Page 1

Modevo Tension Brake


Performance Charts Torques

Model

Minimum (3PSI) (0.2 Bars)1 lb. ft. (Nm) (lb. ft.) (Nm) 1 Actuator

LC2 250/1 250/2 250/4 250/6

300/1 300/2 300/4 300/6 300/8

350/2 350/4 350/6 350/8 350/10

400/2 400/4 400/6 400/8 400/10 400/12

450/2 450/4 450/6 450/8 450/10 450/12 450/14

Std3 25% Actuators

HC4

LC2

Std3 60% Actuators 2.2 (3) 4.4 [2.2] (6) ([3]) 8.8 [2.2] (12) ([3]) 13.2 [2.2] (18) ([3])

HC4

LC2

Std3 HC4 100 % Actuators

2.6 (3.5) 5.1 [2.6]) (6.9) ([3.5]) 10.1 [2.6] (13.8) ([3.5]) 15.2 [2.6] (20.7) ([3.5])

2.2 (3) 4.4 [2.2] (6) ([3]) 8.8 [2.2] (12) ([3]) 13.2 [2.2] (18) ([3])

0.6 (0.8) 1.1 [0.6] (1.5) ([0.8]) 2.2 [0.6] (3) ([0.8]) 3.3 [0.6] (4.5) ([0.6])

0.93 (1.3) 1.9 [0.93] (2.5) ([1.3]) 3.7 [0.93] (5) ([1.3]) 5.5 [0.93] (7.5) ([1.3])

1.1 (1.4) 2.1 [1.1] (2.9) ([1.4]) 4.2 [1.1] (5.8) ([1.4]) 6.3 [1.1] (8.6) ([1.1])

1.3 (1.8) 2.6 [1.3] (3.6) ([1.8]) 5.3 [1.3] (7.2) ([1.8]) 7.9 [1.3] (10.8) ([1.8])

0.7 (0.9) 1.6 [0.78] (5) ([1.1]) 3.1 [0.78] (4.2) ([1.1]) 4.5 [0.78] (6.3) ({1.1]) 6.2 [0.78] (8.4) ([1.1])

1.1 (1.5) 2.6 [1.3] (3.5) ([1.8]) 5.2 [1.3] (7) ([1.8]) 7.7 [1.3] (10.5) ([1.8]) 10.3 [1.3] (14) ([1.8])

1.3 (1.7) 3.0 [1.5] (4) ([2]) 5.9 [1.5] (8.1) ([2]) 8.9 [1.5] (12.1) ([2]) 11.9 [1.5] (16.1) ([2])

1.6 2.6 3.0 2.6 (2.2) (3.6) (4.1) (3.6) 3.7 [1.9] 6.2 [3.1] 7.1 [3.6] 6.2[3.1] (5) ([2.5]) (8.4) ([4.2]) (9.7) ([4.9]) (8.4) ([4.2]) 7.4 [1.9] 12.4 [3.1] 14.2 [3.6] 12.4 [3.1] (10.1) ([2.5]) (16.8) ([4.2]) (19.3) ([4.9]) (16.8) ([4.2]) 11.1 [1.9] 18.5 [3.1] 21.3 [3.6] 18.5 [3.1] (15.1) (2.5]) (25.2) ([4.2]) (29) ([4.9]) (25.2) ([4.2]) 14.9 [1.9] 24.8 [3.1] 28.5 [3.6] 24.8 [3.1] (20.2) ([2.5]) (33.6) ([4.2]) (38.6) ([4.9]) (33.6) ([4.2])

1.8 [0.9] (2.4) ([1.2]) 3.6 [0.9] (4.8) ([1.2]) 5.3 [0.9] (7.2) ([1.2]) 7.1 [0.9] (9.6) ([1.2]) 8.9 [0.9] (12) ([1.2])

3.0 [1.5] (4) ([2]) 5.9 [1.5] (8) ([2]) 8.9 [1.5] (12) ([2]) 11.8 [1.5] (16) ([2]) 14.8 [1.5] (20) ([2])

3.4 [1.7] 4.3 [2.1] 7.1 [3.5] (4.6) ([2.3]) (5.8) ([2.9]) (9.6) ([4.8]) 6.8 [1.7] 8.5 [2.1] 14.2 [3.5] (9.2) ([2.3]) (11.5) ([2.9]) (19.2) ([4.8]) 10.2 [1.7] 12.7 [2.1] 21.2 [3.5] (13.8) ([2.3]) (17.3) ([2.9]) (28.8) ([4.8]) 13.6 [1.7] 17 [2.1] 28.3 [3.5] (18.4) ([2.3]) (9.6) ([2.9]) (38.4) ([4.8]) 17 [1.7] 21.2 [2.1] 35.4 [3.5] (23) ([2.3]) (28.8) ([2.9]) (48) ([4.8])

2.2 [1.1] (3) ([1.5]) 4.4 [1.1] (6) ([1.5]) 6.7 [1.1] (9) ([1.5]) 8.9 [1.1] (12) ([1.5]) 11.1 [1.1] (15) ([1.5]) 13.3 [1.1] (18) ([1.5])

3.7 [1.9] (5) ([2.5]) 7.4 [1.9] (10) ([2.5]) 11.1 [1.9] (15) ([2.5]) 14.8 [1.9] (20) ([2.5]) 18.5 [1.9] (25) ([2.5]) 22.1 [1.9] (30) ([2.5])

4.3 [2.1] (5.8) ([2.9]) 8.5 [2.1] (11.5) ([2.9]) 12.7 [2.1] (17.3) ([2.9]) 17 [2.1] (23) ([2.9]) 21.2 [2.1] (28.8) ([2.9]) 25.5 [2.1] (34.5) ([2.9])

5.3 [2.6] (7.2) ([3.6]) 10.6 [2.6]) (14.4) ([3.6]) 16 [2.6] (21.6) ([3.6]) 21.2 [2.6] (28.8) ([3.6]) 26.6 [2.6] (36) ([3.6]) 31.9 [2.6] (43.2) ([3.6])

2.3 [1.2] (3.2) ([1.7]) 4.7 [1.2] (6.3) ([1.7]) 7 [1.2] (9.5) ([1.7]) 9.3 [1.2] (12.6) ([1.7]) 11.6 [1.2] (15.8) ([1.7]) 13.9 [1.2] (18.9) ([1.7]) 13.6 [1.2] (22.1) ([1.7])

3.9 [2.0] (5.3) ([2.8]) 7.8 [2.0] (10.5) ([2.8]) 11.6 [2.0] (37.8) ([2.8]) 15.7 [2.0] (15.5) ([2.8]) 19.4 [2.0] (26.3) ([2.8]) 23.2 [2.0] (31.5) ([2.8]) 27.1 [2.0] (27.1) ([2.8])

4.5 [2.3] (6.1) ([3.2]) 8.9 [2.3] (12.1) ([3.2]) 13.4 [2.3] (18.1) ([3.2]) 17.8 [2.3] (24.2) ([3.2]) 22.3 [2.3] (15.8) ([3.2]) 26.7 [2.3] (36.2) ([3.2]) 31.2 [2.3] (42.3) ([3.2])

5.6 [2.9] (7.6) ([4.0) 11.2 [2.9] (15.1) ([4.0]) 16.7 [2.9] (22.7) ([4.0]) 22.3 [2.9] (30.2) ([4.0]) 27.9 [2.9] (37.8) ([4.0]) 33.4 [2.9] (45.4) ([4.0]) 39 [2.9] (52.9) ([4.0])

LC

3.7 (5) 7.4 [3.7] (10) ([5]) 14.7 [3.7] (20) ([5]) 22 [3.7] (30) ([5])

4.3 (5.8) 8.5 [4.3]) (11.5) ([5.8]) 16.9 [4.3] (23) ([5.8]) 25.3 [4.3] (34.5) ([5.8])

15. (21. 31. (42. 62. (85 94 (127

4.4 (6) 10.3 [5.2] (14) ([7]) 20.6 [5.2] (28) ([7]) 30.9 [5.2] (42) ([7]) 41.3 [5.2] (56) ([7])

5.1 (6.9) 11.8[6] (16.1) ([8.1]) 23.7 [6] (32.2) (8.1]) 35.5 [6] (48.3) ([8.1]) 47.5 [6] (64.4) ([8.1])

19. (27 39. (54 79. (10 119 (16 159 (21

8.1 [4.1] 7.1 [3.5] (11) ([5.5]) (9.6) ([4.8]) 16.3 [4.1] 14.2 [3.5] (22.1) ([5.5]) (19.2) ([4.8]) 24.4 [4.1] 21.2 [3.5] (33.1) ([5.5]) (28.8) ([4.8]) 32.6 [4.1] 28.3 [3.5] (44.2) ([5.5]) (38.4) ([4.8]) 40.7 [4.1] 35.4 [3.5] (55.2) ([5.5]) (48) ([4.8])

11.8 (16) 23.6 (32) 35.4 (48) 47.2 (64) 59.0 (80)

13.6 [6.8] (18.4) ([9.2]) 27.1 [6.8] (36.8) ([9.2]) 40.7 [6.8] (55.2) ([9.2]) 54.3 [6.8] (73.6) ([9.2]) 67.9 [6.8] (92) ([9.2])

48 (65 95. (13 143 (19 190 (26 239 (32

8.9 [4.4] (12) ([6]) 17.7 [4.4] (24) ([6]) 26.6 [4.4] (36) ([6]) 35.4 [4.4] (480 ([6]) 44.3 [4.4] (60) ([6]) 53.1 [4.4] (72) ([6])

10.2 [5.1] (13.8) ([6.9]) 20.3 [5.1] (27.6) ([6.9]) 30.5 [5.1] (41.4) ([6.9]) 40.7 [5.1] (55.2) ([6.9]) 50.9 [5.1] (69) ([6.9]) 61.1 [5.1] (82.8) ([6.9])

8.9 [4.4] (12) ([6]) 17.7 [4.4] (24) ([6]) 26.6 [4.4] (36) ([6]) 35.4 [4.4] (48) ([6]) 44.3 [4.4] (60) ([6]) 53.1 [4.4] (72) ([6])

14.8 [7.4] 17.0 [8.5] (20) ([10]) (23) ([11.5]) 29.5 [7.4] 33.9 [8.5] (40) ([10]) (46) ([11.5]) 44.3 [7.4] 50.9 [8.5] (60) ([10]) (69) ([11.5]) 59.0 [7.4] 67.9 [8.5] (80) ([10]) (92) ([11.5]) 73.8 [7.4] 84.9 [8.5] (100) ([10]) (115) ([11.5]) 88.5 [7.4] 101.8 [8.5] (120) ([10]) (138) ([11.5])

56. (76. 112 (152 168 (228 22 (30 281 (381 337 (457

9.3 [4.9] (12.6) ([6.6]) 18.6 [4.9] (25.2) ([6.6]) 27.9 [4.9] (37.8) ([6.6]) 37.7 [4.9] (50.4) ([6.6]) 46.5 [4.9] (63) ([6.6]) 55.7 [4.9] (75.6) ([6.6]) 65 [4.9] (88.2) ([6.6])

10.7 [5.6] (14.5) ([7.6]) 21.4 [5.6] (29) ([7.6]) 32.1 [5.6] (43.5) ([7.6]) 42.8 [5.6] (58) ([7.6]) 53.5 [5.6] (72.5) ([7.6]) 64.1 [5.6] (87) ([7.6]) 74.8 [5.6] (101.5) ([7.6])

9.3 [4.9] (12.6) ([6.6]) 18.6 [4.9] (25.2) ([6.6]) 27.9 [4.9] (37.8) ([6.6]) 37.2 [4.9] (50.4) ([6.6]) 46.5 [4.9] (63) ([6.6]) 55.7 [4.9] (75.6) ([6.6]) 65 [4.9] (88.2) ([6.6])

15.5 [8.1] (21) ([11]) 31.0 [8.1] (42) ([11]) 46.5 [8.1] (63) ([11]) 62.0 [8.1] (84) ([11]) 77.5 [8.1] (105) ([11]) 92.9 [8.1] (126) ([11]) 108.4 [8.1] (147) ([11])

64. (88 129 (17 194 (26 259 (35 324 (44 389 (52 454 (61

[5.9] ([8]) [5.9] ([8]) [5.9] ([8]) [5.9] ([8]) [5.9] ([8])

17.8 [9.3] (24.2) ([12.7]) 35.7 [9.3] (48.3) ([12.7]) 53.5 [9.3] (72.5) ([12.7]) 71.3 [9.3] (96.6) ([12.7]) 89.1 [9.3] (120.8) ([12.7]) 106.8 [9.3] (144.9) ([12.7]) 124.7 [9.3] (169.1) ([12.7])

NOTES: 1. Minimum torques were calculated using a multiplier of 0.6 for LC times Standard and a multiplier of 1.15 for HC times Standard 2. LC - Low Coefficient based on 0.2 Coefficient of friction. 3. Standard based on 0.35 Coefficient of friction. 4. HC - High Coefficient based on 0.4 Coefficient of friction. 5. Max speed iw with standard brake disc. A high speed brake disc capable of 50% higher speed is also available. All torque values are obtained based on Wichits's new ModEvo Rolling Diaphragm Actuators. Values in [ ] are for single actuator Values in ( ) are metric


Speed5 MAX Minimum (87PSI) (6 Bars) lb. ft. (Nm)

C2 Std3 HC4 25 % Actuators

LC2 Std3 HC4 60 % Actuators

HP (RW)

LC2 Std3 HC4 100 % Actuators

RPM 2250

.8 .3) .3 .5) .8 5) 4 7.5)

27.5 (37.3) 55 (74.5) 109.8 (149) 164.8 (223.5)

31.5 (42.8) 63 (85.5) 126 (171) 189 (256.5)

37.8 (51) 75 (102) 150.6 (204) 225.6 (306)

66 (89.4) 132 (178.8) 263.4 (357.6) 395.4 (536.4)

75.6 (102.6) 151.2 (205.2) 302.4 (410.4) 453.6 (615.6)

63 (85) 125 (170) 251 (340) 376 (510)

110 (149) 220 (298) 439 (596) 659 (894)

126 (171) 252 (342) 504 (684) 756 (1026)

.8 7) .8 4) .5 8) 9.3 2) 9.3 6)

34.8 (47.3) 69.5 (94.5) 139.3 (189) 209 (283.5) 278.8 (378)

39.5 (53.8) 79.3 (107.5) 158.5 (215) 237.8 (322.5) 317 (430)

47.4 (64.8) 95.4 (129.6) 190.8 (259.2) 286.2 (388.8) 382.2 (518.4)

83.4 (113.4) 166.8 (226.8) 334.2 (453.6) 501.6 (680.4) 669 (907.2)

94.8 (129) 190.2 (258) 380.4 (516) 570.6 (774) 760.8 (1032)

79 (108) 159 (216) 318 (432) 477 (648) 637 (864)

139 (189) 278 (378) 557 (756) 836 (1134) 1115 (1512)

158 (215) 317 (430) 634 (860) 951 (1290) 1268 (1720)

8 5) .9 0) 3.8 5) 0.5 0) 9.7 5)

84.1 (114) 168.2 (228) 252.3 (342) 336.4 (456) 420.4 (570)

96.1 (130.3) 192.2 (260.5) 288.2 (390.8) 384.3 (521) 480.4 (651.3)

115.1 (156) 230.2 (312) 345.2 (468) 457.3 (624) 575.3 (780)

201.8 (273.6) 403.6 (547.2) 605.4 (820.8) 807.2 (1094.4) 1009 (1368)

230.6 (312.6) 461.2 (625.2) 691.7 (937.8) 922.3 (1250.4) 1152.9 (1563)

191.8 (260) 383.6 (520) 575.3 (780) 762.1 (1040) 958.9 (1300)

336.4 (456) 672.7 (912) 1009 (1368) 1345.4 (1824) 1681.7 (2280)

384.3 (521) 768.6 (1042) 1152.9 (1563) 1537.2 (2084) 1921.5 (2605)

.3 .3) 2.5 2.5) 8.7 8.8) 5 5) .2 .3) 7.5 7.5)

98.3 (133.5) 197 (267) 295.4 (400.5) 393.9 (534) 492.4 (667.5) 590.8 (801)

112.7 (152.8) 225.3 (305.5) 338 (458.3) 450.7 (611) 563.4 (763.8) 676 (916.5)

135 (183) 270 (366) 404.9 (549) 539.9 (732) 674.9 (915) 809.9 (1098)

236 (320.4) 472.7 (640.8) 708.9 (961.2) 945.3 (1281.6) 1181.6 (1602) 1417.9 (1922.4)

270.4 225 (366.6) (305) 540.8 450 (733.2) (610) 811.2 674.9 (1099.8) (915) 1081.6 899.9 (1466.4) (1220) 1352 1124.8 (1833) (1525) 1622.4 1349.8 (2199.6) (1830)

393.9 (534) 787.8 (1068) 1181.6 (1602) 1575.5 (2136) 1969.4 (2670) 2363.3 (3204)

450.7 (611) 901.3 (1222) 1352 (1833) 1802.7 (2444) 2253.4 (3055) 2704 (3666)

.9 8) 9.8 6) 4.7 4) 9.6 2) 4.6 0) 9.5 8) 4.4 6)

113.6 (154) 227.2 (308) 340.8 (462) 454.4 (616) 568 (770) 681.6 (924) 795.1 (1078)

130 155.8 272.6 (176.3) (211.2) (369.6) 260 311.6 545.2 (352.5) (422.4) (739.2) 390 467.3 817.9 (528.8) (633.6) (1108.8) 520 623.1 1090.4 (705) (844.8) (1478.4) 650 778.9 1363.1 (881.35) (1056) (1848) 780 934.7 1635.7 (1057.5) (1267.2) (2217.6) 910 1090.4 1908.3 (1233.8) (1478.4) (2587.2)

454.4 (616) 908.7 (1232) 1363.1 (1848) 1817.4 (2464) 2271.8 (3080) 2726.2 (3696) 3180.5 (4312)

520 (705) 1040 (1410) 1560 (2115) 2080 (2820) 2600 (3525) 3120 (4230) 3640 (4935)

d.

Heat Capacity for Effective Cooling Speeds

312 (423) 624 (846) 936 (1269) 1248 (1692) 1560 (2115) 1872 (2538) 2184 (2961)

259.6 (352) 519.3 (704) 778.9 (1056) 1038.5 (1408) 1298.2 (1760) 1557.8 (2112) 1817.4 (2464)

2250

50 RPM

100 RPM

200 RPM

400 RPM

500 RPM

600 RPM

1.61 (1.2)

1.88 (1.4)

Without Fan 2.55 3.22 3.66 (1.9) (2.4) (2.7)

4.02 (3.0)

4.29 (3.2)

4.56 (3.4)

With Electric Cooling Fan 4.6 5.0 5.36 5.36 5.36 (3.5) (3.8) (4.0) (4.0) (4.0)

5.36 (4.0)

2.82 (2.1)

3.22 (2.4)

Without Fan 4.02 4.7 5.36 (3.0) (3.5) (4.0)

6.71 (5.0)

6.71 (5.0)

With Electric Cooling Fan 6.71 6.71 6.71 7.38 8.05 (5.0) (5.0) (5.0) (5.5) (6.0)

8.05 (6.0)

3.75 (2.8)

4.16 (3.1)

Without Fan 5.63 6.44 7.38 (4.2) (4.8) (5.5)

9.66 (7.2)

7.8 (5.8)

With Electric Cooling Fan 8.5 8.7 8.7 8.7 8.7 (6.3) (6.5) (6.5) (6.5) (6.5)

8.7 (6.5)

4.3 (3.2)

5.1 (3.8)

Without Fan 7.2 8.1 9.1 (5.4) (6.0) (6.8)

11.3 (8.4)

10.1 (7.5)

With Electric Cooling Fan 11.1 11.7 12.5 13.4 13.4 (8.3) (8.7) (9.3) (10.0) (10.0)

13.4 (10.0)

4.6 (3.4)

5.8 (4.3)

Without Fan 8.2 9.4 10.5 (6.1) (7.0) (7.8)

13.4 (10.0)

2250 2250

1900 1900

300 RPM

6.03 (4.5)

1900 1900 1900

1650 1650

8.85 (6.6)

1650 1650

Inertia Rotating Parts

Weight

lb. ft.2 (kbm2)

lbs. (kg)

Total 27.3 (12.4) 29.1 1.42 (13.2) (0.060) 38.8 (17.6) 48.7 (22.1)

19.2 (8.7)

38.1 (17.3) 39.9 (18.1) 2.97 49.6 (0.125) (22.5) 59.5 (27.0) 69.4 (31.5)

30.0 (13.6)

5.46 (0.23)

54.7 (24.8) 64.4 (29.2) 74.3 (33.7) 84.2 (38.2) 94.1 (42.7)

44.8 (20.3)

9.49 (0.4)

69.0 (31.3) 78.7 (35.7) 88.6 (40.2) 98.6 (44.7) 108.5 (49.2) 118.2 (53.6)

59.1 (26.8)

14.48 (0.61)

82.7 (37.5) 92.4 (41.9) 102.3 (46.4) 112.2 (50.9) 122.1 (55.4) 131.8 (59.8) 141.8 (64.3)

72.8 (33)

1650

1450 1450

10.5 (7.8)

1450 1450 1450 1450

1250 1250

12.3 (9.2)

1250 1250 1250 1250 1250

11.4 (8.5)

12.7 (9.5)

With Electric Cooling Fan 13.4 14.5 15.6 16.8 (10.0) (10.8) (11.6) (12.5)

17.8 (13.3)

Rotating


Dimensions 8.78 (223)

6.988 18

184

159.5 139.5

Zß 85.25

Brake Disc Centre Line

11

WICHITA

25

¿C

IC W

TA HI

W IC HI TA

¿A

M12x160mm Cap Screw

Air Flow

¿U

ModEvo Side View

ModEvo Front View

¿D ¿B

ModEvo Side View With Fan

44.0 43.6

63.15 63.55

ModEvo Dimensional Table MM (Inches) ØA - Disc Size ØB - Overall ØC - Bolt P.C.D ØD - Clearance Diameter U - As Cast Bore Maximum Bore Z" - Angular Position Maximum Number of Brake Modules Wichita Generic Drawing Number

250 (9.843) 324 (12.756) 298.5 (11.752) 90 (3.543) 25 (0.984) 55 (2.165) 120º

300 (11.811) 369 (14.528) 343.5 (13.524) 140 (5.512) 25 (0.984) 79 (3.110) 90º

350 (13.78) 415 (16.339) 389 (15.315) 190 (7.480) 25 (0.984) 117 (4.606) 72º

400 (15.748) 461 (18.149) 435.5 (17.146) 240 (9.449) 25 (0.984) 136 (5.354) 60º

450 (17.717) 508 (20.000) 482.5 (18.996) 290 (11.417) 25 (0.984) 154 (6.063) 51.429º

3

4

5

6

7

73125-000

73130-000

73141-000

73141-000

73145-000

Notes: Values in ( ) are English

Wichita Company Limited Ampthill Road, Bedford MK 42 9RD, U.K. +44 (0) 1234 350 311 • Fax: +44 (0) 1234 350 317 www.wichita.co.uk e-mail: clutch@wichita.co.uk P- 3/03

Wichita Clutch 2800 Fisher Road, Wichita Falls, TX 76302 940-723-3400 • Fax: 940-723-3436 www.warnerelectric.com

Printed in USA


Blade Brake Clutch Application Guide P-1319 819-0465

Application Guide


Contents

II. Introduction

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Design Considerations. . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Performing Maintenance on the Warner Electric BBC . . . . . . . . . . . . . . . . . . . . . . . . 8 Troubleshooting the Warner Electric BBC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Warranty . . . . . . . . . . . . . . . . . . . . . . Back Page

Warner Electric BBC's are typically used to control the rotation of the cutting blade(s) on walkbehind mowers. These machines are generally designed with a means to automatically stop the blade(s) when the operator releases an operator presence control. (See Note 1) Warner Electric BBC's help accomplish this design goal by providing a means to remove engine power from the blades and braking the blades to a stop while at the same time allowing the engine to continue to run.

