (Same as SM-DCH-XXX home run cables)
Part Number Description
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