Failure to follow these instructions may result in product damage, equipment damage, and serious or fatal injury to personnel. When performing maintenance on either mowing deck or engine, the engine should be stopped and the spark plug wire should be disconnected. I. Scope This manual has been prepared by Warner Electric to assist manufacturers of outdoor power equipment in the selection, installation, operation, and troubleshooting of Warner Electric Blade Brake Clutches (BBC's). The information contained in this publication is to be considered a general guideline for incorporation of BBC's into outdoor power equipment such as walk-behind and ride-on mowers. As each application is unique, the suitability of a BBC for use in a particular machine can only be determined through appropriate testing.

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Warner Electric BBC's provide superior operator convenience to "engine-kill" systems in which the blade(s) and engine both stop when the operator releases the operator presence control. With this system the operator must restart the engine each time he/she leaves the operator zone to perform such common tasks as clearing debris from the lawn or emptying the grass catcher. Note 1: Reference applicable International and U.S. Standards such as ISO-5395, EN-836, CPSC # ---and ANSI/OPEI B71.1.

III. Operation The clutch is engaged by actuating the operator presence lever and pushing the blade engagement handle. This action rotates the ball ramp mechanism, causing three small internal springs inside of the clutch/brake to lift the brake plate clear of the friction disc. As the brake plate is released from the friction disc, a heavy coil spring at the base of the unit pushes the friction disc against the rotating input hub, which is bolted to the engine's crankshaft. The clutch is then engaged and the blade rotates. Releasing the operator presence lever causes the spring to rotate the ball ramp mechanism in the opposite direction which forces the brake plate against the outer portion of the friction disc, releasing the clutch and braking the blade to a stop.

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BBC-II

Blade Mounting Hub Ball Ramp Actuation System

Mower Blade

Replaceable Sealed Ball Bearings Mounting Bolt Removal Thread for Disassembly Internal Brake Return Spring Clutch/Brake Spring Clutch/Brake Friction Material Brake Actuation Spring Attachment Point Brake Anti-rotation Arm Clutch Actuation Cable Attachment Point

IV. Design Considerations A. Mounting Blade Brake Clutches are typically mounted directly to the engine crankshaft. BBC's are available in a shaft end or shoulder mounting configurations. 1. Shaft End Mounting A shaft-end mounting configuration is shown in figure 1. The end of the engine crankshaft bottoms in the bottom of the bore in the BBC. With this type of mounting there must be clearance between the BBC hub and the ground drive pulley. The runout of the end of the engine crankshaft should be held to a maximum of 0.001 inches (0.025mm) to minimize the runout of the blade. Figure 1

Warner Electric • 800-825-9050

2. Shoulder Mounting A shoulder mounting configuration is shown (figure 2). The inner race of the top plate bearing is in contact with a shaft shoulder, spacer, or traction drive pulley. Clearance must be maintained between the end of the crankshaft and the bottom of the bore (2mm + 0 -1mm). With this style of mounting the shoulder runout should be held to a maximum of 0.001 inches (0.025mm) and the parallelism across a spacer or ground drive pulley should Figure 2 also be held to a maximum of 0.001 inches (0.025mm). Ground drive must be chamfered to clear the radius of the crankshaft. Pulley machining and chamfer to be done in one chucking. B. Mounting Bolt Torque The mounting bolt not only retains the BBC on the crankshaft but also generates clamping force to prevent fretting corrosion between internal BBC components.

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C. Anti-Rotation Recommended Bolt Torque

Thread Type

55 ± 10 lbs.ft.

65 ± 5NM

3/8-24 UNF

55 ± 10 lbs.ft.

65 ± 5NM

M10X1.25-6g

Bolt to be grade #8 US, Grade #10 Europe. Note: Please contact Warner Electric for assistance with other thread sizes.

Table 1 To obtain proper bolt torque (See Table 1), the engine shaft must be held from rotating. Check with the engine manufacturer for acceptable methods of preventing shaft rotation. See figure 3 for piston stop used to prevent engine rotation.

BBC installations require an anti-rotation device to prevent the brake plate from rotating. The anti-rotation device should be rigidly mounted to the mower deck or engine block. The anti-rotation device must be designed to allow the brake plate to move axially. Warner Electric recommends that the anti-rotation device be fabricated from a .469 inch (11.9mm) nominal hardened steel pin.

Figure 4

Figure 3 If customer supplied bolt and washer is used washer to be 3MM (0.118") thick and bolt to be grade 10 Europe (grade # 8 US bolt). Do not use lock washer. The use of Loctite or other thread-locking adhesive is not recommended and is not a substitute for proper mounting bolt torque. Proper mounting bolt torque is essential for BBC operation and to prevent premature failure of the BBC.

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Constraining the axial movement of the brake plate may cause the BBC to function improperly, leading to increased blade stop times and premature failure of the BBC. D. Brake Actuation Spring The actuating force for the braking function is generated by a spring connected between the brake spring attachment point (or one of the clutch actuation cable attachment holes) and a rigid location on the mower such as the deck or engine block. Return spring is not provided with the BBC. The total rotation of the actuation arm from the positive stop in the clutched position to the positive stop in the braked position is 17° nominal. A minimum of 150 in.lbs (16.95nm) of torque is required to move the actuation arm from the fully clutched to the fully braked position. The spring force required to achieve this torque is dependent on several factors such as the location of the attachment points, the angle of the spring compared to the plane, and the tangent of rotation. 819-0465


Figure 5 shows typical brake actuation return spring mounting configuration. In figure 5, a spring that provides a force of 60-lb (27kg) tangent to (± 12°) and in plane with the actuation arm rotation is attached at the brake spring attachment point [located on a 2.56-inch (66.04 mm) radius from the centerline of the BBC].

E. Clutch Actuation A control system must be provided which will allow the operator to engage the clutch by rotating the actuation arm from the fully braked position to the fully clutched position. This is typically accomplished with a control in the operator zone, which is connected by a cable to the actuation arm. The control and cable assembly must have sufficient stroke to rotate the actuation arm from the positive stop in the braked position to the positive stop in the clutched position (17° nominal). Warner Electric recommends the use of a cable with an over-travel spring which will allow for mower manufacturing tolerances. Cable manufacturer to provide cable that will not stretch at required force and to add strands as required. F. Clearance

Figure 5

Option 2: When brake spring is attached to one of the holes in the acctuator arm, it should provide a minimum of 12kg (26lb) force tangent to and in plane of rotation. When BBC is in clutch mode this spring force is not to exceed 20kg (44lb). The blade brake feature of the BBC requires a brake return spring that will provide sufficient force to rotate the actuation arm to the positive stop in the braked position. Failure to fully rotate the actuation arm to the positive stop for the brake may result in increased blade stop time and/or premature BBC failure.

Warner Electric • 800-825-9050

Adequate clearance for all parts of the BBC is necessary for the BBC to function properly. No member of the BBC should be constrained by the mower deck, engine housing, or ground drive pulley. Adequate clearance should be available so that the brake plate may move axially up to .375 inches (9.5mm) and the clutch actuation lever may complete its required stroke (dimension varies for different BBC geometry's consult Warner Electric for assistance). G. Engine Oil Drain Plug All walk behind lawnmower engines contain an engine oil drain plug somewhere on the block. Some have the oil drain plug located directly above the BBC. When using these types of engines, Warner Electric strongly suggests that the end user of the lawnmower be clearly instructed to remove the engine oil out of the downspout, and not the engine oil drain plug.

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If engine oil is spilled onto the BBC, the BBC will not perform properly. The blade engagement time as well as the blade stop time may be severely increased. If engine oil is spilled on the BBC, it should be replaced. H. Operating Temperature Warner Electric's BBC is designed to operate in environments where the top plate bearing temperature does not exceed 250° F (121°C). We strongly recommend that the top plate bearing temperature be monitored during testing and any readings over 220° F (104°C) be reported to Warner Electric. I. Torque Capacity The BBC must have adequate clutch torque capacity to stall the engine in the event that the deck becomes blocked. The BBC is available with three different clutch springs for static torque capacities of 100, 144, and 160 in.lbs. (11.3,16.3, & 18 NM). The BBC is generally applicable through 6 hp engines, however the torque output of engines can vary widely. Warner Electric strongly recommends that during testing the stall capacity of the BBC be checked. Blocking the blade with a wooden board and repeatedly engaging the BBC against the blocked blade can easily accomplish this. We recommend the BBC should be capable of stalling the engine five consecutive times over a two-minute period. However, the mower manufacturer should establish the minimum number of times the BBC should be capable of stalling the engine based on the anticipated consumer usage. It is recommended that the stall testing be conducted immediately after the mower has run for at least one half hour and the BBC cycled at least 20 times.

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J. Shrouds Warner Electric recommends that the BBC not be enclosed in a shroud. Historically, shrouds have tended to trap grass clippings, debris and moisture around the BBC rather than protecting the BBC from contamination. K. Blade Design It is important that the mower blade be designed so that its natural frequency is above 60Hertz given a maximum engine speed of 3600 rpm. Failure to do so can result in very high blade deflections when the blade is stationary and the engine is running. The mower manufacturer should test for blade deflection over the entire engine speed range. L. Deck Maintenance Warner Electric strongly suggests that customers “DO NOT” use a pressure washer to clear the underside of the deck. M. Engine Inertia In some cases when using "engine kill" type operator presence controls, the engine manufacturers use the blade inertia as portion of the flywheel effect needed to start the engine. When using the BBC, the blade does not rotate when starting the engine. Some engines will require that a heavier flywheel be specified when using the BBC. Please consult with the engine manufacturer when specifying an engine that will be used with a BBC equipped mower.

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V. Installation The following describes a general procedure for installing a BBC on a mower. Some machines may require deviation from this procedure. In some cases due to the mower configuration, the BBC must be partially assembled to the engine before the engine is assembled to the deck. 1. Apply a small amount of rust inhibitor to the engine crankshaft. 2. If using a loose key, place the key into the key-slot in the engine shaft. 3. Align the key and keyway and slide the BBC onto the engine shaft. Use care not to contaminate the BBC friction surfaces with rust inhibitor. 4. Insert the mounting bolt supplied with the BBC through the clearance hole in the BBC into the threaded hole in the end of the engine crankshaft and hand tighten. 5. While preventing the engine shaft from rotating, torque (Figure 6) the mounting bolt to the appropriate torque specification. (See Table 1, page 4) 6. Install and tighten the anti-rotation bolt. 7. Install the clutch actuation cable. 8. Install the brake return spring. Reference Sec # IV - D. Check to be sure that the spring is strong enough to force the actuation arm to the positive brake stop. Push on the arm towards the brake stop. There should be no additional rotation of the arm. If the actuation arm rotates, it is indicative that the brake return spring is not strong enough. (Cable should be disconnected from deck attachment bracket at this time.) 9. Adjust the cable as necessary to ensure the actuation arm moves to the positive clutch stop. (See Figures 7A and 7B) 10. Install the mower blade. 11. Burnish the BBC per the procedure outlined in section VI Step C.

Failure to fully rotate the clutch actuation (See Figures 7A and 7B) arm to the positive stop may result in the clutch and brake being engaged at the same time resulting in drag on the engine and premature failure of the BBC.

Figure 6

Figure 7A - Slack

Figure 7B - Tight Warner Electric • 800-825-9050

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VI. Performing Maintenance on the Warner Electric BBC Please note that either the Troubleshooting Guide (see page 9) or a Warner Electric representative should be consulted to determine which component needs to be replaced. A. Replacing the Output hub / Lower Assembly 1. Remove the lawn mower blade from the BBC by removing the blade mounting bolts. 2. Remove the lower assembly from the BBC. Install the new lower assembly to the BBC. 3. Check hub disc on upper assembly for excessive wear or discoloration (Blue/Straw etc..) this could indicate that the clutch has become overheated. If this is the case, replace the complete clutch. (See Table 1, page 4) 4. Reinstall the mower blade. 5. Burnish the BBC per the burnish instructions (see section VI. Step C.)

6. Burnish the BBC per the burnish instructions (see Step C below). C. BBC Burnish Instructions Burnish the BBC whenever either the clutch assembly or the brake assembly is replaced without replacing the mating component. The mower should be fully functional before this burnish procedure is initiated. The burnish procedure consists of the following steps: 1. Start the lawn mower engine. 2. Run the mower engine at the maximum engine speed. Allow the mower engine to run a sufficient amount of time so that the engine will not stall upon engagement of the blade. 3. With the engine running at maximum engine speed, engage and disengage the BBC a minimum of 15 times.

B. Replacing the complete BBC Assembly 1. Remove the lawn mower blade from the BBC by removing the blade mounting bolts. 2. Remove the brake actuation spring and remove the BBC mounting bolt. 3. Disconnect the BBC actuation cable. 4. Remove the complete BBC assembly using the removal threads. Note: On some applications the BBC brake assembly will not easily fit through the space allowed in the mower deck. In this instance, the mower engine mounting bolts must be removed and the mower engine lifted off of the deck so that the brake assembly can be removed. 5. Install the new complete BBC assembly directly to the engine crankshaft. (See Section V) In the case where the mower engine was lifted up, remount the engine to the mower deck. (See Table 1, page 4) 8

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V: Troubleshooting the Warner Electric BBC Symptom: BBC will not engage or is slow to engage Problem

Possible Causes

Section Referral/Solution

Clutch and brake are engaged at the same time

Cable is out of adjustment

Readjust the BBC actuation cable. (Refer to Section V #9)

Friction material is contaminated

Engine oil has infiltrated the friction If engine oil has been leaking onto the material friction surfaces, replace the BBC Grass or dirt has lodged around the fric- immediately. If grass or dirt has lodged tion material around the friction material, disassemble and remove the clutch assembly (See Section VI A & B) and remove the contaminants. (Refer to Section IV G)

Mounting bolt torque is inadequate

Mounting bolt improperly installed

Torque the mounting bolt to the specified installation torque. (Refer to Section VI A & B)

Overloaded clutch

Application is improperly sized

Consult Warner Electric personnel for assistance.

Friction material is worn out

BBC has surpassed its life

Replace the clutch assembly or the entire BBC. (Refer to Section VI A)

Symptom: BBC will not brake the mower blade Problem

Possible Causes

Section Referral/Solution

Clutch and brake are engaged at the same time

Cable is out of adjustment

Readjust the BBC actuation cable. (Refer to Section V #9)

Anti-rotation device has failed

Anti-rotation device is missing or failed during mower operation

Replace the anti-rotation device. Inspect the BBC closely for damage and replace if necessary. (Refer to Section IV C)

Friction material is contaminated

Engine oil has infiltrated the friction material Grass or dirt has lodged around the friction material

If engine oil has been leaking onto the friction surfaces, replace the BBC immediately. If grass or dirt has lodged around the friction material, disassemble and remove the clutch assembly (See Section VI A & B) and remove the contaminants. (Refer to Section IV G)

Brake return spring is improperly installed

Installed incorrectly at the manufacturing site or by service personnel

Reinstall the brake return spring per the lawnmower manufacturer's specifications. (Refer to Section IV D)

Overloaded brake

Application is improperly sized

Consult Warner Electric personnel for assistance.

Mounting bolt torque is inadequate

Mounting bolt improperly installed

Torque the mounting bolt to the specified installation torque. (Refer to Section IV A & B)

Friction material is worn out or glazed

BBC has surpassed its life, cable out of adjustment, or brake spring too weak.

Replace the brake assembly / the entire BBC, or replace brake spring / adjust cable. (Refer to Section V A & B)

Warner Electric • 800-825-9050

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9


Quick Review Check List for BBC Applications

❒1

❒2 ❒3 ❒4

Mounting Bolt Torque: 55 -lbs.ft. ± 10 lbs.ft. (65NM ± 5NM) ( 3/8-24 UNF or M10X1.25-6g) Make sure the mounting bolt does not bottom in crank threaded bore. Anti-rotation: anti-rotation device allows axial movement of BBC. Min. pin dia. 0.469" Note: Perform Steps 4 & 5 (of this check list) before return spring and cable are attached.

Position actuation arm so that BBC is in the full braked position, then mark leading edge position on deck.

❒5

Position actuation arm so that BBC is in the full clutched position, then mark leading edge position on deck.

❒6

Clearance: Adequate clearance for all parts of the BBC in both braked and clutched modes. Insure that the BBC does not bind or rub on any part of mower.

❒7 ❒8

❒9

Attach Brake Actuation Spring: Brake actuation spring must have enough force to rotate the brake plate to the fully braked position.(See Step # 4, of this check list) Control Cable: Control cable must have sufficient stroke to rotate the actuation arm from the positive stop in the braked mode to the positive stop in the clutched position (adjust if necessary). (use of an over travel spring will allow for cable stretch and manufacturing tolerances. (See Steps # 4 & 5, of this check list)

Engine Oil Drain plug: Instruct end user to remove oil from the filler tube and not from drain plug. Do not allow oil to contaminate BBC, replacement of BBC will be required if oil contamination occurs.

❒ 10

Operation temperature: Top plate bearing not to exceed 220 degrees F.

❒ 11

Shrouds: Warner Electric does not recommend the use of shrouds.

❒ 12 ❒ 13 10

Check Mounting: A. Shaft End Mounting: must have clearance between BBC hub and ground drive pulley, shaft end runout to be 0.001 inches maximum. B. Shoulder-mounting: Inner race of top plate bearing is in contact with crankshaft shoulder, spacer or ground drive pulley. Clearance must be maintained between the bottom of the BBC bore and the end of crankshaft. Shoulder runout to be held to maximum 0.001 inches and parallelism across a spacer or ground drive to be held to maximum 0.001 inches

Blade design: Blade design to be designed so that its natural frequency is above driving frequency of engine.

Engine inertia: Fly wheel of sufficient size to allow for starting without the added inertia of the blade.

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Warner Electric • 800-825-9050

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Warranty Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any product manufactured and sold by it which proves to be defective in material or workmanship within a period of one (1) year from the date of original purchase for consumer, commercial or industrial use. This warranty extends only to the original purchaser and is not transferable or assignable without Warner Electric LLC’s prior consent. Warranty service can be obtained in the U.S.A. by returning any defective product, transportation charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information may be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449 Gardner Street, South Beloit, Illinois 61080, or by calling 815-389-3771. A purchase receipt or other proof of original purchase will be required before warranty service is rendered. If found defective under the terms of this warranty, repair or replacement will be made, without charge, together with a refund for transportation costs. If found not to be defective, you will be notified and, with your consent, the item will be repaired or replaced and returned to you at your expense. This warranty covers normal use and does not cover damage or defect which results from alteration, accident, neglect, or improper installation, operation, or maintenance. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you. Warner Electric LLC’s obligation under this warranty is limited to the repair or replacement of the defective product and in no event shall Warner Electric LLC be liable for consequential, indirect, or incidental damages of any kind incurred by reason of the manufacture, sale or use of any defective product. Warner Electric LLC neither assumes nor authorizes any other person to give any other warranty or to assume any other obligation or liability on its behalf. WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. Changes in Dimensions and Specifications All dimensions and specifications shown in Warner Electric catalogs are subject to change without notice. Weights do not include weight of boxing for shipment. Certified prints will be furnished without charge on request to Warner Electric.

Warner Electric LLC 449 Gardner Street • South Beloit, IL 61080 815-389-3771 • Fax: 815-389-2582 www.warnerelectric.com P-1319 819-0465 10/04

Printed in USA


Sensors Industrial Switches and Safety Technology Products


WARNER ELECTRIC Sensors, Industrial Switches and Safety Technology Products Warner Electric has many years of experience in applying sensors in motion control applications. Warner Electric’s broad range of innovative and technologically advanced product range offers our customers the exact solution to satisfy their sensing applications. Our full product range is available through more than 800 distributor locations, throughout the United States, Canada and Mexico. Local Sales Support is provided by a well trained sales force that is backed up by Application Engineering providing immediate technical support.

Non-Contact Sensors Photoelectric Sensors Ultrasonic Sensors Inductive Proximity Sensors Capacitive Sensors Magnetic Sensors Industrial Switches Limit Switches Foot Switches Cable Pull Switches Safety Technology Products Safety Interlocks Cable Pull Switches Coded Magnetic Monitoring Systems

Approvals and Certification Each model is individually identified with its own certification. Documentation is available upon request.

Š2004 Warner Electric, Inc.

For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Standard Sensor Products

Contents

Choosing the Correct Sensor Photoelectric Sensors

................................2

Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 OR20 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 OR90 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 MCS-144 / 159 / 165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 MCS-500 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Compact Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 OT18 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 MCS-638 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Ultrasonic Sensors Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 With Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 With Isolated Solid State Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Inductive Proximity Sensors Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 4mm / M4 / M5 / M8 / M12 / M18 / M30 Voltage 10-30 DC, Integral Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 M8 / M12 / M18 / M30. Voltage 10-30 DC, Quick Disconnect . . . . . . . . . . . . .20 M12 / M18 / M30. Voltage AC, Integral Cable and Quick Disconnect . . . . . . .22

Capacitive Sensors Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 M12 / M18 / M30 / M32 / 34mm dia Integral Cable and Quick Disconnect. Voltage DC and AC. . . . . . . . . . . . . . .24

Magnetic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Sensor Controls MCS 149 / 680 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Thermoplastic Limit Switches Body Styles Ti2 / Bi / I88 / ENK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Metal Limit Switches Body Style ENM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Foot Switches Single, Two and Three Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Safety Technology Products Safety Position Interlocks Important Safety Warning... The Non Contact sensors described in this catalog do NOT include the self-checking redundant circuitry necessary to allow them to be used in personnel safety applications. A sensor failure or malfunction can result in either an energized or a de-energized output condition. Never use these non contact products as sensing devices for personnel protection. Their use as safety devices may create an unsafe condition which could lead to serious bodily injury or death.

SKT / SKI Body Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 SK / SKC Body Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 GC Body Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Safety Hinge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 I88 Style Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Solenoid Locking SLK Spring and Magnetic Lock (Plastic Housing) . . . . . . . . . . . . . . . . . . . . . .54 SLM Spring and Magnetic Lock (Metal Housing) . . . . . . . . . . . . . . . . . . . . . .55

Coded Magnetic Monitoring Systems MUZ 602 / 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Coded Magnet Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Cable Pull Switches Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Two Directional to 250 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Glossary of Terms

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Index to Part Numbers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

1 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Choosing the correct sensor for your application Many situations have developed that have resulted in the loss of valuable production hours, due to not enough time being taken to choose the correct sensor for the application. These situations can be avoided if each application is systematically approached in the following manner.

Which sensor? Four basic questions should be asked:

2 – What is the environment?

AC circuits generally come in two types, solid state and electromechanical relays.

Consider the surrounding and working conditions, steam coolant, metal surfaces, temperature both high and low, all can influence the performance of the sensor.

Finally remember, any problems or questions, call Sensor Application Support for help.

Ensure not only that the sensor can detect the target cleanly and clearly, but how it will be able to withstand maintenance and wash–down situations. Sensing variables/least to most affected relating to ambient conditions. Magnetic

1 – What are you sensing?

Inductive Proximity Photoelectric – Through-Beam

2 – What is the environment?

Ultrasonic – Proximity Photoelectric – Convergent Beam

3 – What is your input voltage?

APPLICATION ASSISTANCE CALL

1-800-451-8279 FAX

1-815-389-6678

Photoelectric – Retroreflective Photoelectric – Background Suppression

4 – What are you controlling?

1 – What are you sensing? It is extremely important to know what the material is you are sensing as the material relates directly to the type of sensor chosen. At this stage, it is also relevant to consider what distance away from the target would suit your application best. The final information required is to know the size and shape. To give a general guideline, the following chart gives an indication of each type of sensor relating to sensing distances.

Photoelectric – Diffuse Reflective Capacitive Proximity

3 – What is your input voltage? A large factor relating to the exact sensor or sensor system you might eventually choose. A lot of the smaller type sensors need to have power supplies in order that the correct stable D.C. voltage is available. Eventually this question may not be needed to be taken into account as more and more sensors are becoming available in a multivoltage AC/DC format, 12-265 AC/DC.

4 – What are you controlling? Range/longest to shortest Photoelectric – Through-Beam Photoelectric – Retroreflective Ultrasonic – Proximity Photoelectric – Diffuse Reflective Photoelectric – Background Suppression Photoelectric – Convergent Beam Photoelectric – Fiber Optics Magnetic Capacitive Proximity

Always examine the type of output required and its capability to drive the external circuitry. The most common problem when dealing with D.C. output circuits relates to “sourcing” or “sinking” PNP or NPN. Always determine the answer to this question prior to any purchase by examining the specification of the control or counter system you are interfacing with, to ensure compatibility.

Inductive Proximity

2 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Photoelectric Applications

Photoelectric Identification Codes 1. Example: O

• Jam detection and prevention • Empty line detection • Counting • Sorting by size, color or surface • Automatic routing • Feed control • Hopper level control • Color mark registration • Edge guiding • Web break detection • Positioning • Cut-off control • Filling • Folding and wrapping • Batch counting • Missing part detection • Correct count • Open flap detection • Ejected part detection • Incorrect closure • Door control • Sizing

MCS-627

3. 1

4. 2

1

O = Photoelectric Sensor

2

M = Metric metal housing T = Metric thermoplastic housing R = Rectangular design Z = Cylindrical design

3/4

Specification of housing dimensions e.g. 12 = M12 18 = M18 20 = 20 series 90 = 90 series

5/6

MCS-627

2. M

5. R

ES = Through-beam sensor (Complete set) EE = Through-beam, receiver only SE = Through-beam, transmitter only LC = Fiber optic control (sensor with fiber optics connection) RH = Diffuse reflective sensor with background suppression RS = Retroreflective sensor RT = Diffuse reflective sensor FF = Convergent beam sensor, fixed focus PR = Print registration sensor PS = Polarized retro sensor

7

Dash

8

Voltage type A = AC D = DC M = Multivoltage, AC/DC, UC P = Programmable voltage (AC or DC)

6. T

7. — 9

10

8. D

9. 10. 11. H T P

12. 13. 14. 15. 16. — 0 2 0 0

Output function A = Complementary LA/DA (light activated/ dark activated) D = Dark activated (DA) H = Light activated (LA) O = No output (throughbeam transmitter) P = Selectable LA/DA (light activated/ dark activated) X = Customer-specified output Output type A = Analog output N = NAMUR O = No output Q = Triac R = Relay S = Others T = Transistor Y = Thyristor

11

N = NPN transistor output (switched to negative) P = PNP transistor output (switched to positive) G = Push/Pull S = Through-beam light source U = Switch selectable NPN/PNP 2 = 2-wire output 3 = 3-wire output 4 = 4-wire output

12

Dash

17. 18. 19. — C L

+

13-16 Sensing distance Sensing distance specifications are always indicated by 4 digits – mm: without decimal point – m: with decimal point e.g. 06.0 = 6 m e.g. 15.0 = 15 m e.g. 0500 = 500 mm 17

Dash

18

Connection type A = Screw termination B = Plug with screw terminals C = Cable (standard C = 2 m or length in m) S = Plug-in connector

19

Options C = Control/diagnostic input D = LED for output indication E = Adjustable sensitivity F = Diagnostic circuit with output and LED for indicator G = LED for output mode, supply voltage and beam control indication H = LED for supply voltage and output mode indication L = LED for output indicator T = Adjustable timer circuit V = LED for operating voltage indication X = Customer-specific options Z = Fixed timer

Truck Height Control A long range through-beam sensor was positioned at a height just below the overhanging roof and a couple of feet in front, so the breaking of the beam would activate an output wired to an alarm alerting the driver to stop.

Diffuse Reflective Sensor

Retroreflector MCS-638 Color Mark Sensor

Shrink wrap film

Retroreflective Sensor

Conveyor/Material Handling

Bag Cutting Machine

Object Detection

Basically, with this being a specialized application, there is only one solution and product selection, and that is the MCS 638 Series Color/Print Registration Sensor.

By placing a diffuse reflective type underneath the conveyor and looking up through the rollers, a safe sensing position has been found for the sensor away from fork lift trucks and other possible damaging actions.

These units were designed to solve this application with the sensor being capable of sensing small changes in contrast levels or shade differences.

A retroreflective sensor was chosen to look across the conveyor at the retroreflector. When the book blocks the beam, a signal is given to stop the conveyor.

3 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Photoelectric Sensors OR20 Series Description The OR20 Series is a family of self-contained photoelectric sensors, with multi-voltage input and relay output. Standard features include adjustable sensitivity and timing circuits which are easily accessible after removing the “snap cover”. Sensing modes available include: Through-Beam, Retro, Polarized, Diffused Reflective and Background Suppression. • Rectangular high impact plastic housing

• Timing range 0.1-10 seconds

• LED indication of output

• Multi-voltage 12-265 VAC / DC

• NEMA 4

• Screw terminals for wiring

• Sensitivity control

• Snap shut hinged back cover

• Programmable timing Delay or Hold

• Relay output - 3A

• Temperature range -4°F to +158°F

OR20 Series

Sensor Selection Sensing Principle

Sensing Range

Input Voltage

Switching Output Maximum Output Function Mode Cycle Rate Current

Through-Beam 65 ft. 12-265 VAC / DC SPDT Relay Retro-Reflective 26 ft. 12-265 VAC / DC SPDT Relay Polarized Retro 19 ft. 12-265 VAC / DC SPDT Relay Diffuse Reflective 4.9 ft. 12-265 VAC / DC SPDT Relay Diffuse Reflective 1.9 ft. 12-265 VAC / DC SPDT Relay BkGnd Suppression 1.2 ft. 12-265 VAC / DC SPDT Relay * A Through-Beam Sensor can be supplied as separate pieces Projector = Part # 655-1086-001 Receiver = Part # 655-1686-003

>50 >50 >50 >50 >50 >50

Hz Hz Hz Hz Hz Hz

3A 3A 3A 3A 3A 3A

Model OR20 OR20 OR20 OR20 OR20 OR20

Part Number

ES-MAR5-20.0-ALET RS-MAR5-08.0-ALET PS-MAR5-06.0-ALET RT-MAR5-01.5-ALET RT-MAR5-0600-ALET RH-MAR5-0400-ALET

655-1686-103* 655-4686-001 655-5686-001 655-7686-003 655-7686-001 655-8686-002

Mechanical Data (Dimensions are in inches) 2.48 1.48 .22

LED

.93 Sensitivity

1 Snap-cover housings (to be opened with screwdriver)

3

1

Time

Optical Area

Notes on operation of OR20 Series Housing types:

4 Delay Hold

.63 2.44

.79

1

5

Operation elements:

3.46

6

1 2 3 4 5

3 4 5 6

Sensitivity potentiometer Timer potentiometer Delay-type switch Connection terminals

Wiring Data (1) (2) (3) (4) (5)

Relay Output

COM N.O. N.C. AC / DC Input

Accessories Reflective Disc – 3 1/4” Dia. Mounting Bracket – Fixed Mounting Bracket Adjustable

4 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

Part # 610-8002-001 Part # 7430-448-005 Part # 7430-448-010


Photoelectric Sensors OR90 Series Description The OR90 Series offers a low cost self-contained family of sensors, housed in a high impact rectangular thermoplastic housing. Termination is made via a 6 ft. long 5 conductor integral cable. Features include, multi-voltage input with relay output, and LED indication of output signal. The series includes 3 sensing modes: Retro, Diffuse and Background Suppression. The OR90 is a simple, low maintenance sensor ideal for material handling applications. • Totally sealed plastic housing • LED indication of output • NEMA 1,3,4,12 • Temperature rating -4°F to +158°F

OR90 Series

• 6 ft. cable -5 conductor • Multi-voltage 12-265 VAC / DC

Sensor Selection Sensing Principle

Sensing Range

Retro-Reflective BkGnd Suppression Diffuse Reflective

Input Voltage

Switching Output Maximum Output Function Mode Cycle Rate Current

26 ft. 12-265 VAC / DC 3 in. 12-265 VAC / DC 23.6 in. 12-265 VAC / DC

SPDT SPDT SPDT

Relay Relay Relay

>80 Hz >80 Hz >80 Hz

3A 3A 3A

Model OR90 RS-MAR5-08.0-CL OR90 RH-MAR5-0080-CL OR90 RT-MAR5-0600-CL

Part Number 655-4696-001 655-8696-001 655-7696-001

(Dimensions are in inches) 1.97 1.42

.91 .47

LED

Optical Area

.55 1.71

2.80

3.38

2.26

M4 x 4 .18 .28

Wiring Data black UB

blue brown white grey

AC / DC Input N.C. N.O. C

Relay Output

Accessories Reflective Disc – 3 1/4” Dia. Part # 610-8002-001 Mounting Bracket Part # 7430-448-007

5 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Photoelectric Sensors MCS-144/159/165 Description This proven range of photoelectric sensors provides the user with a standard self-contained sensor with the possibility of modular expansion with plug-in timer, counter and output modules. A “plug-in” double pole double throw 7 amp relay is supplied with all units. Features include a light activated/dark activated switch, adjustable sensitivity and LED output indication.

MCS-144

MCS-159/165

• Heavy duty plastic housing

• Selectable LA/DA operation

• LED indication of sensing

• Temperature rating 0°F to 125°F

• Sensitivity control

• Screw terminals for wiring

• Optional timing and counting modules

• NEMA 12

• Replaceable industrial relay

• Screw down back cover

Sensor Selection Sensing Principle Retro-Reflective Retro-Reflective Diffuse Reflective

Sensing Range 30 ft. 15 ft. 6 ft.

Input Voltage 110 VAC 110 VAC 110 VAC

Switching Function DPDT DPDT DPDT

Output Mode Relay Relay Relay

Maximum Cycle Rate >25 Hz >25 Hz >25 Hz

Output Current 7A 7A 7A

Model MCS-144/814 MCS-165/814 MCS-159/814

Part Number 7120-448-004 7120-448-015 7100-448-002

MCS-144, 159 – Plug-in Modules (Order Separately)

MCS-165 – Plug-in Modules (Order Separately)

Timer Modules

Timer Modules

Model MCS-836 MCS-836-1

Part Number 7400-448-024 7400-448-029

Timing Range 0.4 to 15 seconds 1 to 30 seconds

Model MCS-830 MCS-830-1

Part Number 7400-448-018 7400-448-026

Timer Functions (Programmable) On Delay / Off Delay / Dual Delay / One-Shot One-Shot Drop / Delayed One-Shot / Delayed One-Shot Drop

Timer Functions

Counter Modules

Counter Modules

Model MCS-831 MCS-832

Part Number 7400-448-019 7400-448-020

Output Module Model MCS-814

Counting Range 1 to 99 1 to 9999

(Supplied as Standard) Part Number 7410-448-008

(Programmable) On Delay / Off Delay / Dual Delay / One-Shot One-Shot Drop / Delayed One-Shot / Delayed One-Shot Drop

Model MCS-833 MCS-834

Part Number 7400-448-021 7400-448-022

Output Module Switching Type DPDT 7 Amp

Mechanical Data (Dimensions are in inches)

Model MCS-814

.400

Counting Range 1 to 99 1 to 9999

(Supplied as Standard) Part Number Switching Type 7410-448-008 DPDT 7 Amp

Wiring Data MCS-814

2.578

Timing Range 0.4 to 15 seconds 1 to 30 seconds

MCS-814

4.156 Lens 1.500 Dia.

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

C N0 NC NC NO C

C NC NO C NC NO

Relay Output 7.562 6.375

Mounted from bottom with bracket, conduit or 4 mounting holes

110 VAC INPUT

MCS-144, 159

Relay Output

110 VAC INPUT

MCS-165

Accessories Reflective Disc – 3 1/4” Dia. Mounting Bracket

6 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

Part # 610-8002-001 Part # 7430-448-001


Photoelectric Sensors MCS-500 Series Description The MCS-500 Series is a self-contained modular design with many standard features that include programmable multi-function timing circuits, sensitivity adjustment, and LED output indication. Once installed, the base module will accept any of the 3 sensing control heads, which can provide Retro, Polarized and Diffused Reflective modes of sensing. The MCS-850 relay is a plug-in module and is supplied as a standard component when purchased as a complete sensor. • Modular design (Control Head/Output Module/Base)

• Two timing ranges Low range 0.5-10 seconds High range 3.0-30 seconds

• LED indication of sensing status

• Programmable timing

• Sensitivity control

• Temperature range 0°F to 125°F

• NEMA 12

• Screw terminals for wiring

• High impact plastic housing

MCS-500 Series

Sensor Selection Sensing Sensing Principle Range Retro-Reflective 15 ft. Polarized Retro 12 ft. Diffuse Reflective 6 ft.

Input Voltage 110 VAC 110 VAC 110 VAC

Switching Function SPDT SPDT SPDT

Mechanical Data (Dimensions are in inches) 1.65

Output Maximum Output Mode Cycle Rate Current Relay >50 Hz 5A Relay >50 Hz 5A Relay >50 Hz 5A

Model MCS-500-01 MCS-500P-01 MCS-501-01

Part Number 7150-448-004 7151-448-001 7150-448-003

MCS-500 Timing Functions Switch selectable, multi-function timing is a standard feature on the MCS-500, MCS-500P and MCS-501.

2.800

The timing function can be switched from a low timing range of 0.5 to 5.0 seconds to a high timing range of 3.0 to 30 seconds. When no timing is required, the function can be switched off. 4.906

On delay, off delay, dual delay, one shot, and delayed one shot functions are quickly achieved by setting the timing switches on the unit. Easy-access timing adjustment controls are accessible from the top of the unit to allow fine tuning during operation. Timing functions can be employed for light or dark operation.

1.35

3.185

Wiring Data MCS-850

Timing Ranges Low range 0.5 to 5.0 seconds

Ordering Information for Individual modules

High range 3.0 to 30 seconds

Control Module

On-Off switch selectable

MCS-500-120-CON MCS-500P-120-CON MCS-501-120-CON

Part Number 7150-101-004 7151-101-001 7150-101-003

Base Module

N.C. N.O. C

MCS-500-120-BAS

7150-101-013

Output Module 110 VAC INPUT

MCS-850-REL-OUT SPDT Relay 5A

7150-101-016

Relay Output

Accessories Reflective Disc – 3 1/4” Dia. Mounting Bracket Cable Gland

Part # 610-8002-001 Part # 7150-101-020 Part # 7420-448-029

7 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Photoelectric Sensors Compact Series Description The COMPACT Series of photoelectric sensors are rugged industrial DC voltage input photoelectric sensors with a reliable performance for many general purpose applications. Sensing mode capabilities include: Through-Beam (up to 500 ft.), Retro and Diffuse Reflective. Output standard on all units is light activated/dark activated NPN transistor. LA/DA is selectable at the time of installation by wire selection. All Compact Series of sensors are designed to work with the Warner Electric range of sensor controls.

• Heavy duty zinc die cast housing • LED indication of output • NEMA 1, 12 • Temperature rating -40°F to +158°F (MCS-629 only) • Temperature rating -22°F to +158°F

Compact Series

• 10 ft. cable

Sensor Selection Sensing Principle

Sensing Range

Through-Beam Through-Beam Through-Beam Retro-Reflective Retro-Reflective Diffuse Reflective Diffuse Reflective Diffuse Reflective Diffuse Reflective

500 ft. 50 ft. 50 ft. 15 ft. 15 ft. 0 to 1 ft. 0 to 1 ft. .1 to 6 ft. .1 to 6 ft.

Mechanical Data

Input Voltage 10-30 12-18 22-28 12-18 22-28 12-18 22-28 12-18 22-28

Switching Function

Output Mode

Maximum Cycle Rate

LA / DA LA / DA LA / DA LA / DA LA / DA LA / DA LA / DA LA / DA LA / DA

NPN NPN NPN NPN NPN NPN NPN NPN NPN

>25 Hz >250 Hz >250 Hz >250 Hz >250 Hz >250 Hz >250 Hz >250 Hz >250 Hz

VDC VDC VDC VDC VDC VDC VDC VDC VDC

Output Current 250 250 250 250 250 250 250 250 250

mA mA mA mA mA mA mA mA mA

Model MCS-629 MCS-627 MCS-637 MCS-625 MCS-635 MCS-626 MCS-636 MCS-626-2 MCS-636-2

Part Number 7115-448-005 7115-448-003 7115-448-001 7125-448-002 7125-448-003 7105-448-002 7105-448-005 7105-448-007 7105-448-011

(Dimensions are in inches) 1.625

1.625

2.125 .306

2.125

1.625

2.125 .306

1.667

1.667

2.76

2.075

2.76

2.018

2.018

1.325

.400

Cable

Cable

.590

.400

.590

MCS-626/636

MCS-627/629

.400

.590

MCS-625/635

Wiring Data RECEIVER

TRANSMITTER red

Loads red

+U

B

white Osc.

Amp black

green black

O.V.

+ UB Norm. OFF Norm. ON O.V.

RL

Outputs

RL

shield

shield

MCS-627/629 red Osc.

+ UB

white

Norm. OFF

green

Norm. ON

Amp black

Loads RL

Outputs

RL

O.V.

shield

MCS-625/635/626/636/626-2/636-2

Accessories Reflective Disc – 3 1/4” Dia. Part # 610-8002-001 Mounting Bracket Part # 7430-448-003

8 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Photoelectric Sensors OT18 Series Description This series of 18mm plastic tubular sensors provides the user with a self-contained DC low voltage sensor with NPN or PNP output. Programmable light activated/dark activated output. Modes of sensing include: ThroughBeam, Retroreflective, Polarized Retroreflective, Diffuse Reflective and Fixed Focus types. • 18mm diameter cylindrical plastic housing

• Reverse polarity protection

• Self-contained with 6.5 ft. cable

• Short circuit protected

• IP 67 / NEMA 4

• 200mA switching current

• LED indication of output

• Voltage drop ≤2 VDC

• Temperature range –20°C to +70°C (–4°F to +158°F)

• Hysterisis ≤15%

• 10–36 VDC input voltage

• Switching frequency 500 Hz

OT18 Series

• Repeat accuracy ≤10%

• No-load supply current ≤15 mA (Emitter ≤20 mA)

Sensor Selection Sensing Principle Through-Beam Through-Beam Retro-Reflective Retro-Reflective Polarized Retro-Reflective Polarized Retro-Reflective Diffuse Reflective Diffuse Reflective Diffuse Reflective Diffuse Reflective Fixed Focus Fixed Focus

2 2 0 0

Sensing Range

Switching Function

Sensitivity

26 ft. 26 ft. in. to 9.5 in. to 9.5 in. to 8.2 in. to 8.2 19.6 in. 19.6 in. 11.8 in. 11.8 in. 1.57 in. 1.57 in.

NPN PNP NPN PNP NPN PNP NPN PNP NPN PNP NPN PNP

Fixed Fixed Fixed Fixed Adjustable Adjustable Adjustable Adjustable Adjustable Adjustable Fixed Fixed

ft. ft. ft. ft.

Model Description OT18ES-DPTN-08.0-CL OT18ES-DPTP-08.0-CL OT18RS-DPTN-03.0-CL OT18RS-DPTP-03.0-CL OT18PS-DPTN-02.5-CLE OT18PS-DPTP-02.5-CLE OT18RT-DPTN-0500-CLE OT18RT-DPTP-0500-CLE OT18RT-DPTN-0300-CLE OT18RT-DPTP-0300-CLE OT18FF-DPTN-0040-CL OT18FF-DPTP-0040-CL

Through Beam Sensors:

Accessories

To order separate transmitters and receivers use the following:

Reflective Disc-3-1/4" Dia. Part #610-8002-001 Mounting Bracket

Part Number 655-1219-102 655-1819-101 655-4219-002 655-4819-003 655-5219-001 655-5819-003 655-7219-006 655-7819-006 655-7219-005 655-7819-005 655-8219-001 655-8819-001

Part #7125-101-001

Transmitter: Part Number 655-1019-001 Model: OT18SE-DOOS-08.0-C

Note: The sensors on this page are also available in nickel–plated brass or stainless steel housings, also available in quick disconnect version. Contact Factory.

Receiver: Part Number: 655-1219-002 Model: OT18EE-DPTN-08.0-CL Part Number: 655-1819-001 Model: OT18EE-DPTP-08.0-CL

9 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Photoelectric Sensors OT18 Series Dimensions and Wiring Details

56 (2.2 in.)

POT

POT

60 (2.3 in.) 4

LED

46 (1.8 in.)

LED

46 (1.8 in.)

M18x1

M18x1

Through-Beam, Retro, Diffuse, Fixed Focus, Sensors

Polarized Retroreflective Sensors

Wiring Diagram of the Through-Beam Emitter Wire Colors: Brown = Plus 10 – 36 Volts DC

BN

Blue = Zero Volts Common Black = Output Wire

BK

C

White = Control Wire BU

Note: The LED output indicator is on when the output is active.

Black = Control Input. The emitter will be turned off when the control wire is connected to minus (common). System Test Function.

Normally Off

PNP – sensors

NPN – sensors

BN

BN BK

WH LOAD

WH

BK

BU

BU

LOAD

Normally On

PNP – sensors

NPN – sensors BN

BN

BK

WH

LOAD

WH

BK

BU

BU

LOAD

With the Control Wire (White) the output function is programmable. A not connected white wire produces a Normally Open function. Diffuse Reflective and Fixed Focus types are usually operated light active (Normally Off) and other sensors like the Retro, Polarized Retro, and the Through-Beam are usually operated Dark Active (Normally On).

10 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Photoelectric Sensors MCS-638 Series Print Registration/Color Mark/Contrast Sensor • Dual Lens Position • Automatic selection of best color light source (Green, Red, Blue) • Static Mode Teach allows one automatic teach step for the target and one automatic teach step for the background. • Remote Teach Imput allows colors to be programmed externally • Light Operate / Dark Operate modes • Housing Material Makrolon • Quick Disconnect (2 Meter Straight Cable included with Sensor) • Temperature Range -4°F to + 140°F • LED Indication of Output Status • Output - Push-Pull (NPN/ PNP)

MCS-638 Series

Sensor Selection Sensing Range 9.5 mm (3/8 in.) 25 mm (1 in.)

Input Voltage 10 -30 VDC 10 -30 VDC

Current Consumption ≤60 mA ≤60 mA

Maximum Cycle Rate 16.5 KHz 16.5 KHz

Mechanical Data

Output Current 200 mA 200 mA

Model MCS-638-3 MCS-638-4

Knife or Heat Seal

(Dimensions are in mm)

Part Number 7135-448-011 7135-448-012

MCS-149 Power Supply

19 4

33

60.8

4

19

16.5 Cover*

28

23.5

21

28

28

85.6

38.6

M5x8 Screw Depth 5

19

MCS-638 Lens*

Programming

19

1. Connect the supply voltage to the wires noted in the wiring diagram.

M12x1 *Interchangeable

47.9

1.5

Color Mark

LED Yellow: Output Status Yellow: (flashing): Contrast not found from programmed values

Teach In

2. Aim the light spot at the target mark. For glossy or reflective surfaces, the sensor should be angled at 10° to 15° off the perpendicular axis from the target.

Teach Push Button

Wiring Diagram Black 4

3

1

2

NPN

Gray

Black 3

1

2

4. Aim the light spot at the background.

0V Blue U B+ ET (teach-in

Brown

4

3. Press the Teach push button on the sensor or apply V+ to the Teach Input for a minimum of 50 milliseconds. The LED should flash slowly (at a rate of approximatel 1 Hz).

Blue

Brown Gray

min. 5 ms)

External Teach Switch Customer Supplied.

PNP 0V U B+ ET (teach-in min. 5 ms) External Teach Switch Customer Supplied.

5. Press the Teach push button on the sensor or apply V+ to the Teach Input for a minimum of 50 milliseconds. The LED will now turn on when the target mark is present and off when it is absent after a successful teach. If the teach was not successful or the contrast was not sufficient, the LED flashes quickly (at a rate of approximately 4 Hz). Programming the MCS-638 as indicated above sets the switching threshold exactly in the middle of the target and background values. The above procedure is for Light Operate mode. For Dark Operate mode, reverse steps 2 and 4.

11 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Ultrasonic Sensors Ultrasonic Applications • Level Control

Ultrasonic Sensor Identification Codes 1

2

Type of Type of Sensor Housing

3 4

5 6

Size of Sensing Dash Housing Discipline Series/Name

• Roll Diameter

1

U = Ultrasonic

• Level Detection

2

M = Metric threaded barrel metal T = Metric threaded barrel plastic R = Rectangular Housing

• Liquid Level Control • Web Break Detection • Object Detection • Loop Control

3/4

Size of housing e.g. 30 = 30mm Diameter

5/6

UP = Ultrasonic Proximity

7

Dash

8

Voltage type A = AC D = DC

9

Output function C = Current/Voltage output S = 2x NO/NC solid state B = Current output

• Thickness and Gauging • Stacking Height Control

Feed Conveyor Hood Sensor

7

8 9 10 11

12

Electrical Spec

Dash

13

Sensing Distance

10

Output type A = Analog output R = Relay S = Solid state relay

11

3 4 5 6 7

12

= = = = =

14 15 16

3-wire output 4-wire output 5-wire output 6-wire output 7-wire output

18

19 20 +

Dash

Type of Termination

Functions & Features

18

Connection type A = Screw termination S = Quick disconnect C = Cable (standard 2 m or length in m)

19

Options S = LED with strength indicator L = LED T = Adjustable detection setting H = Adjustable hysteresis setting I = Current/Voltage inverter circuit M = Microprocessor calibration and gain control circuit C = Current inverter circuit P = PVC housing and PVC sensing face

Dash

13-16 Sensing distance – mm: without dot – m: with dot e.g. 06.0 = 6 m e.g. 15.0 = 15 m e.g. 0050 = 50 mm e.g. 10.0 = 10m e.g. 13.0 = 13m 17

17

Dash

Quick Selection Guide Hopper

Level Control of Sand in a Hopper

Model/Part #

Input Voltage

Sensing Distance

Output Type

UT30UP-DCA4-1016-CSI 7600-448-001

20-30 VDC

1016 mm/40 in.

4-20 mA or 0-10 VDC Inverted & Non-inverted Short Circuit Protected

Page # 13

UT30UP-DCA4-2032-CSI 7600-448-002

20-30 VDC

2032 mm/80 in.

4-20 mA or 0-10 VDC Inverted & Non-inverted Short Circuit Protected

13

UT30UP-DSS5-1016-CSHT 7600-448-003

20-30 VDC

1015 mm/40 in.

2x Solid State Relays

15

UT30UP-DSS5-2032-CSHT 7600-448-004

20-30 VDC

2032 mm/80 in.

2x Solid State Relays

15

Quality Control Inspection

Loop Control

Roll diameter, Tension Control, Winding and Unwind

Web Break Detection

45° Deflection; Ink Well Level Detection; Hard to Get At Places

Liquid Level Control

12 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Ultrasonic Sensors with Analog Output 4-20 mA and 0-10 V Wire selectable inverted or non-inverted outputs

Threaded plastic barrel M 30 x 1.5

Threaded plastic barrel M 30 x 1.5

Sensing range

101..1016 mm (4-40")

203..2032 mm (8-80")

Switching functions/output

Analog 4-20 mA and 0-10 V

Analog 4-20 mA and 0-10 V

Ordering Information

UT30UP-DCA4-1016-CSI 7600-448-001

UT30UP-DCA4-2032-CSI 7600-448-002

Model description Part number

Electrical data Voltage range

20-30 VDC reverse polarity protected

20-30 VDC reverse polarity protected

Input current

min./ max.

50 mA

50 mA

Transducer frequency

212 KHz

150 KHz

Short circuit protected

Yes

Yes

LED - (strength indicator)

Yes - green to red; see note (d) on pg. 14

Yes - green to red; see note (d) on pg. 14

Response time

30 mSec

50 mSec

Range control

Zero and span (2 potentiometers)

Zero and span (2 potentiometers)

0°C / +60°C / 32°F / 140°F IP 65 / NEMA 12 Valox plastic PVC 4 x 22 gauge Versions available to order 1) Brackets 0-95% non-condensing

0°C / +60°C / 32°F / 140°F IP 65 / NEMA 12 Valox plastic PVC 4 x 22 gauge Versions available to order 1) Brackets 0-95% non-condensing

Mechanical Data Temperature range min./ max Degree of protection Body material Termination cable 2 m/6 ft. Plug / socket Accessories Humidity 1) Brackets for M 30 x 1.5

Adjustment Pots Zero and Span Control

Dimensions

Ordering Information Plastic - BKS-D34PA Part number 596-0223-041 Metal - M 30 ST Part number 7430-448-003

104 mm 4.1"

P2

P1

30 mm 1.18"

LED

Wiring Data Brown + Blue

20-30 VDC

White

Voltage 0-10 V

Black

Current 4-20 mA

Non Inverted Output

Brown + 20-30 VDC Blue –

Brown +

White Black

White

Blue

Current 20-4 mA

20-30 VDC

– Voltage 10-0 V

Black

Current Output Inverted

Voltage Output Inverted

13 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Allowable Angle of Tilt

Ultrasonic Sensors Operation and Set-Up

+8°

–8°

+10°

4" to 40"

8" to 80"

–10°

Minimum Analog Ranging Minimum analog ranging is when you desire to have the full 4-20 mA or 0-10 V output over the minimum 5 inch sensing span. 5 inches of minimum sensing span can be adjusted anywhere in the sensing range. For example 10"-15" or 25"-30". To make this adjustment, you place your target at the minimum sensing range and adjust P1 to 4 mA. Then move your target to the maximum sensing range and adjust P2 to 20 mA. Re-check the readings and make appropriate adjustments, if necessary. See diagram (A).

Maximum Analog Ranging Analog sensing in the maximum range means utilizing the entire 36" span (4"-40") and 72" span (8"-80"). To adjust, set your target at the minimum range, either 4" or 8" and adjust P1 to 4 mA. Move the target to the maximum range and adjust P2 to 20 mA. Re-check readings and make appropriate adjustments, if necessary. See diagram (B).

Beam Spread vs. Target Distance Beam Diameter (in.)

1.5

0 4 Distance from Sensor (in.)

2.0

3.5

4.5

5.0

6.5

8.0

8.5

9.0

9.0

6

8

10

12

16

20

24

28

30

Beam Diameter (in.)

4.5

8.0

10.0

13.0

14.0

14.5

14.5

0 Distance from Sensor (in.)

10

20

30

40

50

60

72

Minimum Analog Ranging Adjustable 15" 24"

10" 40" Range 12" 80" Range

10 V 20 mA

0V 4 mA

Target

Inverted Analog Outputs Inverted outputs means that the 4-20 mA or 0-10 V output signal will decrease proportionally with distance. To adjust, place your target at the minimum sensing distance and adjust P1 to 20 mA. Place your target at the maximum sensing distance and adjust P2 to 4 mA. Re-check readings and make appropriate adjustments, if necessary. See diagram (C).

LED Operation

(Note D)

Diagram A Maximum Analog Ranging Adjustable 40" 80"

4" 40" Range 8" 80" Range

10 V 20 mA

0V 4 mA

Target

The LED is green when the unit is powered up. It will fade to red as a target is detected with increased intensity as more signal is being reflected from the target. Note: Any color other than green equals a workable signal level.

Diagram B Inverted Analog Ranging Adjustable 40" 80"

Adjustment Pots Zero and Span Control

0V 4 mA

P2

P1

4" 40" Range 8" 80" Range 10 V 20 mA

Target

LED

14

Diagram C

For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Ultrasonic Sensors with Isolated Solid State Relay Outputs fitted with Range and Hysteresis Control Threaded plastic barrel M 30 x 1.5

Sensing range

Threaded plastic barrel M 30 x 1.5

101..1016 mm (4-40")

203..2032 mm (8-80")

Switching functions/output

2 Solid State Relays

2 Solid State Relays

Ordering Information

UT30UP-DSS5-1016-CSHT 7600-448-003

UT30UP-DSS5-2032-CSHT 7600-448-004

Electrical data Voltage range min./ max. Input current Transducer frequency Short circuit protected LED Response time Range control

20-30 VDC reverse polarity protected 50 mA 212 KHz Yes Yes - green (not detecting), red (detecting) 30 mSec Range and Hysteresis

20-30 VDC reverse polarity protected 50 mA 150 KHz Yes Yes - green (not detecting), red (detecting) 50 mSec Range and Hysteresis

Mechanical data Temperature range min./max. Degree of protection Body material Termination cable 2 m / 6 ft. Plug / socket Accessories Humidity

0°C/+60°C / 32°F/140°F IP 65 / NEMA 12 Valox plastic PVC 4 x 22 gauge Versions available to order 1) Brackets 0-95% non-condensing

0°C/+60°C / 32°F/140°F IP 65 / NEMA 12 Valox plastic PVC 4 x 22 gauge Versions available to order 1) Brackets 0-95% non-condensing

Model description Part number

1) Brackets for M 30 x 1.5

Adjustment Pots Detection and Hysteresis Control

Dimensions

Ordering Information Plastic - BKS-D34PA Part number 596-0223-041

104 mm 4.1"

Metal - M 30 ST Part number 7430-448-003

(Range) P1

(Hysterisis) P2

30 mm 1.18"

LED

Wiring Data Output Specification brn

INPUT POWER

20-30 VDC

blu GND blk yel wht

• • • •

2 x Solid state relays N.O. / N. C. 160 VAC or VDC 100 mA continuous Short circuit protected 1500 volts RMS isolation

N.O. COM N.C.

15 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Allowable Angle of Tilt

Ultrasonic Sensors Operation and Set-Up

+8°

+10°

4" to 40"

–8°

8" to 80"

–10°

Beam Spread vs. Target Distance Beam Diameter (in.)

1.5

2.0

3.5

4.5

5.0

6.5

8.0

8.5

9.0

9.0

6

8

10

12

16

20

24

28

30

0 4 Distance from Sensor (in.) Beam Diameter (in.)

4.5

8.0

10.0

13.0

14.0

14.5

14.5

0 Distance from Sensor (in.)

10

20

30

40

50

60

72

Proximity Sensing Proximity Sensing Adjustable Detection Point

Proximity detection is the detection of an object at a set distance. The sensing range is controlled by the “Range Control” potentiometer. Any object within the desired range is detected while objects beyond the set range are ignored. The sensing distance is dependent upon the sensor chosen, 40" or 80". In the proximity mode of operation, the hysteresis potentiometer must be turned to 'off' by turning the pot counterclockwise.

40" 80"

4" 80"

40" Range 80" Range

Target

Hysteresis Control

Hysteresis Control Adjustable Turn-Off Point

The sensor is also fitted with a hysteresis control potentiometer. This control allows you to adjust the turn off point while the detection potentiometer sets the “turn on” point. (Example: Range pot set for 10", hysteresis pot set for 20". With these settings the sensor will detect when the target reaches 10" and stays on as the target moves away to 20".) This hysteresis can be adjusted from .5" to 40" from the detect point with the 40" sensor and 1" to 80" with the 80" sensor.

Adjustable Detection Point

4" to 40" or 8" to 80" (dependent upon sensors range)

Target

16 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Proximity Sensors Inductive Sensors

Capacitive Sensors

Inductive Proximity Sensors are used when the target or object to be sensed is metal. Inductive types are the most widely used proximity sensors for industrial applications.

Capacitive Sensors can sense conducting and non-conducting materials in solid, powder or liquid form. The higher the dielectric constant of the target material, the greater the sensing range.

Typical Applications

Typical Applications

• Parts Detection

• Liquid Level Control

• Parts Counting

• Package Inspection (Content and Fill Level)

• Positioning

• Plastic Pellet Detection

• Broken Tool Detection

• Wire Break Detection

• Indexing • Robotics and Conveyors • Motion and Speed Control • Punch Press Feed and Ejection Control • Parts Inspection • Parts Diverting

Inductive and Capacitive Proximity Sensors Identification Codes 1

2

3

Product Group

1

K

4 —

5 6

7

Type/Size of Housing

= Non-contact proximity sensor

2

I C

= Inductive = Capacitive

3

B N A

= Flush/shielded = Non-flush /Non-shielded = Adjustable flush/nonflush via sensitivity control = Sensor amplifier

V 4

Dash

5

M T D R Q P E S N B

6

= Metric threaded metal barrel = Metric threaded plastic barrel = Cylindrical metal smooth barrel = Cylindrical plastic smooth barrel = Rectangular metal housing = PG threaded metal barrel = Rectangular plastic housing = Slot type sensor = DIN standard housing = Bar sensor

If the housing is cylindrical or barrel, the two digit code refers to the diameter in millimeters.

7

8

9

10

Output

Type of Output

11 12

14

Sensing Distance

Example 03 = 3 mm dia 40 = 40 mm dia format for other shapes: digits 5, 6 and 7 S03 = 3.5 mm slot sensor Q05 = 5 x 5 x 25 mm Q08 = 8 x 8 x 40 mm side sensing Q80 = 8 x 8 x 40 mm middle sensing Q12 = 12 x 12 x 55 mm B40 = Bar sensor E50 = 50 x 25 x 55 mm E28 = 28 x 16 x 11 mm E40 = 40 x 26 x 12 mm N40 = 40 x 40 x 40 mm N04 = 40 x 40 x 72.5 mm N44 = 40 x 40 x 112 mm E68 = 68 x 30 x 15 mm E80 = 80 x 30 x 20 mm PNP NPN AC2-wire Namur DC2-wire AC / DC-multivoltage Relay Triac Thyristor AC3-wire Push/ Pull NPN / PNP

8

P N A E Z M R Q T G D

= = = = = = = = = = =

9

S O P

= Normally open = Normally closed = Programmable switch selectable NO/NC = Analog = Complementary 4-wire NO/ NC

A U

13

15

10

16

17

Options

Dash

11-13 Sensing distance Example: 1.5 = 1.5 mm 002 = 2.0 mm 040 = 40.0 mm 14

Dash

15

K

= Short circuit protection

16

L

= LED

17

Cable length in meters Example: 2 = 2 meters 6 = 6 meters S = Socket E = Sensor with extended sensing range V = Short body housing P = Potentiometer PU = Polyurethane cable SD = Plug with terminals according to DIN standard usually comes with plug fitted SM = Mini socket snap fit (quick disconnect) S8 = M8 quick disconnect screw type S12 = M12 quick disconnect screw type SM8= M8 quick disconnect universal snap and screw N = Stainless steel F = High switching frequency C = High chemical resistance surface T = High temperature

17 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Inductive Proximity Sensors 4mm dia. - Smooth Metal Barrel M4, M5, M8, M12, M18, M30 - Threaded Metal Barrel All with potted - in Cable - 6 Feet Long Input Voltage: 10-30 Volts DC - 3 Wire Output Type: NPN (sinking) or PNP (sourcing) - Normally Open • NEMA 4 • Temperature range -13°F + 158°F • Short circuit protected • Reverse polarity protected • Transient noise protected • LED function, Output energized

Sensor Selection Type and Construction 4mm Dia. Smooth Metal Barrel M4 x 0.5 Threaded Metal Barrel M5 x 0.5 Threaded Metal Barrel

Sensing Range Mounting 0.8 mm Flush 0.8 mm Flush 0.6 mm Flush 0.6 mm Flush 1 mm Flush 1 mm Flush 1.5 mm Flush 1.5 mm Flush 2 mm Non-Flush 2 mm Non-Flush 2 mm Flush 2 mm Flush 4 mm Non-Flush 4 mm Non-Flush 5 mm Flush 5 mm Flush 8 mm Non-Flush 8 mm Non-Flush 10 mm Flush 10 mm Flush 15 mm Non-Flush 15 mm Non-Flush mm x .03937 = inches

M8 x 1 Threaded Metal Barrel

M12 x 1 Threaded Metal Barrel M18 x 1 Threaded Metal Barrel Input Voltage 10-60 VDC M30 x 1.5 Threaded Metal Barrel Input Voltage 10-60 VDC

Switching Function NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO NPN/NO PNP/NO

Switching Freq. Hz 3000 3000 3000 3000 3000 3000 1000 1000 1000 1000 800 800 400 400 500 500 200 200 300 300 100 100

Output Current 200 mA 200 mA 100 mA 100 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA

Model KIB-D04NS/0.8 KL2PU KIB-D04PS/0.8 KL2PU KIB-M04NS/0.6 KL2 KIB-M04PS/0.6 KL2 KIB-M05NS/001 KL2 KIB-M05PS/001 KL2 KIB-M08NS/1.5 KL2 KIB-M08PS/1.5 KL2 KIN-M08NS/002 KL2 KIN-M08PS/002 KL2 KIB-M12NS/002 KL2 KIB-M12PS/002 KL2 KIN-M12NS/004 KL2 KIN-M12PS/004 KL2 KIB-M18NS/005 KL2 KIB-M18PS/005 KL2 KIN-M18NS/008 KL2 KIN-M18PS/008 KL2 KIB-M30NS/010 KL2 KIB-M30PS/010 KL2 KIN-M30NS/015 KL2 KIN-M30PS/015 KL2

Part Number 650-2399-004 650-2999-004 650-2399-018 650-2999-020 650-2399-003 650-2999-003 693-2301-001 693-2901-001 650-2316-003 650-2916-003 693-2303-001 693-2903-001 693-2304-001 693-2904-001 693-2305-001 693-2905-001 693-2306-001 693-2906-001 650-2307-135 650-2907-068 650-2308-001 650-2908-002

Wiring Diagrams brn (1) blk (sw)

• Load (4)

blu (3)

+

brn (1)

+

blk (sw) (4) –

blu (3)

brn = Brown blk = Black

Load •

blu = Blue sw = Switch

NPN – Normally Open

PNP – Normally Open

During operation, output NPN transistor is switched to negative.

During operation, output of PNP transistor is switched to positive.

For Brackets see Page 23.

18 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Data (Dimensions are in inches) M4 x 0.5

.98

.16

.87 .75

LED SW6

LED

.08

4 mm Dia.

M4 x 0.5

1.47

LED

16

.26

M8 x 1

.79

1.26

.01

.25

M8 x 1

M5 x 0.5

.98

.98

LED .16

.16

LED

SW7

.10

SW13

M8 x 1 Flush

M5 x 0.5

M8 x 1 Non-Flush

1.97 LED

LED

M18 x 1 .65

.02

1.99 1.54 .22

.41

1.53

M12 x 1

1.97

M12 x 1 .42

SW13

LED

1.54 .04

LED

.08 SW17

SW24

.16

M12 x 1 Non-Flush

M12 x 1 Flush

M18 x 1 Flush

1.54 .28

3.19

2.40 .04

LED

2.36 .39

1.10

LED

M30 x 1.5

3.23

1.99

M18 x 1 .65

SW17

.16

M30 x 1.5 1.11

.16

.16

SW24

M18 x 1 Non-Flush

LED

LED

.20

SW 36

M30 x 1.5 Flush

.20

SW36

M30 x 1.5 Non-Flush

19 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Inductive Proximity Sensors M8, M12, M18, M30 - Threaded Metal Barrel M12 x 1 Quick Disconnect/M8 x 1 Quick Disconnect Input Voltage: 10-30 Volts DC-3 Wire Output Types: NPN (sinking) or PNP (sourcing) - Normally Open • NEMA 4 • Temperature range -13°F + 158°F • Short circuit protected • Reverse polarity protected • Transient noise protected • LED function, Output energized

Sensor Selection Type and Construction M8 x 1* Threaded Metal Barrel Quick Disconnect * USE M8 QD M12 x 1 Threaded Metal Barrel Quick Disconnect M18 x 1 Threaded Metal Barrel Quick Disconnect 10-60 VDC M30 x 1 Threaded Metal Barrel Quick Disconnect 10-60 VDC

Sensing Range 1.5 mm 1.5 mm 2 mm 2 mm 2 mm 2 mm 4 mm 4 mm 5 mm 5 mm 8 mm 8 mm

Mounting Flush Flush Non-Flush Non-Flush Flush Flush Non-Flush Non-Flush Flush Flush Non-Flush Non-Flush

10 mm

Flush

Switching Switching Function Freq. Hz NPN/NO 1000 PNP/NO 1000 NPN/NO 1000 PNP/NO 1000 NPN/NO 800 PNP/NO 800 NPN/NO 400 PNP/NO 400 NPN/NO 500 PNP/NO 500 NPN/NO 200 PNP/NO 200

15 mm Non-Flush mm x .03937 = inches

Output Current 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA 200 mA

Model KIB-M08NS/1.5 KLSM8* KIB-M08PS/1.5 KLSM8* KIN-M08NS/002 KLSM8* KIN-M08PS/002 KLSM8* KIB-M12NS/002 KLS12 KIB-M12PS/002 KLS12 KIN-M12NS/004 KLS12 KIN-M12PS/004 KLS12 KIB-M18NS/005 KLS12 KIB-M18PS/005 KLS12 KIN-M18NS/008 KLS12 KIN-M18PS/008 KLS12

Part Number 693-2342-001 693-2942-001 650-2342-004 650-2942-006 693-2343-001 693-2943-001 693-2344-001 693-2944-001 693-2305-004 693-2905-004 693-2306-004 693-2906-004

PNP/NO

300

200 mA

KIB-M30PS/010 KLS12

650-2939-004

PNP/NO

100

200 mA

KIN-M30PS/015 KLS12

650-2935-005

Quick Disconnect Selection (Available in 2M or 5M Cable Lengths) M12 x 1 Quick Disconnects with Lock Nuts

Terminal Code

1

2

1 = brown 2 = black

4

3

M8 x 1

1

Terminal Code

Quick Disconnects

1 = brown

with Lock Nuts

2 = black

3 = blue

2 Meters

Model Part #

5 Meters

Model Part #

WDK-M12US/S00-2 413-9100-280 WDK-M12US/S00-5 413-9100-281

3

3 = blue

For M12 and M18 Sensors Cable Length

2

For M8 Sensors 3-wire

3-wire

GDK-M08US/S00-2.5PU 413-9100-261 GDK-M08US/S00-5PU 413-9100-263

WDK-M08US/S00-2.5PU 413-9100-278 WDK-M08US/S00-5PU 413-9100-279

For Brackets see Page 23.

20 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Data (Dimensions are in inches) 1.97

1.80

.16

SW13

.16 .26

M8 x 1

M8 x 1

.25

M8 x 1

1.46 .01

M8 x 1

1.61

4x LED

.16

LED SW13

M8 x 1 Flush

M8 x 1 Non-Flush

2.30

2.30

4x LED

.16

M12 x 1

.22 .41

M12 x 1

M12 x 1

1.40

.02 .42

M12 x 1

1.40

4x LED

.16

SW17

SW17

M12 x 1 Flush

M12 x 1 Non-Flush

2.30

.16

SW24

M12 x 1

M18 x 1

1.54 .28 .65

M12 x 1

.65

.04

SW24

.16

LED

M18 x 1 Flush

LED

M18 x 1 Non-Flush

3.23

3.19 2.36

2.40 .04

M30 x 1.5

M12 x 1

.10

M12 x 1

1.11

.39

M30 x 1.5

M18 x 1

2.30 1.54

.20

SW36

M30 x 1.5 Flush

LED

.20

SW36

LED

M30 x 1.5 Non-Flush

21 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Inductive Proximity Sensors 2 Wire AC M12, M18, M30 - Threaded Metal Barrel With Potted - in Cable - 6 Feet Long M18 - Threaded Metal Barrel With M12 x 1 Quick Disconnect Input Voltage: 2 Wire AC Output: Normally Open • NEMA 4 • Temperature range -13°F + 158°F • Cable length, 2 meters (standard length) • LED function, Output energized on cable version only • Switching frequency 10 hertz

Sensor Selection Type and Construction M12 x 1 Integral Cable Threaded Metal Barrel M18 x 1 Integral Cable Threaded Metal Barrel M30 x 1.5 Integral Cable Threaded Metal Barrel

Sensing Range 2 mm 4 mm 5 mm 8 mm 10 mm 15 mm mm x .3937

Mounting Flush Non-Flush Flush Non-Flush Flush Non-Flush = inches

Switching Function NO NO NO NO NO NO

Input Voltage 90-250 VAC 90-250 VAC 20-250 VAC 20-250 VAC 20-250 VAC 20-250 VAC

Output Current 4/180 mA 4/180 mA 4/400 mA 4/400 mA 4/400 mA 4/400 mA

Model KIB-M12AS/002 L2 KIN-M12AS/004 L2 KIB-M18AS/005 L2 KIN-M18AS/008 L2 KIB-M30AS/010 L2 KIN-M30AS/015 L2

Part Number 650-3503-001 650-3504-001 650-3505-004 650-3506-002 650-3507-378 650-3508-246

Wiring Diagram For Sensors with Integral Cable blk(3)

blu (4) Load

L1

AC – 2-wire Normally Open

N

During operation, a thyristor which is positioned above a rectifier bridge applies the load to the operating voltage.

blk = black blu = blue For Brackets see Page 23.

22 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Data (Dimensions are in inches) 2 Wire AC 2.62

.16

LED

SW17

2.40 LED

.04

.16

SW17

.16

M12 x 1 Flush

M18 x 1 .65

LED

3.25

.79 .22 .41

M12 x 1

.02

.26

M12 x 1

2.62 .79

SW24

M18 x 1 Flush

M12 x 1 Non-Flush

M18 x 1 .65

3.21 2.36 .28

3.19

.04

LED

2.36 .39

M30 x 1.5 1.11

M30 x 1.5

3.23 2.40

LED

1.10

LED

.16

SW24

SW36

.20

.20

M30 x 1.5 Non-Flush

M30 x 1.5 Flush

M18 x 1 Non-Flush

SW36

Brackets 1.77 1.32 .59

0.3

0.3

.35

.87

.53

.23 .41

.23 .41

0.2

0.2

.20

.32 .20

.02

.02

.56

0.3

0.2

0.2

0.3

1.10

0.6

.81

0.6 0.1

0.1

1.26 .85

Model Part #

BKB-D04PA 596-0223-069

.21

0.2

BKS-D05PA 596-0223-070

.79 .55

.79 .55

.09

.05

.05

.09

0.4 0.1

0.4 0.1

0.1

.21

.36 1.97

BKS-D22PA 596-0223-040

.36 2.56

BKS-D34PA 596-0223-041

23 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

P-1201 4/98*

Printed in USA


Capacitive Sensors Barrel Sizes: M12, M18, M30, M32, 34mm Dia Input Voltage: 3 Wire DC and 2 Wire AC Integral Cable and Quick Disconnect Versions All Sensors Fitted With Sensitivity Adjustment • NEMA 12 • LED output indication • Temperature range -13°F + 158°F • Short circuit protected • Reverse polarity protected • Transient noise protected

Sensor Selection Type and Construction M12 x 1 Threaded Plastic Body M18 x 1 Threaded Plastic Body Quick Disconnect Quick Disconnect Quick Disconnect M30 x 1.5 Threaded Plastic Body M32 x 1.5 Threaded Plastic Body M32 x 1.5 Threaded Metal Body 34mm dia. Smooth Plastic Body

Sensing Range 4 mm *** 4 mm *** 8 mm *** 8 mm *** 8 mm *** 8 mm *** 8 mm *** 8 mm *** 20 mm*** 20 mm*** 20 mm*** 30 mm***

Input Voltage 10-36 VDC 10-36 VDC 10-60 VDC 10-60 VDC 20-250 VAC 10-60 VDC 10-60 VDC 20-250 VAC 10-60 VDC 10-60 VDC 20-250 VAC 10-60 VDC

Switching Switching Output Function Freq. Hz Current NPN/ NO 25 200 mA PNP/ NO 25 200 mA NPN/ NO 100 200 mA PNP/ NO 100 200 mA NO 15 5/ 300 mA NPN/ NO 25 200 mA PNP/ NO 25 200 mA NO 15 5/300 mA NPN/ NO 25 400 mA PNP/ NO 25 400 mA NO 15 5/ 300 mA NPN/ PNP* 25 400 mA NO/ NC NPN/ PNP* 25 400 mA NO/ NC NPN/ NO 10 400 mA PNP/ NO 10 400 mA NO 10 10/ 300 mA

15 mm** 10-60 VDC Flush 30 mm*** 10-60 VDC 30 mm*** 10-60 VDC 30 mm*** 48-250 VAC mm x .3937 = inches * See Wiring Diagram PNP/NPN Switch Selectable ** This sensor can be mounted flush. *** These Capacitive Sensors are Non-Flush Mount, Adjustable by Sensitivity Adjustment

Model KCN-T12NS/ 004 KLP2 KCN-T12PS/ 004 KLP2 KCA-T18NS/ 008 KLP2 KCA-T18PS/ 008 KLP2 KCN-T18AS/ 008 LP2 KCN-T18NS/ 008 KLPSM8 KCN-T18PS/ 008 KLPSM8 KCN-T18AS/ 008 LPS12A KCN-T30NS/ 020 KLP2 KCN-T30PS/ 020 KLP2 KCN-T30AS/ 020 LP2 KCN-T32DP/ 030 KLP2

Part Number 650-7319-001 650-7919-001 650-7321-723 650-7921-724 650-8521-001 650-7321-002 650-7921-002 650-8521-004 650-7323-001 650-7923-727 650-8523-001 650-7013-001

KCB-M32DP/ 015 KLP2

650-7013-011

KCN-R34NS/ 030 KLP2 KCN-R34PS/ 030 KLP2 KCN-R34AS/ 030 LP2

650-7315-001 650-7915-001 650-8515-001

Quick Disconnect Selection (Available in 2 M or 5 M Cable Lengths) M12 x 1 Quick Disconnect AC Input Voltage

Model Part # Model Part #

1

2 3

4

M8 x 1 Quick Disconnect DC Input Voltage

1

2

3

2-wire

2-wire

3-wire

3-wire

GDK-M12AS/ S00-2 413-9100-248 GDK-M12AS/ S00-5 413-9100-249

WDK-M12AS/ S00-2 413-9100-250

GDK-M08US/ S00-2.5PU 413-9100-261 GDK-M08US/ S00-5PU 413-9100-263

WDK-M08US/ S00-2.5PU 413-9100-278 WDK-M08US/ S00-5PU 413-9100-279 For Brackets see Page 23.

24 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Data (Dimensions are in inches) 2.40

LED

3.19 2.36 .79

POT LED

SW17

M18 x 1 with Cable

3.19

M18 x 1

2.36

PO T

.79

SW24

M18 x 1 with QD-AC

3.19 LED/POT

2.36

2.76 2.64

LED POT

.98

M8 x 1

.53

LED

M30 x 1.5

M12 x 1 with Cable

4.2

SW24

4.2

M32 x 1.5

.17

M12 x 1

.53

LED

POT

M18 x 1 .63

M12 x 1 .42

.31

3.19 2.36 .79

M18 x 1

POT

1.57

SW24

4.2

SW36

.20

M18 x 1 with QD-DC

.31

M30 x 1.5 with Cable

SW41

M32 x 1.5 Plastic with Cable

2.76 LED PO T

LED/POT

3.30

1.34

M32 x 1.5

1.87 .04

.31

SW41

34 mm Dia. with Cable

M32 x 1.5 Metal with Cable

Wiring Diagram

br (1)

brn (1)

+

+

sw (2/4) A

blk (s w) (4) bl (3) blu (3)

Load

PNP Normally Open

*PNP/NPN Switch selectable

During operation, output of PNP transistor is switched to positive .

Two integrated switches selection between PNP/NPN switching and normally open/ normally closed functions.

brn (1)

blk (3)

L1

+

blk blu (3)

Load

blu (4)

N

– Load

NPN Normally Open

2 Wire AC Normally Open

During operation, output of NPN transistor is switched to negative.

During operation, a thyristor which is positioned above a rectifier bridge applies the load to the operating voltage.

brn = Brown blk = Black blu = Blue sw = Switch

25 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Magnetic Sensors Description A magnetic sensor is a simple, inexpensive sensing device that can be used in very harsh environments because its completely sealed housing makes it unaffected by heavy dust or corrosive atmospheres. The basic sensor system consists of a sensor and a magnet and can be typically used in food production, printing, and packaging industries. Their rugged construction also makes magnetic sensors suitable for agricultural applications. The operating component in the magnetic sensor is a reed switch.

Cylindrical

Operation of a Magnetic Sensor These sensors are used mainly as proximity switches. The magnet and sensor must be positioned correctly so the strength of the flux magnet and the sensitivity of the sensor operate to the specified sensing distance. Sensor operation does not depend on direction or angle of travel.

Features • NEMA 4, 4X • Temperature range -13°F + 158°F • Cable length, 3 feet (standard length) • Extremely stable switching point

Rectangular

• Repeatability better than 0.025 inch 8

• Life expectancy 10 switching operations • Extremely cost effective • Operating voltage up to 250 VAC

Sensor Selection Sensor and Magnet Combination Smooth Plastic Barrel / MA-30 Magnet T-67 N/S Threaded Metal Barrel / MA-08 Magnet T-62 N/S Threaded Metal Barrel / MA-23 Magnet T-62 N/S Rectangular Plastic / MA-11 Magnet TK-11-11 Rectangular Plastic / MA-12 Magnet TK-21-12 Rectangular Plastic / MA-45 Magnet TK-45 Rectangular Plastic / MA-42 Magnet TK-42

*Sensing Range 0.1 inch

Output Max **Switching Max Current Supply Volts Function Power/Current At 120VAC 250 VAC NO 10 VA / 0.5 A 80 mA

0.6 inch

250 VAC

NO

10 VA / 0.5 A

80 mA

0.3 inch

250 VAC

NO

100 VA / 3 A

830 mA

0.4 inch

250 VAC

NO

10 VA / 0.5 A

80 mA

0.8 inch

250 VAC

NO

100 VA / 0.3 A

830 mA

0.4 inch

250 VAC

NO

10 VA / 0.5 A

80 mA

1.0 inch

250 VAC

NO

100 VA / 3 A

830 mA

Model MAK-3012-B T-67 N/S MAN-0812-B T-62 N/S MAM-2312-F T-62 N/S MAK-1112-B TK-11-11 MAK-1212-F TK-21-12 MAK-4512-B TK-45 MAK-4212-F TK-42

*Sensing range is based on the use of the specified magnet. **NO = Normally Open

26 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

Part Number 631-1230-571 630-1167-054 631-1208-596 630-1262-039 631-4223-268 630-1262-039 631-1211-541 630-2111-047 631-4212-217 630-2121-030 631-1245-539 630-2145-048 631-4242-533 630-2142-049


Mechanical Data (Dimensions are in inches) .78

1.12

.39

.24

.17

Mounting Instructions for Mounting a Magnetic Sensor on Ferrous Materials If a magnet and magnetic sensor are mounted on ferrous materials, the specified sensing distance will be reduced. To ensure good operation, the magnet and switch should be a minimum of 0.6 inch from the ferrous material.

Sensor

MA-30

Magnet

T-67 N/S

Part #

631-1230-571

Part #

630-1167-054

Sensor and Magnets are purchased independently.

1.26 .90

90째

M8 x 1 .31 x .04

.07

.39

.17

.51

.2

Sensor

MA-08

Magnet

T-62 N/S

Part #

631-1208-596

Part #

630-1262-039

SW 17 .67

.90

.07 90째

M12 x 1 0.47 x 0.04

.16

2.36 .39

3.15

.17

MA-23

Magnet

T-62 N/S

Part #

631-4223-268

Part #

630-1262-039

.25

0.13

1.13

.1

1.13

.19

.35

Sensor

1.77 .27

.51 1.0

1.0

.7

.49

= =

.71

0.13

.29

.35

.25

.16

1.77

II

.62

1.53

.13

.13

.44

.14

.17

.41 .15

II

.83

.12

.78

.81

Magnet

TK-11-11

Sensor

MA-45

Magnet

TK-45

631-1211-541

Part #

630-2111-047

Part #

631-1245-539

Part #

630-2145-048

.51

.17 .28

.12

.59

2.68

2.6

.79

3.18

.51 .43

MA-11

Part #

.39

Sensor

3.46 .19

.01 .01

.42 .28

.2 2.76 3.16

4.5

Sensor Part #

MA-12

Magnet

631-4212-217

Part #

.18

3.07

.72

2.36 .26

.17

.79 .16

.98

.59

3.07

TK-21-12

Sensor

MA-42

Magnet

TK-42

630-2121-030

Part #

631-4242-533

Part #

630-2142-049

27 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Sensor Controls Description The Warner Electric range of sensor controls are designed to aid the use of sensors in fulfilling applications by adding an extra dimension to a sensor’s capability. These controls act as a simple interface to allow the output signal of the sensor to be converted from a solid state transistor to a relay. All controls offered have 110 VAC input voltage capability and, in the case of the MCS-149/814 ‘plug-in’ modules are available with added timing and counting features. (see note 1 below) All the MCS-680 Series controls are ‘DIN-rail’ mount, with the MCS 680-1 being the only control to offer a programmable timing circuit as standard. (see note 2 below)

Control Selection Model Part Number Function

MCS-149/814 6210-448-003 1 x Input 1 x Output 120 VAC 12V at 250 mA NPN MCS-814 7 Amp DPDT Optional (note 1) -30°F to 140°F 4 Mounting Holes NEMA 12

Operating Voltage DC Output Input Signal Accepted Output Relay Timing Functions Operating Temperature Mounting NEMA Rating

MCS-149/814 (Note 1)

MCS-680 7500-448-008 1 x Input 1 x Output 120/240 VAC 12V at 90 mA NPN MCS-850 5 Amp SPDT N/A -4°F to 140°F TS 35 DIN Screw Mount NEMA 1

MCS-680-1 7500-448-009 1 x Input 1 x Output 120/240 VAC 12V at 90 mA NPN MCS-850 5 Amp SPDT integral (note 2) -4°F to 140°F TS 35 DIN Screw Mount NEMA 1

MCS-680-3 651-2101-045 1 x Input 1 x Output 120 VAC 10-20 VDC NPN or PNP 1 x 10 A SPDT N/A -4°F to 140°F TS 35 DIN NEMA 1

Mechanical Drawing (Dimensions are in inches)

Plug-in Modules (Order Separately) 6.159

Timer Modules Model Part Number MCS-836 7400-448-024 MCS-836-1 7400-448-029

3

Timing Range 0.4 to 15 seconds 1 to 30 seconds

5.159

Timing Functions

(Programmable) Delay Pull, Delay Drop, Dual Delay, One-Shot, OneShot Drop, Delayed One-Shot, Delayed One-Shot Drop Part Number 7400-448-019 7400-448-020

1.9

Switching Type 1 to 99 1 to 9999

Part Number 7410-448-008

Switching Type DPDT 7 Amp

0.3

2.796

Output Module (Supplied as Standard) Model MCS-814

4.3

MCS-680-1/2

Counter Modules Model MCS-831 MCS-832

2

3.8 3/4-14 NPSM x .431

MCS-149/814

MCS-680-1 (Note 2) Timer Functions (Integrated) Delay Pull / Delay Drop / One Shot Timing Range - 0.1 to 10 seconds

0.4 1.7

MCS-680-3

Output Relay Model MCS-850

2.6

4

(Supplied as Standard) Switching Type Part Number 7150-101-016 SPDT 5 Amp

28 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Limit Switches Thermoplastic International Style Body Style Ti2 • Insulating plastic housing and integral cover • Mounting and dimensions conform to DIN EN 50047 • Actuator head position can be changed in 90° increments

Enclosure Body: PBT, Glass Fiber Reinforced (UL 94-V0) Enclosure Cover: PA6.6 (Black) Protection Class: NEMA 4 Mechanical Life: 3 x 106 Temperature: -22°F to + 176°F Switch Rate: 100 per minute max.

• Contacts galvanically isolated • One cable entry point

Ti2 Body Style

• Conduit adapter or cord grip provided • Manufactured per IEC 947-5-1 and VDE 0660 T200

Contact Block Technical Data

• UL, CSA and BG approved

Type

• Can be used as component in safety applications

U1Z 1 N.C. 1 N.O. Slow Yes 250 VAC 10 A SU1Z 1 N.C. 1 N.O. Snap Yes 250 VAC 10 A Notes: 1. All Contact Blocks Break-Before-Make 2. Normally Closed Contacts Forced Disconnect per IEC 947-5-1 Ch.3 (As Indicated)

Model Identification Body Style

Contact Block

Actuator Style

Ti2

U1Z

AH

Contacts

Action

Forced Disconnect

Contact Block Wiring Details U1Z - Slow Make-and-Break 11

Current (max.)

SU1Z Snap Action

12

-14

13

Switch Selection

Voltage (max.)

21 23

Model

Part Number

Ti2-U1 AD

608-8137-027

Ti2-U1Z AH

608-8135-021

Ti2-SU1Z AH

608-8185-022

Ti2-SU1Z FF

608-8190-040

Ti2-U1Z Hw

608-8121-015

Ti2-SU1Z Hw

608-8171-016

Ti2-U1Z w

608-8103-001

Ti2-SU1Z w

608-8153-002

Ti2-U1Z Riw

608-8117-007

Ti2-SU1Z Riw

608-8167-008

-24

22

Types of Contact Block and Action

U1Z

Break-Before-Make the NC contact opens before the NO contact closes

Linear Type Actuator 0 11-12

11-12

23-34

23-34 4.4 N

0

SU1

SUVA Approved for Safety Applications

Mechanical Data

Snap action arrow indicates direction of travel

.31

.11

.03

Rotary Type Lever

.09

0

13°

0

10°

38°

75°

6.3 N

.21

.47

21-22

21-22

13-14 13-14

13-14 13-14

21-22

21-22

11-12, 21-22, 23-24 Indicates terminal identification for wiring. Operating force shown in Newtons. Newtons x .2248 = lbs. Graduation Tolerance + 3.5° Accuracy of switching point + .009 Tolerance of switching pressure + 10%

35°

75°

= contact open = contact closed = Point of forced openingpositive disconnect

(Dimensions are in inches) .87

ø.17

.83

Switching Action Explanation Slow Action • Used in precision applications for switching on and off at the exact point • Contact closes at the same speed as actuator/lever

.22 .06 1.77

Snap Action • Used when good solid contact is required

.43

• Used with inductive loads to prevent arcing M16 x 1.5 1.18

1.06 1.06

29 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Drawing Data Contact Block Data

Mechanical Data

Contact Block Data

Mechanical Data

(Dimensions are in inches)

(Dimensions are in inches) .41

1.94 .71

65°

0 .02

23°

U1Z

6

1.06 .08

.07

.08

60° 65°

0 .03

.06 .07

34°

14 Ncm

3.5

2.88

3.58

22° 32° 34°

7

.19

.31

.94

3.5

.73

.53

10 Ncm

10 N

.18

SU1Z

AH

.15 .18

7 N

U1Z

SU1

Hw

1.48

Ø.28

.41

■ .12

34°

34°

65°

14 Ncm

65°

2.5

.05 .06

.16

10 Ncm

0

5

.02 .06

10 N

.14 .16

2.24

23°

0 .02

.69

22°

7

.08

5.9

3.5

0.71”

7 N

.06

U1Z

AD

U1Z

SU1

w .41 .13

.28

0 .02

2.5

0

5

.02

.05 .06

2.52

5.51

.39

.97 .08

.06

SU1Z

.06

.22

.41 .16

FF

10 N

U1Z

.14 .16

7 N

SU1

Riw

= Point of Forced Opening, Positive Disconnect U1Z = Slow Make-and-Break with Positive Disconnect SU1Z = Snap Action with Positive Disconnect

30 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Limit Switches Thermoplastic International Style Body Style Bi Enclosure Body:

PA 6 Thermoplastic (UL 94-V0) Enclosure Cover: PC Thermoplastic (UL 94-V0) Protection Class: NEMA 4 Mechanical Life: 10 x 106 Cycles Temperature: -22°F to + 176°F Switch Rate: 100 per minute max.

• Insulating plastic housing and integral cover • Mounting and dimensions conform to DIN EN 50047 • Actuator head position can be changed in 90° increments • Contacts galvanically isolated

Bi Body Style

• Two cable entry points • Conduit adapter or cord grip provided • Manufactured per IEC 947-5-1 and VDE 0660 T200

Contact Block Technical Data

• UL, CSA and SEV approved

Type

Model Identification Body Style

Contact Block

Actuator Style

Bi

U1Z

AH

Contacts

Action

Forced Disconnect

Contact Block Wiring Details U1Z - Slow Make-and-Break

Switch Selection

11

Part Number

Bi-U1 AD

608-5137-007 608-5185-012

Bi-SU1 AV

608-5186-013

Bi-SU1 FF

608-5190-015

Bi-SU1Z Hw*

608-5171-017

Bi-U1Z w*

608-5103-001

Bi-SU1Z w*

608-5153-008

Bi-U1Z Riw*

608-5117-002

Bi-SU1Z Riw*

10 A 10 A 10 A

Indicated)

-14

21 23

Bi-SU1Z AH*

Current (max.)

SU1Z Snap Action

12 13

Model

Voltage (max.)

1 N.C. 1 N.O. Slow Yes 500 VAC U1Z SU1Z 1 N.C. 1 N.O. Snap Yes 500 VAC SU1 1 N.C. 1 N.O. Snap No 500 VAC Notes: 1. All Contact Blocks Break-Before-Make 2. Normally Closed Contacts Forced Disconnect per IEC 947-5-1 Ch.3 (As

-24

22

Types of Contact Block and Action

U1Z

Break-Before-Make the NC contact opens before the NO contact closes

Linear Type Actuator 0

608-5167-009

*SUVA approved for safety applications Many more styles of actuators available. Contact local factory for more information.

.31

.11

11-12

11-12

23-34

23-34 4.4 N

0

SU1Z Snap action arrow indicates direction of travel

.03

Rotary Type Lever

.09

0

13°

0

10°

38°

75°

6.3 N

.21

.47

21-22

21-22

13-14 13-14

13-14 13-14

21-22

21-22

11-12, 21-22, 23-24 Indicates terminal identification for wiring. Operating force shown in Newtons. Newtons x .2248 = lbs. Graduation Tolerance + 3.5° Accuracy of switching point + .009 Tolerance of switching pressure + 10%

35°

75°

= contact open = contact closed = Point of forced openingpositive disconnect

Mechanical Data (Dimensions are in inches) .87 .79

Switching Action Explanation ø.17

Slow Action .79

• Used in precision applications for switching on and off at the exact point M16 x 1.5

.41 .31

• Contact closes at the same speed as actuator / lever

Snap Action

.16 1.97

1.57

• Used when good solid contact is required • Used with inductive loads to prevent arcing

1.65 2.32

1.26

31 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Contact Block Data

Mechanical Data

Contact Block Data

(Dimensions are in inches)

Mechanical Data (Dimensions are in inches)

1.46

.39 .22

ø.53

3.08

1.26 1.16 1.00

.93

.83 .67

5.90

■ .12

U1

AD

SU1Z

Hw

1.92 .31

.94

.71

.39

.93 .83

2.44

3.78

.88 .78 .63

.67

ø.31

SU1Z

AH

U1Z

SU1Z

w

1.86 .31

.98

.39 .12

1.6

3.15

U1Z

AV

SU1

1.5 1.34

3.68-5.12

.77-2.16

.93

.83 .67

0.55

SU1Z

Riw

.39

6.38

5.35

5.61 5.51

ø.28

SU1

FF

= Point of Forced Opening, Positive Disconnect U1Z = Slow Make-and-Break SU1Z = Snap Action with Positive Disconnect SU1= Snap Action

32 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Limit Switches Thermoplastic International Style Body Style I88 • Insulating plastic housing and integral cover • Mounting and dimensions conform to DIN EN 50047 • Actuator head position can be changed in 90º increments • Contacts galvanically isolated • One cable entry point

Enclosure Body:

PA 6 Thermoplastic (UL 94-V0) Enclosure Cover: PC Thermoplastic (UL 94-V0) Protection Class: NEMA 4 Mechanical Life: 10 x 106 Cycles Temperature: -22°F to + 176°F Switch Rate: 100 per minute max.

I88 Body Style

• Conduit adapter or cord grip provided • Manufactured per IEC 947-5-1 and VDE 0660 T200

Contact Block Technical Data

• UL, CSA and SEV Approved

Type

Contact Block

Actuator Style

I88

U1Z

AH

Action

Forced Disconnect

Contact Block Wiring Details U1Z - Slow Make-and-Break

Switch Selection

11

Model

Part Number

I88-SU1 AD

608-6187-042

I88-U1Z AH*

608-6135-033

I88-SU1Z AH*

608-6185-034

I88-SU1 AF

608-6139-054

I88-U1 AV

608-6136-037

I88-SU1Z Hw*

608-6171-022

I88-U1Z Hw*

608-6121-021

I88-U1Z w*

608-6103-008

I88-SU1Z w*

608-6153-012

I88-U1Z RiwK*

608-6117-017

I88-SU1Z RiwK* 608-6167-018 * SUVA Approved for safety applications. Many more styles of actuators available. Contact local factory for more information.

Mechanical Data (Dimensions are in inches) 1.20

10 A 10 A 10 A

indicated)

-14

21 23

.17

Current (max.)

SU1Z Snap Action

12 13

.87

Voltage (max.)

U1Z 1 N.C. 1 N.O. Slow Yes 500 VAC SU1Z 1 N.C. 1 N.O. Snap Yes 500 VAC SU1 1 N.C. 1 N.O. Snap No 500 VAC Notes: 1. All Contact Blocks Break-Before-Make 2. Normally Closed Contacts Forced Disconnect per IEC 947-5-1 Ch.3 (as

Model Identification Body Style

Contacts

-24

22

Types of Contact Block and Action

U1Z

Break-Before-Make the NC contact opens before the NO contact closes

Linear Type Actuator 0

.31

.11

0

13°

0

10°

38°

75°

11-12

11-12

23-34

23-34 4.4 N

0

SU1Z Snap action arrow indicates direction of travel

.03

Rotary Type Lever

.09

6.3 N

.21

.47

21-22

21-22

13-14 13-14

13-14 13-14

21-22

21-22

11-12, 21-22, 23-24 Indicates terminal identification for wiring. Operating force shown in Newtons. Newtons x .2248 = lbs. Graduation Tolerance + 3.5° Accuracy of switching point + .009 Tolerance of switching pressure + 10%

35°

75°

= contact open = contact closed = Point of forced openingpositive disconnect

Switching Action Explanation Slow Action

.39

• Used in precision applications for switching on and off at the exact point • Contact closes at the same speed as actuator / lever .31

Snap Action .16

.79

• Used when good solid contact is required • Used with inductive loads to prevent arcing

2.44 1.22 M20 x 1.5 .63

33 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Contact Block Data

Mechanical Data

Contact Block Data

(Dimensions are in inches)

Mechanical Data (Dimensions are in inches) .39

1.52

.22

.43

5.90

.12

.83

max. 8.54

1.20

SU1

3.54

AD

U1Z

SU1Z

Hw

1.38 .07 .39

8.15

5.19

.31

.78 .83

2.91

SU1

AF

U1Z

SU1Z

w

1.92

.39

.71

.39

.31

.13

1.24 .94

3.37 .83

U1Z

SU1Z

4.25

AH

U1Z

SU1Z

RiwK

1.86 .31

.83

4.17 - 5.61

U1

.77 - 2.16

.98

AV

= Point of Forced Opening, Positive Disconnect U1Z = Slow Make-and-Break SU1Z = Snap Action with Positive Disconnect SU1= Snap Action

34 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Limit Switches Thermoplastic International Style Body Style ENK • Insulating plastic housing and integral cover

Enclosure Body:

PA 6 Thermoplastic (UL 94-V0) Enclosure Cover: PC Thermoplastic (UL 94-V0) Protection Class: NEMA 4 Mechanical Life: 10 x 106 Cycles Temperature: -22°F to + 176°F Switch Rate: 100 per minute max.

• Mounting and dimensions conform to DIN EN 50041 • Actuator head position can be changed in 90° increments • Contacts galvanically isolated • One cable entry point

ENK Body Style

• Conduit adapter or cord grip provided • Manufactured per IEC 947-5-1 and VDE 0660 T200

Contact Block Technical Data

• UL, CSA and SEV Approved

Type

Contact Block

Actuator Style

ENK

U1Z

AH

Action

Forced Disconnect

Voltage (max.)

Current (max.)

U1Z 1 N.C. 1 N.O. Slow Yes 500 VAC SU1Z 1 N.C. 1 N.O. Snap Yes 500 VAC SU1 1 N.C. 1 N.O. Snap No 500 VAC Notes: 1. All Contact Blocks Break-Before-Make 2. Normally Closed Contacts Forced Disconnect per IEC 947-5-1 Ch.3 (As

Model Identification Body Style

Contacts

Contact Block Wiring Details U1Z - Slow Make-and-Break

Switch Selection

11

Part Number

ENK-U1Z AD ENK-SU1Z AD ENK-U1Z AHS-V ENK-SU1Z AHS-V ENK-U1 AV ENK-SU1 AV ENK-SU1 FF ENK-U1Z Riw* ENK-SU1Z Riw* ENK-U1Z iw* ENK-SU1Z iw*

608-1137-011 608-1187-017 608-1135-003 608-1185-009 608-1136-012 608-1186-018 608-1190-045 608-1117-002 608-1167-008 608-1102-001 608-1152-007

Indicated)

SU1Z Snap Action

12

-14

13

Model

10 A 10 A 10 A

21 23

-24

22

Types of Contact Block and Action

U1Z

Break-Before-Make the NC contact opens before the NO contact closes

Linear Type Actuator 0

* SUVA Approved for safety applications. Many more styles of actuators and contact blocks available. Contact factory for more information.

Mechanical Data

.31

.11

11-12

11-12

23-34

23-34 4.4 N

0

SU1Z Snap action arrow indicates direction of travel

.03

Rotary Type Lever

.09

0

13°

0

10°

38°

75°

6.3 N

.21

.47

21-22

21-22

13-14 13-14

13-14 13-14

21-22

21-22

11-12, 21-22, 23-24 Indicates terminal identification for wiring. Operating force shown in Newtons. Newtons x .2248 = lbs. Graduation Tolerance + 3.5° Accuracy of switching point + .009 Tolerance of switching pressure + 10%

35°

75°

= contact open = contact closed = Point of forced openingpositive disconnect

(Dimensions are in inches) 1.57

Switching Action Explanation

1.57

1.18

1.14

Slow Action • Used in precision applications for switching on and off at the exact point • Contact closes at the same speed as actuator/lever

.21

Snap Action • Used when good solid contact is required

.28

• Used with inductive loads to prevent arcing 2.36

2.89 M20 x 1.5

.08

.59

35 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Contact Block Data

Mechanical Data

Contact Block Data

Mechanical Data

(Dimensions are in inches)

(Dimensions are in inches) .29

ø.24

.63

.96

max. 10.91

8.17

7.87

5.55

1.89

U1Z

SU1Z

AD

SU1

FF

2.38 .71

.31 .63 .15

.96

4.57

5.14

1.59

1.16

.71

U1Z

SU1Z

AHS-V

U1Z

SU1Z

Riw

2.43 .98

.31

.63

U1

SU1

AV

4.09

4.65 - 6.79

1.06-3.20

.96

1.48

.39

U1Z

SU1Z

iw

= Point of Forced Opening, Positive Disconnect U1Z = Slow Make-and-Break SU1Z = Snap Action with Positive Disconnect SU1= Snap Action

36 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Limit Switches Metal International Style Body Style ENM2 • Metal housing with screw down cover • Mounting and dimensions conform to DIN EN 50041 • Actuator head position can be changed in 90° increments • Contacts galvanically isolated

Enclosure Body: Enclosure Cover: Protection Class: Mechanical Life: Temperature: Switch Rate:

Metal Metal NEMA 4 10 x 106 Cycles -22°F to + 176°F 100 per minute max.

• One cable entry point • Conduit adapter or cord grip provided • Manufactured per IEC 947-5-1 and VDE 0660 T200 • UL, CSA and SEV approved

Contact Block

Actuator Style

ENM2

U1Z

AH

608-7137-018 608-7387-019 608-7135-013 608-7385-014 608-7136-016 608-7386-017 608-7117-004 608-7367-005 608-7102-001 608-7352-002 608-7121-007 608-7371-008 608-7127-010 608-7377-011

* SUVA approved for safety applications. Many more styles of actuators and contact blocks available. Contact factory for more information.

Mechanical Data (Dimensions are in inches) ø.39

Contacts

Action

Forced Disconnect

Voltage (max.)

Current (max.)

U1Z 1 N.C. 1 N.O. Slow Yes 400 VAC SU1Z 1 N.C. 1 N.O. Snap Yes 400 VAC SU1 1 N.C. 1 N.O. Snap No 400 VAC Notes: 1. All Contact Blocks Break-Before-Make (in metal housing - replaceable) 2. Normally Closed Contacts Forced Disconnect per IEC 947-5-1 Ch.3 (as

Model Part Number ENM2-U1Z AD ENM2-SU1Z AD ENM2-U1Z AHS-V* ENM2-SU1Z AHS-V* ENM2-U1 AV ENM2-SU1 AV ENM2-U1Z Riw* ENM2-SU1Z Riw* ENM2-U1Z iw* ENM2-SU1Z iw* ENM2-U1Z DGHw ENM2-SU1Z DGHw ENM2-U1Z DGKw ENM2-SU1Z DGKw

Contact Block Technical Data Type

Model Identification Body Style

ENM2 Body Style

.63

Contact Block Wiring Details U1Z - Slow Make-and-Break 11

10 A 10 A 10 A

indicated)

SU1Z Snap Action

12

-14

13 21 23

-24

22

Types of Contact Block and Action

U1Z

Break-Before-Make the NC contact opens before the NO contact closes

Linear Type Actuator 0

.31

.11

11-12

11-12

23-34

23-34 4.4 N

0

SU1Z Snap action arrow indicates direction of travel

.03

Rotary Type Lever

.09

0

13°

0

10°

38°

75°

6.3 N

.21

.47

21-22

21-22

13-14 13-14

13-14 13-14

21-22

21-22

11-12, 21-22, 23-24 Indicates terminal identification for wiring. Operating force shown in Newtons. Newtons x .2248 = lbs. Graduation Tolerance + 3.5° Accuracy of switching point + .009 Tolerance of switching pressure + 10%

35°

75°

= contact open = contact closed = Point of forced openingpositive disconnect

Switching Action Explanation Slow Action

1.2

.295

• Used in precision applications for switching on and off at the exact point • Contact closes at the same speed as actuator/lever

Snap Action .08

• Used when good solid contact is required

2.3

• Used with inductive loads to prevent arcing 3.05

ø.20

.69 1.18 1.57

1.3 1.65

37 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Contact Block Data

Mechanical Data

Contact Block Data

(Dimensions are in inches) .39

Mechanical Data (Dimensions are in inches)

1.97 ø .24

max. 11.0

ø.39

.63

.63 7.87 .295

.295

1.2

.69 .08

.08

2.3

2.36

ø.20

3.05

ø.20

3.05

.69

.69 1.18 1.57

U1Z

SU1Z

1.3 1.65

1.18 1.57

AD

U1Z

ø.98

2.44

1.3 1.65

SU1Z

Iw

.31 .8-1.1 .82-3.20

.31

.96

Ø.79

1.46

.08 .69

.295 .63 .295

.63 .08

2.36 3.05

ø.20

2.36

ø.20

3.05 .69

.69 1.18 1.57

U1

1.3 1.65

SU1

1.18 1.57

AV

U1Z

ø.71

SU1Z

DGHw

2.4 .31

.295

.63

.63

.08

U1Z

SU1Z

1.18 1.57

1.3 1.65

AHS-V

U1Z

SU1Z

1.3 1.65

DGKw

.16

1.32

.295

.63 .08

2.36

Closed Open

3.05

ø.20

.69 1.18 1.57

SU1Z

3.05 .69

ø.70

U1Z

2.36

ø.20

3.05 .69 1.18 1.57

ø.787

.295

.69

2.36 ø.20

.31

.27-.59 .43 .79

1.2 .08

1.3 1.65

1.3 1.65

Riw

= Point of Forced Opening, Positive Disconnect U1Z = Slow Make-and-Break SU1Z = Snap Action with Positive Disconnect SU1= Snap Action

38 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Heavy Industrial Foot Switches Single / Two / Three Pedal with and without Protective Guard Operational Modes Available Momentary: Press pedal to start process. Remove foot and allow pedal to spring back to initial position and process to stop. Maintained: Press pedal once to start process. Press pedal again to stop process. Proportional Output: When the pedal is pressed, the output is proportional to the movement of the 10 K Ohm, 2 Watt potentiometer. Anti-Trip: The Anti-Trip lever is an additional safety feature allowing the pedal to be activated only when the lever has been pushed forward.

Specification Overview Mechanical Features: Case Material: Aluminum die cast Protective Guard: Aluminum die cast Actuator: Foot lever Ambient Air Temperature: -22° F to 176° F Switch Action: Dependent upon switch selected Contacts: Dependent upon switch selected Mechanical Life: 10 x 106 for on/off version switch operations Switching Frequency: 50 times per minute Mounting: Free standing on rubber bumpers Terminals: 4 screw terminals per contact block (replaceable) Cable Entries: All switches supplied with 1/2” conduit adapter Weight: Approximately - F1 types 1.5 Kg. (3.3 lbs.)

Electrical Features: Maximum Voltage: 500V AC Enduring Current: 20 Amps Inrush Current: Per IEC 947-5-1, AC 15, DC 13 Standards: According to VDE 0660, 0113 IEC 947-5-1 Protection Class: NEMA 4, according to DIN 40 050 UL/CSA Approved: 10 Amp, 300 VAC, A300 (same polarity)

Type and Operating Contact Construction Mode Block Model Part Number Drawing Single Pedal Momentary 1 N.O. - 1 N.C. F1-SU1Z 606-1300-011 a Single Pedal with Guard Momentary 1 N.O. - 1 N.C. F1-SU1Z UN 606-1800-012 b Single Pedal with Guard & Anti-Trip Momentary 1 N.O. - 1 N.C. F1 SU1Z AT UN 616-1800-482 b Single Pedal Maintained 1 N.O. - 1 N.C. F1-U1Y 606-1100-001 a Single Pedal with Guard Maintained 1 N.O. - 1 N.C. F1-U1Y UN 606-1600-002 b F1-SU1 Mi RG 616-1300-327 a 10K 0hm, 2W** Proportional Single Pedal Single Pedal with Guard Proportional 10K 0hm, 2W** F1-SU1 Mi RG UN 616-1800-328 b d 606-2330-021 F2-SU1Z-SU1Z 2 x 1 N.O. - 1 N.C. Momentary Two Pedal* Two Pedal with Guard* Momentary 2 x 1 N.O. - 1 N.C. F2-SU1Z-SU1Z UN 606-2830-022 e Three Pedal* Momentary 3 x 1 N.O. - 1 N.C. F3-U1Z-U1Z-U1Z 606-3111-025 f 3 x 1 N.O. - 1 N.C. F3-SU1Z-SU1Z-SU1Z UN 606-3833-045 g Momentary Three Pedal with Guard* * On multi-pedal switches, each pedal operates independently. **Contacts rated at 5 amps See page 40 of catalog for data on the Safety Foot Switch. F1-SU1Z / UV1DUN Part # 616-1000-203 Other special versions available include, Foot Switches for Medical Applications and Foot Switches for use in explosive areas, these foot switches can be designed and manufactured to order.

Safety Foot Switches Safety Foot Switches are “enabling devices” that are generally used on machinery where the operator needs to be able to immediately interrupt any given process in order to avoid bodily harm. Safety Foot Switch on Page 40.

39 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Mechanical Data (Dimensions are in inches) F3

F2

F1

Side View

2.36

2.76

7.48 7.48

2.36

2.36

12.80

2.59

8.66

8.66

8.66

2.58 2.58

2.58 2.24

2.58

2.58 4.92

2.24

2.58 2.584.92

4.65

F1-UN

2.24 2.58

2.24

4.65

Side View

F3-UN

F2-UN 7.69

7.69

3.70

3.70

2.96

8.66

3.70

12.80

3.70

9.83 9.84

9.83

9.83

3.66

3.66

3.66

2.58 2.58

4.92

4.65 2.36

6.14

2.58 5.79

2.24 2.58

10.87

5.73

2.58 4.92 16.14 2.58

3.66

2.58

2.24 5.73

4.65

2.24

2.58

5.73

10.87

SAFELOCK Safety Foot Switch A safety foot switch is based on the operation of a standard type momentary action switch, with an additional safety latching switch mechanism. The machine will only operate when the foot switch pedal is pushed down. Releasing the pedal or applying overpressure on the pedal will stop the machine. The foot switch locks in the emergency stop position when pushed through the secondary switch. To prevent accidental restarts, it must be manually reset. • • • • • •

Rugged, heavy duty, metal housing Forced disconnect of the N.C. contact Contacts galvanically isolated Three cable entry points Cord grip provided UL, CSA, SEV and BG Approved

Model: Part Number: Enclosure: Contacts:

F1-SU1Z/UV1 DUN 616-1000-203 Die Cast Aluminum 1 Normally Closed Forced Disconnect per IEC 947-5-1 Ch. 3 2 Normally Open Voltage Rating: 500 VAC (max.) Current Rating: 10 A (max.) Protection Class: NEMA 4 Mechanical Life: 10 x 106 Cycles Temperature: –22°F to +176°F Switch Rate: 50 per minute max.

Home

Run

Stop

(Dimensions are in inches) Reset

3.70

2.95

Home Position - Operating Contacts Open

9.84

Run Position - Operating Contacts Closed 3.66

Emergency Stop - Safety Contact Open (Foot switch locks in emergency position until manually reset) Manual Reset - Operation now back to home position

2.58 6.14

40 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

2.36 5.79


SAFELOCK Safety Switches Warner Electric offers a large selection of different styles of safety switches. All of the safety switches carry the “CE” mark and are manufactured to all relevant European and International Safety Standards such as, the Machine Directive 89/392/EEC, IEC 947-5, as well as other sub-standards that pertain to specific types of machinery and/or safety installations.

Safety Interlock Switches Safety Interlock Switches are generally used on the guarding (i.e. protective doors/covers) of industrial machinery, such as test and assembly or packaging machinery in order to shield operators from potential injuries that could result due to unauthorized access.

Solenoid Locking Switches Solenoid Locking Switches are typically used in applications that require guarding for machines that have coasting rundown cycles after the power supply has been turned off. Application examples include robotic cells, sawmills, as well as stamping presses.

Hinge Interlock Switches Actuator arms VKS, VKWRE and VKWLI give the user the opportunity to install them as permanently mounted operational arms on flaps and covers or in the case of the AHDB styled actuator to be directly connected to a hinge point of a rotating shaft. The normally closed safety contacts will open after 10 degrees of movement.

Safety Hinge Switches Safety Hinge Switches are load bearing hinges with the safety contact mounted internally. They are designed for mounting onto extruded aluminum profiles, steel or plastic doors, etc. The switch point of the safety contact is programmable to any point within the 180° operation angle of the switch.

Safety Cable Pull Switches Safety Cable Pull Switches are used in applications where large exposed areas exist that need to be secured. Application examples include large printing presses and conveyor systems. Safety Cable Pull Switches are required to operate in emergency stop installations and therefore are governed by European Standard EN 418 which governs emergency stop devices.

Attention Replacement Keys: Replacement Keys are made available for replacement purposes only and shall not be used for other purposes such as defeating the Safety Function of any Interlock Switch. To do so may create an unsafe situation which could lead to serious injury or death. For Replacement Keys: Please contact your local Warner Electric Distributor.

41 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK SKT and SKI Safety Interlock Switches with Separate Actuator The SKT and SKI safety interlock switches slim compact design according to EN50047 are perfect for safety applications that require a particularly slim and compact switching device while still offering the same advantages, relating to safety, as all other products in this range. The principal function of the SKT and SKI safety interlock switches is to switch the machine drive off when a movable protective guard is opened or removed.

SKT

SKI

Common Features: • Limit Switch Design (EN 50047) •

Insulated device (IEC 60947-5-1) on all models with plastic housing

Positive Opening safety contacts (IEC 60947-5-1)

• Rotating head allows actuator engagement from four sides or four top positions; no tools are required to rotate head Model SKT-U1Z M3 SKT-SU1Z M3 SKT-A2Z M3 SKT-SA2Z M3 SKI-U1Z M3 SKI-SU1Z M3 SKI-A2Z M3 SKI-UV15Z M3

Part Number 601-6419-059 601-6409-060 601-6469-066 601-6469-067 601-6819-052 601-6809-057 601-6869-056 601-6869-058

1 1 2 2 1 1 2 2

Contacts NO/1 NC (U1Z) NO/1 NC (SU1Z) NC (A2Z) NC (SA2Z) NO/1 NC (U1Z) NO/1 NC (SU1Z) NC (A2Z) NC/1 NO (UV15Z)

Voltage (Max.) 250 VAC 250 VAC 250 VAC 250 VAC 250 VAC 250 VAC 250 VAC 400 VAC

Current (Max.) 10A 10A 10A 10A 10A 10A 10A 6A

Model Identification Body Style SKT = 3.27" tall SKI = 3.94" tall

Contact Block

Actuator Style

U1Z = 1 NC /1 NO Slow Action SU1Z = 1 NC/1 NO Snap Action A2Z = 2 NC Slow Action SA2Z = 2 NC Snap Action UV15Z = 2 NC /1 NO Slow Action Make before Break Z = Forced Disconnect per IEC 60947-5-1

Other Specifications Max Switching Speed Max Actuator Speed Minimum Actuator Radius Contact Material Actuator Extraction Force Mechanical Life Operating Temperature Construction Environmental Rating Certifications Weight

M3 = Stainless Steel Actuator For other styles contact factory

30 operations per minute 1 meter per second 150 mm (6 inches) Silver-nickel alloy 12 Newtons (2.6 lbs.) 1 million operations –30° to +80°C (–22° to +176°F) Glass fiber-reinforced polyamide thermoplastic housing UL94-VO rating NEMA 4/IP65 CE CSA UL BG SLT = .26 lb. SLI = .29 lb.

42 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SKT and SKI Operational Features Features Easy Access The wiring chamber is accessed via a hinged door. Simply insert a flat-blade screwdriver, as shown, and pry gently down to open.

Rotating Actuator Head The actuator head may be rotated in 90째 increments to create eight possible actuator engagement locations. To rotate the head, pull the holding clamp forward, rotate the head to the desired position, and push the holding clamp back into lock.

SKT Dimensions

SKI Dimensions

inches (mm) 1.19 (30)

1.19 (30) 1.50 (38)

1.50 (38)

0.32 (8)

0.22 (5.5) 3.98 (100)

3.30 (83) 1.79 (45)

0.08 (2)

M5 Clearance

M5 Clearance 0.44 (11) 1.07 (27)

M16 x 1.5 Thread

0.16 (4)

2.46 (62)

0.87 (22) 0.91 (23)

M20 x 1.5 Thread

0.64 (16) 1.21 (30.5)

0.79 (20) 0.87 (22)

43 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK SK and SKC Safety Interlock Position Switches with Separate Actuator Description The SK and SKC safety position switches offer outstanding performance in personal protective functions.

SKC

Common Features

Constructional safety features of these models have been implemented according to DIN EN 60947-5-1 and test principle GS-ET 15.

Safety Category: Protection Class: Mechanical Life: Temperature: Switch Rate: Actuator Holding Force: Enclosure:

The principle function of the SK and SKC safety position switches is to switch the machine drive off when a movable protective guard is opened or removed. The SKC series is ideal for space limited applications since its overall length is just 2.85 inches (75 mm). A standard SK switch is 3.55 inches (90 mm) long. Model SKC-A1Z M SK-U1Z M SK-U1Z MRH SK-U1Z MRV SK-UV15Z M SK-UV15Z MRH SK-UV15Z MRV SK-UV15Z F

Part Number 601-6169-039 601-6119-016 601-6119-041 601-6119-040 601-6169-026 601-6169-064 601-6169-065 601-6169-063

1 1 1 1 2 2 2 2

SK

Contacts N.C. N.C., 1 N.O. N.C., 1 N.O. N.C., 1 N.O. N.C., 1 N.O. N.C., 1 N.O. N.C., 1 N.O. N.C., 1 N.O.

Approvals: Voltage (max.) 500 VAC 500 VAC 500 VAC 500 VAC 400 VAC 400 VAC 400 VAC 400 VAC

4 NEMA 4 1 x 106 Cycles -22°F to +176°F 30 per minute max. 2.3 lbs. [10 N] other options available PA 6 Thermoplastic (UL 94-V0) UL, CSA, and BG approved

Current (max.) 10 A 10 A 10 A 10 A 6A 6A 6A 6A

Actuator Style M M MRH MRV M MRH MRV F

Drawing A B B B B B B B

Model Identification Body Style SK

Contact Actuator Block Style U1Z

M

A1Z = 1 N.C., Forced Disconnect U1Z = 1 N.C., 1 N.O., Forced Disconnect UV15Z = 2 N.C., 1 N.O., Forced Disconnect Make Before Break

Type M Metal Actuator Cast Stainless Steel

Normally Closed Contacts Forced Disconnect per IEN EN 947-5-1 Ch. 3

Type F Flexible Actuator Tolerates Misalignment of Guard Door

Type MRH Horizontal Short Radius Actuator Hinge Distance 2” [50 mm] Or More

Type MRV Vertical Short Radius Actuator Hinge Distance 2” [50 mm] Or More

Model SK

Model SKC (Dimensions are in inches)

(Dimensions are in inches) 2.05

2.05

.24 1.18

1.57

1.57

1.18

Non-Standard Options

.31

.31

1.06

1.06 .24

F30: Actuator holding force of 7 lbs. [30 N] F100: Actuator holding force of 23 lbs. [100 N] FE10: Actuator not retained

.31

.31

.23

.23

.71

1.15

1.15 2.95

3.55

.71

Other contact arrangements are also available. Consult the factory for details.

M16 x 1.5

A

1.30

.22 1.57

2.05

.22 1.57

.28 M20 x 1.5

B

1.30

44 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

2.05

.28


SK and SKC Operational Features Easy Access

Multi Directional Actuation

The self retained snap on cover is released by a screw driver (Fig. 1) and can be opened to an angle of 135˚ providing easy access to the wiring terminals (Fig. 2).

After opening the switch cover, the head can be removed from the top (Fig. A). After a rotation of 180˚ (Fig B) the head can be attached again on the enclosure and locked by the switch cover. This results in four directions of approach.

180° Fig. 1

Fig. 2

Removal Protection A cover cap with one-way latching to seal the assembly screws prevents unauthorized removal of the actuator.

Fig. B

Fig. A

• Forced disconnection of the N.C. contacts • Three cable entries • Conduit adapter provided (1/2 NPT) Cord grip available upon request • Manufactured to DIN EN 60947-5-1, IEC 947-5-1, and test principle GS-ET 15

• Triple coding of the actuator for a high level of safety • Increased functional safety through two interlocks operating independently • Actuator mates with switch in one of four positions • Actuator has smooth surface with no protruding sharp parts

GC Safety Interlock Position Switch with Separate Actuator Description The GC Style Interlock Position Switch is a unique type of switch because of its “Pole” type actuator that fits more like a plug than the other interlock switches. The head offers a flexible spring type adjustment, making it very flexible in operation. • Rugged, heavy duty metal housing • Positive forced disconnection of the N.C. contacts • Contacts galvanically isolated • Cord grip provided • UL, CSA, and SUVA Approved

GC (Dimensions are in inches)

Model: Part Number: Enclosure: Contacts:

Voltage Rating: Current Rating: Protection Class: Mechanical Life: Temperature: Switch Rate:

GC-U1Z VT 90˚ 612-1100-555 Die Cast Aluminum 1 Normally Closed Forced Disconnect per IEC 947-5-1 Ch. 3 1 Normally Open 500 VAC (max.) 10 A (max.) NEMA 4 25 x 103 Cycles -22°F to +176°F 10 per minute max.

2.52

1.02 .69 1.02

.17 2.46

.22

.57 2.83

.98

1.42

1.30

For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

45


SAFELOCK Integral Safety Hinge Switch IP 67 Metal housing Hinged machinery guards and covers as well as safety fence doors may be found in every type of industry. The safety hinge switch SHS is the integration of a safety switch and load bearing hinge for industrial applications. Designed to facilitate mounting onto extruded aluminum profiles, steel or plastic doors, the slim profile of the SHS even when fully closed, allows the hinge to be readily mounted where space is constrained. Traditional safety switches with separate actuator keys are often subject to mechanical wear, particularly when mounted on the closing edge of guards where accumulated tolerances can cause misalignment. The SHS removes this problem with the safety contact mounted internally, inaccessible to the user and therefore providing excellent tamper protection. One or more switches may be used dependent on the category of safety protection required. Matching hinges without safety contacts are also available, allowing the style to be standardized for general use. In operation, consideration must be given to the required contact operation angle, which is determined by guard size and the maximum allowable guard opening distance before actuation.

UL ®

Safe: • 2 SHS hinge switches each with a forced disconnect safety contact allow safety category 4 systems to be configured subject to the required risk analysis and safety contact monitoring. Flexible: • The hinge operation angle is 0-180°. • The switch point may similarly be selected through 180°. • AC/DC to 250 V or 60 VDC versions available.

Fast: • Industry standard M12 x 1 connectors with axial and radial (rear) mounting available as well as fixed cable version. Reliable: • A cast Zinc alloy body allows the SHS a high degree of mounting freedom. • In its hinge capacity the SHS can bear up to 750 N axially and over 1000 N radially, when the switching point has been set. • Ingress protection to IP 67

SHS Configuration Summary Part No. 601-9261-009 601-9261-010 601-9261-011 601-9261-014 601-9261-015 601-9261-016 601-9261-017 601-9261-018 601-9291-013

Contact Function A1Z A1Z A1Z A1Z A1Z A1Z A1Z A1Z

Type DC Description SHS-A1Z-SA — SHS-A1Z-SR X — SHS-A1Z-KA5 SHS-A1Z-KR5 — SHS-A1Z-SA X SHS-A1Z-SR — SHS-A1Z-SA-BG — SHS-A1Z-SR-BG — SHS-OZ Hinge without safety contact —

Type AC/DC X — X X — X X X —

Quick Fixed Cable Disconnect axial radial axial (SA) (SR) (KA) Metal — — — Plastic — — — X — — — Metal — — — Metal — Metal — — — Metal — — — —

46 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

radial BG-Type (KR) Approval — — — — — BG X BG — — — — — BG — BG — —


True Category 4

Installation example:

(EN 954-1/2) l l l

24 VDC

true electrical redundancy true mechanical redundant safety avoids mechanical common mode failure

feedback path

SCR Cat. 4 start button power contactor

motor

Plug M 12 x 1with molded cable

AC/DC Configuration

DC Configuration

AC/DC Configuration

Ø14.5 M12x1

Terminal code, AC/DC configuration 1 = brown 2 = black 3 = blue 4 = green-yellow

M12x1

Terminal code, DC configuration 1 = brown 2=3 = blue 4 = black

Ø14.5

Terminal code, AC/DC configuration 1 = green-yellow 2 = black 3 = blue

Ø14

39.5

1 11.3

25

40.5

45.5

5000

Ø14,5 POL 2

POL 3

Pol Nr. Leiter 1 GNYE (Grün/Gelb) 2 BK (Schwarz) 3

POL 1

BU (Blau)

Straight line

Right-angle

on request AN-KAB.SHS 5M AC 325-1103-234

on request AN-KAB.SHS 5M 325-1103-236

Material of cable sleeve: Material body/Contact carrier: Rated voltage max.: Current carrying capacity max.: Temperature range min./max.: Cable structure mm2: Protection class after installation:

PVC (UL)/PVC (UL) PUR (UL)/PUR (UL) 300 VAC 3A -25 °C/+70 °C -13 °F/+158 °F 3 x 0.5 IP 67

3

4

2

1 5

Straight line AN-KAB.SHS 2M DC 325-1003-221 AN-KAB.SHS 5M DC 325-1003-222 AN-KAB.SHS 10M DC 325-1003-223

1

4

Right-angle AN-KAB.SHS 2M DC 325-1003-224 AN-KAB.SHS 5M DC 325-1003-225 AN-KAB.SHS 10M DC 325-1003-226

Material of cable sleeve: Material body/Contact carrier: Rated voltage max.: Current carrying capacity max.: Temperature range min./max.: Cable structure mm2: Protection class after installation:

PVC/PVC PUR/PUR 60 VAC/75 VDC 1.5 A -25 °C/+70 °C -13 °F/+158 °F 3 x 0.34 IP 67

2

3

Straight line

Right-angle

— AN-KAB.SHS 5M AC 325-1004-219

— AN-KAB.SHS 5M AC 325-1004-220

Material of cable sleeve: Material body/Contact carrier: Rated voltage max.: Current carrying capacity max.: Temperature range min./max.: Cable structure mm2: Protection class after installation:

PVC/PVC PUR/Nylon 6.6 300 VAC 4.0 A -5 °C/+70 °C +23 °F/+158 °F 4 x 0.34 IP 68

47 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Safety Hinge Switch Operation and Set Point Programming Only on SHS-A1Z-SA Operating range 90°

30° 20

Only on SHS-A1Z-SR Assembly free space in the frame Ø 18 mm (for 90° connector)

Ø1 8

Ø18

180°

For proper installation the procedure below must be followed. a) SHS without switching point set shall be mounted under no load condition on the guard. b) SHS switching point shall be set in one successive procedure. c) The guard shall be moved only after properly setting the switch point. d) Finally, the set SHS shall be completely fixed on the guard.

Hinge wing Housing S

Check wall strength at the attachment position

On Off

3c 1 1-4 -2 3°

4

3b approx. 5 Nm

Set screw SW 13

3a

1. The guard door must turn freely through the total operating range. 2. Fix the guard door in the closed position. 3.a Tighten the setscrew with a box spanner (SW13/max. 20 mm) until resistance is met. 3.b Continue until the setscrew shears. (Md = 25Nm) 3.c The set point for the switching angle is now fixed. 4. An increased actuation force (torque approx. 5 Nm) is required during the first use of the guard.

1 1-4 -2

1 2

The hexagonal head of the setscrew must always be sheared off otherwise the safety function will not be achieved.

Operating angle 0° - 30° = Allen Screw DIN 6912 necessary without washer in the hinge wing M6

30° - 180° = Allen Screw DIN 912 permissible washer DIN 125 in the hinge wing Allen Screws DIN 6912 M6 (Low head)

48 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK SHS Hinge Switches

1 2

2

3 Plug

1 2

•/ –

3 Plug

•/ – iw

1-2

1-4

1-2 1-2

iw

10° 10°

10°

3° 3°

3° 10° 10°

Setpoint

Programmable Setpoint

Operating Angle

Off

1

2

180°

On

SHS-A1Z-SR-BG 601-9261-018

1

Setpoint

Switch angle degrees Tol. + 1, 5° -1, 0°

SHS-A1Z-SA-BG 601-9261-017

Setpoint

Designation Part number Contact diagram Forced disconnect to IEC 947-5-1 annex k Za: non-galv. separated contact Zb: galv. separated contact Slow make and break/ snap action Sealed internally (iw)/ externally (w)

10°

Switching hysterisis: -1.0° Voltage max. Thermal current max. Utilization category per IEC 947-5-1 AC 15/DC 13 Switching frequency Mechanical life - switching operations Operating temperature

max. min./max.

Approvals Weight Delivery: ex-stock/ built to order

250 VAC 3A 60 V / 0.5 A 230 VAC / 1.5 A 1200 / h 1 x 10 6 –25 °C / +70 °C –13 °F / +158 °F BG, UL and CSA 0.4 kg •/ –

250 VAC 3A 60 V / 0.5 A 230 VAC / 1.5 A 1200 / h 1 x 10 6 –25 °C / +70 °C –13 °F / +158 °F BG, UL and CSA 0.4 kg •/ –

(All dimensions in mm) 72 15

16

10

Ø10.5

80 64 +-0.1

Ø6.5

11

Assembly free space in the frame Ø 18 mm

49 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK SHS Hinge Switches

Designation Part number Contact diagram Forced disconnect to IEC 947-5-1 annex k Za: non-galv. separated contact Zb: galv. separated contact Slow make and break/ snap action Sealed internally (iw)/ externally (w)

1

1

2

2

2

1

2

Fixed cable, 5 m

GNYE

1 Fixed cable, 5 m

GNYE

•/ –

•/ – iw 1-4

1-2

180°

1-2

iw

1-2

Switch angle degrees Tol. + 1, 5° -1, 0°

SHS-A1Z-KR-5 601-9261-014

SHS-A1Z-KA-5 601-9261-011

Setpoint

Setpoint

10° 3°

Setpoint

Off

Programmable Setpoint

On

Operating Angle

10°

10°

10°

10°

10° 0°

Switching hysterisis: -1.0° Voltage max. 250 VAC Thermal current max. 3A Utilization category per IEC 947-5-1 AC 15/DC 13 60 V / 0.5 A 230 VAC / 1.5 A Switching frequency max. 1200 / h Mechanical life - switching operations 1 x 10 6 Operating temperature min./max. –25 °C / +70 °C –13 °F / +158 °F Approvals BG, UL and CSA Weight 0.4 kg Delivery: ex-stock/ built to order •/ –

250 VAC 3A 60 V / 0.5 A 230 VAC / 1.5 A 1200 / h 1 x 10 6 –25 °C / +70 °C –13 °F / +158 °F BG, UL and CSA 0.4 kg •/ –

R9

72 15

16

Ø10.5 5000

21

Ø12

Ø5.2

4.5

5m

6.5 2.5 6.6

R9

10

Ø6.5

80 64 + – 0.1

Ø10.5

80 64 +-0.1

Ø6.5

11

10

10

GD-ZnAl4Cu1

16

(19) 15.5

15

4.5

72 11

2.5 6.5

10

15.5 (19)

(All dimensions in mm)

12

50 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK SHS Hinge Switches

SHS-A1Z-SR 601-9261-010

SHS-A1Z-SA 601-9261-015 4

4

1

2 1 Plug

4 3

4 3

•/ –

1 Plug

•/ – iw 1-4

1-2

180° 180°

1-41-2

1-2

iw

Switch angle degrees Tol. + 1, 5° -1, 0°

1

2

1-4

Designation Part number Contact diagram Forced disconnect to IEC 947-5-1 annex k Za: non-galv. separated contact Zb: galv. separated contact Slow make and break/ snap action Sealed internally (iw)/ externally (w)

180° 10°

10°

Setpoint

3° 3°

Programmable Setpoint

Setpoint

Operating Angle

Setpoint

10°

Setpoint

Operating Angle

Off

Programmable Setpoint Programmable

On

Operating Angle

10°

3° 10°

10°

0° 0°

16

10

15.5

10

R9

GD-ZnAI 4Cu 1 17

Ø10.5

80 64 +-0.1

Ø6.5

R9

15

(19)

72 11

M12x1

4.5

6.5 2.5

(All dimensions in mm)

4.5

Approvals Weight Delivery: ex-stock/ built to order

10

min./max.

M12 x 1

GD-ZnAl4Cu1

max.

250 VAC 3A 60 V / 0.5 A — 1200 / h 1 x 10 6 –25 °C / +70 °C –13 °F / +158 °F UL and CSA 0.4 kg •/ –

6.5 2.5

Switching frequency Mechanical life - switching operations Operating temperature

250 VAC 3A 60 V / 0.5 A — 1200 / h 1 x 10 6 –25 °C / +70 °C –13 °F / +158 °F UL and CSA 0.4 kg •/ –

21

Voltage max. Thermal current max. Utilization category per IEC 947-5-1 AC 15/DC 13

(19) 15.5

Switching hysterisis: -1.0°

12

51 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK SHS Hinge Switches

SHS-A1Z-SA 601-9261-009

2 4 3 2

1

4 3 2

Plug

Plug

1-2

1-4

10° 10°

1-4

•/ – iw

iw

Programmable Setpoint

10°

Setpoint Setpoint

Operating Angle

Off

1

1

2

•/ –

180°

On

4

1

1-2 1-41-2

Switch angle degrees Tol. + 1, 5° -1, 0°

4

SHS-A1Z-SR 601-9261-016

3° 3°

10° 10°

Setpoint

Designation Part number Contact diagram Forced disconnect to IEC 947-5-1 annex k Za: non-galv. separated contact Zb: galv. separated contact Slow make and break/ snap action Sealed internally (iw)/ externally (w)

10°

Switching hysterisis: -1.0° Voltage max. Thermal current max. Utilization category per IEC 947-5-1 AC 15/DC 13 Switching frequency Mechanical life - switching operations Operating temperature

max. min./max.

Approvals Weight Delivery: ex-stock/ built to order

250 VAC 3A 60 V / 0.5 A 230 VAC / 1.5 A 1200 / h 1 x 10 6 –25 °C / +70 °C –13 °F / +158 °F UL and CSA 0.4 kg •/ –

4.5 GD-ZnAI 4Cu 1

R9

10

17

16

Ø10.5

Ø6.5 80 64 +-0.1

15

10

72 11

15.5

(19)

6.5 2.5

(All dimensions in mm)

250 VAC 3A 60 V / 0.5 A 230 VAC / 1.5 A 1200 / h 1 x 10 6 –25 °C / +70 °C –13 °F / +158 °F UL and CSA 0.4 kg •/ –

M12 x 1

Assembly free space in the frame Ø 18 mm

52 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK I88 Style Position Safety Hinge Interlock Switches The I88 style Hinge Safety Switch is available with two distinctive types of operational actuators. Actuator arms VKS,VKW RE and VKW LI give the user the opportunity to install them as permanently mounted operational arms on flaps and covers, as shown in the drawings below.

Arm/Linear • • • •

The AHDB styled actuator is designed to be directly connected to a hinge point of a rotating shaft. The normally closed safety contacts will open after 10 degrees of movement.

Shaft/Rotary

Insulated plastic housing with hinged cover Forced disconnection of the N.C. contacts Contacts galvanically isolated Conduit adapter

Open Closed

Hinged Arms

VKS (Vertical) Model: Part Number: Operation:

I88-U1Z VKS 608-6100-093 Central

Model: Part Number: Operation:

I88-U1Z VKW RE 608-6100-094 Right

Model: Part Number: Operation:

I88 -U1Z VKW LI 608-6100-095 Left

Hinged Shaft

VKW (Horizontal)

(Dimensions are in inches) 3.68 2.76

Model: Part Number: Enclosure: Contacts:

.39 1.77

.31

.79

.20

.79

2.44

.17

.87

Enclosure: Contacts:

Thermoplastic 1 Normally Closed Forced Disconnect per IEC 947-5-1 Ch. 3 1 Normally Open Voltage Rating: 500 VAC (max.) Current Rating: 10 A (max.) Protection Class: NEMA 4 Mechanical Life: 1 x 106 Cycles Temperature: -22°F to +176°F Switch Rate: 50 per minute max. Approvals: UL, CSA

1.22

M20 x 1.5

1.20

I88-U1Z VKW RE

Voltage Rating: Current Rating: Protection Class: Mechanical Life: Temperature: Switch Rate: Approvals:

.39 .20

.10

1.81 .79 1.77

.51

2.76

2.76 1.77

I88-U1Z AHDB 618-6100-267 Thermoplastic 1 Normally Closed Forced Disconnect per IEC 947-5-1 Ch. 3 1 Normally Open 500 VAC (max.) 10 A (max.) NEMA 4 1 x 106 Cycles -22°F to +176°F 50 per minute max. UL, CSA

M3

.39

.32 .47

.79

.20

.51

6.30

.16

3.31 .31 .17

.31 2.44 .17

.87

.79

.14 2.44

2.44

.39

.87 .79

.79

1.22

1.20 M20 x 1.5

M20 x 1.5

M20 x 1.5

1.20

1.22

I88 -U1Z VKW LI

1.22

I88-U1Z VKS

1.20 1.20

I88-U1Z AHDB

53 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK Solenoid Locking Interlock Switches with Separate Actuator Description The SLK series of Solenoid Locking Switches are designed to ensure movable protective guards and are kept locked in place on machinery until the operating sequence or machine cycle is completed. The actuator key is held in position under force, while the interlocking mechanism is activated. The interlocking mechanism is directly connected to the machine’s control system.

SLK

Safety Interlock Switches perform three functions: 1. Allow the machine/process to operate when the protective guard is in position and locked. 2. Ensure the machine/process cannot operate when the actuator key is not in the locked and closed position. 3. Monitor the switch and the interlocking mechanism during operation.

(Dimensions are in inches) .31 1.25 So

2.0 .82

.78

So 1.18-1.57

.19

System Description

.18

Two types of locking methods are available: .31

Spring Lock...Mechanically locked-power to solenoid unlocks actuator .07 7.2

Magnetic Lock...Power to solenoid locks actuator in position.

.20 6.69

Features • Compact and slim in design • Rugged plastic insulated housing • Triple coding of the actuator for a high level of safety • Flexible mounting options with rotatable actuator head (4X90°) and horizontal or vertical actuator approach • Three cable entries • Wiring chamber protected to IP 67/ NEMA 4

.72 .19

Electrical Features Switching Devices 250 V 10 A AC 15 230 V / 4 A DIAZEDDIN VDE 0636 Part 1 6 A/inert gl / gG

Solenoid Duration of Current: Temperature Class: Inrush Power Consumption: Permanent Power Consumption: Switching Frequency:

3.4 / 100% ED E (120°C) 56 VA (0.2s) 1.1 VA (constant) 600 / hr. max.

Actuation • Standard actuator allows 8 different mounting positions 4 Horizontal in 90° increments 4 Vertical in 90° increments

Part Number

.59 1.25 1.67

Rated isolation voltage max.: Thermal Continuous Current max.: Category of Use: Short Circuit protection:

Designation

Locking Spring Force Magnet Force

5.31

4.88

1.47 1.77

M20 x 1.5

Head Mounted Vertical (Standard Actuator)

Head Mounted Horizontal (Standard Actuator)

Mechanical Characteristics Enclosure: Actuator Key: Ambient Temperature: Switching Function: Mechanical Life: Actuation Radius: Approach Speed: Weight: Locking Force:

Connection Assembly Safety Equipment Locking

Control Voltage

PA 6 GV (UL94-V0) Stainless Steel / PA –25°C to +70°C 2 NC; 2 NO contacts 1,000,000 cycles 400mm min. V = 0.5m / s max approx. 0.3 kg 1000 N (250 lbs.) Add. Functions Auxiliary Release LED (AR) (L)

Actuator Standard Radial Actuator

601-8119-001

SLK-FVTU24UC-55-AR

Spring Force

1 NC

1 NO

1 NC

1 NO

24 VAC/DC

AR

Standard

601-8119-002

SLK-FVTU24-230MC-55-AR

Spring Force

1 NC

1 NO

1 NC

1 NO

24–48 VDC + 24–230 VAC

AR

Standard

601-8119-003

SLK-MVTU24UC-55

Magnet Force

1 NC

1 NO

1 NC

1 NO

24 VAC /DC

Standard

601-8119-004

SLK-MVTU24-230MC-55

Magnet Force

1 NC

1 NO

1 NC

1 NO

24–48 VDC + 24–230 VAC

Standard

54 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK Solenoid Locking Interlock Switches with Separate Actuator Description The SLM series of Solenoid Locking Switches is designed to ensure movable protective guards are kept locked in place on machinery until the operating sequence or machine cycle is completed. The actuator key is held in position under force, while the interlocking mechanism is activated. The interlocking mechanism is directly connected to the machine’s control system.

SLM

Safety Interlock Switches perform three functions:

Z

1. Allow the machine/process to operate when the protective guard is in position and locked. 2. Ensure the machine/process cannot operate when the actuator key is not in the locked and closed position. 3. Monitor the switch and the interlocking mechanism during operation.

Z Y

X

90°

X

System Description Two types of locking methods are available:

Y

Spring Lock...Mechanically locked-power to solenoid unlocks actuator Magnetic Lock...Power to solenoid locks actuator in position Features: • UL, CSA, and BG approved • Triple coding of the actuator for a high level of safety • Rugged, heavy duty, metal housing • Actuator approach direction can be changed in 90° increments • Actuator has smooth surface with no protruding sharp parts • Forced disconnection of the N.C. contacts • Contacts galvanically isolated • Two cable entries • Conduit adapter or cord grip provided • Manufactured to VDE 0660 part 200, IEC 947-5-1, and test principle GS-ET 19

Model Identification Body Style

SLM

Lock Solenoid Type Actuator Voltage

F VTW

24 DC

Contact Block

Release Type

55

AR AR = Auxiliary Release

F = Spring Lock M = Magnetic Lock

Common Features Safety Category: Contact Voltage: Contact Current: Protection Class: Mechanical Life: Temperature: Actuator Locking Force: Actuator Holding Force: Operating Radius: Enclosure:

4 250 V (maximum) 10 A (maximum) NEMA 4 1 x 106 Switching Cycles -22°F to +140°F 225 lbs. [1000 N] 4.5 lbs. [20 N] 15.7" [400 mm] (minimum) Die Cast Aluminum

Model (Spring Lock)

Part Number

Part Number

Solenoid Voltage

SLM-MVTW 24 DC-55 SLM-MVTW 120 AC-55

601-7119-023 601-7119-033

24 VDC 120 VAC

(Dimensions are in inches) 3.13

.39

.12 1.63 1.45

.08

1.18 2.36

Non-Standard Options 230 VAC/50 Hz solenoid voltage Key operated auxiliary release (Spring Lock Only) Mushroom head auxiliary release with key reset (Spring Lock Only) LED indicators for switch status Extended length actuator

Consult the factory for details.

24 VDC 120 VAC

Model (Magnetic Lock)

24 DC = 24 VDC 55 = 1 N.C., Forced Disconnect per 120 AC = 110-130 VAC IEC 947-5-1 Ch. 3 50-60 Hz 1 N.O. (Actuator and Lock Monitor Contacts)

• • • • •

Solenoid Voltage

SLM-FVTW 24 DC-55-AR 601-7119-020 SLM-FVTW 120 AC-55-AR 601-7119-032

.31

3.94

6.33 .87

.79 1.77

1.18 M20 x 1.5

3.54

55 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK MUZ-602 and MUZ-202 Coded Magnetic Monitoring Systems BIA Rated for Safety Category 3 EN 954-1 Single Failsafe System With Partial Fault Recognition Description

Features

The monitoring controls available to Category 3 certification are the MUZ-202, two channel control and the MUZ-602 six channel control. The number of channels indicated refers to the maximum number of Coded Magnetic Sensors that can be used per control.

• • • •

Both controls can only be used with series MAK-xx36 Coded Magnetic Sensors and corresponding Magnets TK-xx-CD, as shown on page 57.

The correct operation of the system is ensured, as the circuitry monitors each sensor and magnet to ensure they are aligned correctly, by using an evaluation circuit with two timing stages.

These systems are intended for use with movable protective guard installations, i.e. flaps, doors, and covers.

Only when all the sensors have met this requirement will the controls output relay give the signal for the machine to operate.

Magnetic Coded Monitoring Systems offer an alternative to mechanical interlock switches, especially on machines that operate in areas where cleaning, disinfecting, or contamination play a major role, as the sensor and magnet are fully encapsulated.

Within this series of controls an additional output contact is available, to be used for informational purposes only and not for any safety function.

BIA rated for Safety Category 3 Forced disconnection of the safety contacts Control unit mounts to 35 mm DIN rail (TS 35) BIA Approved

MUZ 202

System Operation

MUZ 602

Typical Application

Model MUZ-202/D24-UM MUZ-602/D24-UM Part Number 639-2702-301 639-2706-302 Enclosure PA 6.6 Plastic Channels 2 6 Safety Contact 1 Normally Closed, Forced Disconnect Monitor Contact 1 Normally Open Operating Voltage 24 VDC Operating Current 100 mA Switching Voltage 250 VAC (max.) Switching Current 8 A (max.) Switching Capacity 1700 VA (MAX.) Protection Class IP 20 (Equivalent to NEMA 1) Temperature +32°F to +131°F [0°C to +55°C] (Dimensions are in inches)

3.78

2.6 1.42

3.78

2.6

1.89

.43 1.65

1.89

.43

2.91

1.65

MUZ 202

MUZ 602

56 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


SAFELOCK

Coded Magnetic Sensors Coded Magnets

Coded magnetic sensors and coded magnets are designed for use with special purpose safety controllers. They cannot be operated by simple bar magnets.

(Dimensions are in inches) Model MAK-4236-31 MAK-4236-STK2 TK-42-CD

Part Number 649-0642-301 649-0642-305 640-2042-301

3.46 3.07 .18 2.68

.26 .98

1

Sensor with 10 ft. (3 m) Cable (19 ft. (6 m) and 29 ft. (9 m) Special Order) 2 Sensor with Connector (Cable Sold Separately) Uses either a 413-9100-228 or 413-9100-230 cable Enclosure: PA 6.6 Plastic Voltage Rating: 30 VDC (max.) Current Rating: 4 mA (max.) Protection Class: NEMA 6 Operating Range: 0.12" (3 mm) On (min.) 0.55" (14 mm) Off (max.) Temperature: –4°F to +158°F Controller Type: MUZ-x02/xxx Model MAK-5336-3 1 MAK-5336-STK TK-43-CD

2

Part Number 649-0653-310 649-0653-313 640-2043-023

.10 .42 .28 .12 .51

.51 .12 .28 .42 .10 .98 .26

2.68 3.07 3.46

.18

1

Sensor with 10 ft. (3 m) Cable (19 ft. (6 m) and 29 ft. (9 m) Special Order) 2 Sensor with Connector (Cable Sold Separately) Uses cable 413-9100-266 Enclosure: PA 6.6 Plastic Voltage Rating: 30 VDC (max.) Current Rating: 4 mA (max.) Protection Class: NEMA 6 Operating Range: 0.12" (3 mm) On (min.) 0.28" (7 mm) Off (max.) Temperature: -4°F to +158°F Controller Type: MUZ-x02/xxx

1.38 1.34 .08 1.08 M1.18 x .06 SW1.42

.20

.59

1.38 .98

.35

.17

Model MAK-5236-3 1 MAK-5236-STK TK-52-CD-HF

2

Part Number 649-0652-306 649-0652-309 640-2052-305

.41

1

Sensor with 10 ft. (3 m) Cable (19 ft. (6 m) and 29 ft. (9 m) Special Order) 2 Sensor with Connector (Cable Sold Separately) Uses either a 413-9100-228 or 413-9100-230 cable Enclosure: PA 6.6 Plastic Voltage Rating: 30 VDC (max.) Current Rating: 4 mA (max.) Protection Class: NEMA 6 Operating Range: 0.16" (4 mm) On (min.) 0.31" (8 mm) Off (max.) Temperature: –4°F to +158°F Controller Type: MUZ-x02/xxx

ø.17 1.02

.33

.28 .87 1.14 1.69

.51

.51

1.69 .27

.18

.87

ø.17

.33

Cables for Sensors with Connectors Material: Cable Length: Protection Class:

PUR (Cable) PA 12 (Connector) 8 ft. (2.5 m) NEMA 6

Model GDK-R06US/S00-2.5PU WDK-R06US/S00-2.5PU WDK-M12UA/S00-2.5PU

Part Number 413-9100-228 413-9100-230 413-9100-266

R06

GDK

R06

WDK

M12

WDK 57

For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Cable Pull Safety Switches For Cable Lengths of 10, 15, 30 and 75 ft. Single Direction for Standard and Safety Applications Description Cable pull switches give personal ready access to a machine stop switch over a long distance by pulling on the cable. They are especially suited for use along conveyors or on the perimeter of large manufacturing machines. Safety cable pull switches (type Si) are safety devices according to IEC 947-5-1 and VDC 0660, T200. The action of the N.C. emergency stop contacts is forced due to the contact elements being securely attached to the plunger. This safety switch has make-before-break contacts. The machine will stop when the cable is pulled or when the cable breaks. These functions are made possible by the overlapping contacts of the UV type contact blocks. This operation requires the Cable to be held in position under tension. See the Typical Installation drawing on page 59 for further information. A latch option keeps the stop contact open after the cable has been pulled and released. The latch is reset by operating a push-button on the switch. Machine restarting is not possible until the latch is reset. The maximum length of the cable is only limited by its weight. The weight of the cable must not exceed the tension force of the switching system. The maximum length of unsupported cable must not exceed 15 ft.

Standard Cable Pull Switch Model SI-U1Z SEK-U1Z SEM2-U1Z SD-U1 SD-U1/LATCH

Part Number 601-3812-075 601-1811-133 601-2811-029 601-1411-856 601-1411-868

*Cable Length 10 ft. 15 ft. 15 ft. 30 ft. 30 ft.

Pull Force 5.5 lbs. 18 lbs. 18 lbs. 27 lbs. 27 lbs.

Voltage (max.) 380 VAC 500 VAC 500 VAC 500 VAC 500 VAC

Current (max.) 10 A 10 A 10 A 16 A 16 A

Enclosure Plastic Plastic Aluminum Aluminum Aluminum

**Drawing A B C F E

*Cable Length 10 ft. 15 ft. 15 ft. 15 ft. 30 ft. 30 ft. 75 ft. 75 ft.

Pull Force 5.5 lbs. 18 lbs. 18 lbs. 18 lbs. 27 lbs. 27 lbs. 45 lbs. 45 lbs.

Voltage (max.) 380 VAC 500 VAC 500 VAC 500 VAC 380 VAC 380 VAC 500 VAC 380 VAC

Current (max.) 10 A 10 A 10 A 10 A 16 A 16 A 16 A 16 A

Enclosure Plastic Plastic Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum

**Drawing A B C D F E G H

Safety Cable Pull Switch Model SiI-UV1Z SiEK-UV1Z SiEM2-UV1Z SiEM2-UV1Z/LATCH SiD-UV1Z SiD-UV1Z/LATCH SiD-UV1Z SiD-UV2Z/LATCH

Part Number 601-3832-076 601-1831-134 601-2831-022 601-2831-023 601-1431-857 601-1431-869 601-2431-877 601-2441-907

*Recommended Cable Length **Drawings shown on page 59

Accessories Single Direction Cable Kit Cable Length 15 ft. 30 ft. 75 ft.

Part Number 8010-448-001 8010-448-002 8010-448-003

Each One Way Cable Kit Includes: Length of cable as listed 1 Wrought Iron Tension Screw 4 Galvanized Clamps 4 Galvanized Thimbles (Customer to provide Eye Screws) Individual accessories are also available.

Model Identification Type

Si

Body Contact Style Block Actuator

D

UV1Z AK U1 = UV1 = UV1Z = UV2Z =

Latch

LATCH

1 N.O., 1 N.C 1 N.O., 1 N.C Make Before Break 1 N.O., 1 N.C. Make Before Break Positive Disconnect 2 N.O., 2 N.C. Make Before Break Positive Disconnect

S = Standard Switch Si = Safety Cable Pull Switch

58 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


(Dimensions are in inches)

Cable Pull Switches

.39

.63 .20

.98 .59

.39

.75

For Cable Lengths of 10, 15, 30 and 75 Feet Single Direction Mechanical and Installation Information

.18

2.20 1.93 .26

5.33

.28

4.49

4.48 1.18

.79

2.36

Common Features Degree of Protection: Temperature: Enclosure: Approvals:

NEMA 4 A –22°F to +176°F Die cast aluminum or glass fiber reinforced thermoplastic UL, CSA

B

.63

.98 .59

.63

.98

.20 .20

.59

Standard Switch Installation

2.89 2.24 .30

6.36

.30 5.41

Normal Position 1.18

1.18 2.36

3.27

2.36

D

C

Cable Pull

.94

.81

.59

.33

.20

Safety Switch Installation

2.83

6.08

2.36

Normal Position - Both sets of contacts closed

.20

.20 5.61

2.20

.28

Tension Screw

.12

1.38

Cable Pulled - Back Contacts Open

E

3.23

F

2.58

.94 .59

.33

Cable Break - Front Contacts Open

1.73

.81 .20

2.83 2.43

.30

7.17 2.99

3.76

.47 .12

1.38

G

3.23

1.79

H

2.58

59 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Cable Pull Switches For Cable Lengths Up To 250 Feet Two Way Direction For Standard and Safety Applications Description For cable runs greater than 75 feet, two directional cable pull switches are recommended. Two directional switches can be used in applications of cable runs up to 250 feet (125 feet on each side of the installed switch). This type of cable pull switch operates with the cables under tension. During prestressing of the cable, both sets of contacts are in their original state. Pulling the cable on either side of the switch will cause the actuator on the switch to be displaced. When the displacement reaches a prespecified angle, the switch will lock and the contacts will not be able to switch back to their original state. The lock-out feature ensures that the machine cannot be restarted until the switch is manually reset by the operator. Cocking springs must be used at both ends of the installation, as shown in the Typical Installation drawing. Any cable length over 15 feet should be supported with an eye screw.

Si1

Two Way Direction Accessory Cable Kit Cable Length 105 ft. [32 m] 200 ft. [61 m] 250 ft. [76 m]

Part Number 8010-448-004 8010-448-005 8010-448-006

Each Two Way Direction Cable Kit Includes: Length of cable as listed 2 Tension Springs 4 Galvanized Clamps 4 Galvanized Thimbles (Customer to provide Eye Screws) Individual accessories are also available.

Common Features Degree of Protection: Temperature: Enclosure: Latch: Approvals:

Si2

NEMA 4 –22°F to +176°F Die cast aluminum Standard with pull ring reset UL, CSA, (Si1 = BG)

Two Way Direction Safety Cable Pull Switch Model Si1-UV1ZAK/LATCH Si2-UV1AK/LATCH * Recommended Cable

Part Number 601-4735-001 601-5735-002 Length

Cable Length* 225 ft. 250 ft.

Switching Angle 30 Degrees 30 Degrees

Contact Block

L

R

L

UV1

2

Actuator

R

.98

2.28

Latch

LATCH

AK

Drawing A B

.79

4.21

3.94

Si

Current (max.) 10 A 10 A

(Dimensions are in inches)

Model Identification Body Type Style

Voltage (max.) 500 VAC 500 VAC

4.90

5.39 .96

.39

2.36 1.18

UV1 = UV1Z =

1 N.O., 1 N.C Make Before Break 1 N.O., 1 N.C. Make Before Break Positive Disconnect

1.02

.28

3.43 1.85

.47

4.72 5.47

2.56

3.94 2.36

3.70 .39

1.93

Typical Installation Arrangement Spring

A

Tension Screws

B Spring

Normal Position

60

Cable Pull For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

1.10


Glossary of Terms NPN

Alignment The correct relation of emitter to receiver as it is important for optimum performance.

Background Suppression A general term for diffuse sensors that can be adjusted to ignore the influence of objects/ surfaces behind the target object. Background Suppression Sensors minimize variations in sensing distances because of the difference in reflectivity between highly reflective and dark targets.

Capacitive A sensing device that is actuated by conductive and nonconductive materials with a dielectric constant greater than 1.

Color Mark Sensor A sensor specifically designed to differentiate between colored marks or between a mark and a background color.

Converged Beam (Fixed Focus) The convergent mode is similar to the diffuse sensing mode because an object is sensed when the receiver sees light reflected back to the sensor by the object itself. The emitter and receiver are focused at a fixed point. Because convergent beam sensors make much more efficient use of sensing light energy, they can sense relatively non-reflective materials and objects with small reflective surfaces.

Dark Activated Operating mode for photoelectric sensors where the output is turned on (transistor becomes conducting, or relay coil is energized) when light is not received.

Diffuse Reflective Sensor configuration with the emitter and receiver located in the same housing. Sensing of target is based on reflection of light from the target itself.

Hysteresis The difference between the switch-on and switch-off point for a sensor.

Inductive Sensing A sensing technology that identifies the presence of metallic objects by detecting eddy current losses in a magnetic field produced at a sensing face.

IP International Protection; an international standard scale for enclosure ratings.

Kodak 90% Reflective White Card A standard reference manufactured by Kodak designed to reflect 90% of white light. Used as a standard target for diffuse reflective sensors.

Transistor output designed to provide a path to ground for current passing through the load (sinking). When the NPN output is on, current can then pass from Positive, through the load, and through the NPN transistor to ground, completing the circuit.

Off-Delay Off delay timers prolong or hold an output signal by a preset time interval after the target leaves the sensing area. The OFF delay can be used as an output pulse extender when target presence is not of sufficient duration for control requirements.

On-Delay On-Delay timers delay the generation of an output signal by a preset time interval from the appearance of the target. Target presence shorter in duration than the preset delay interval will not generate an output signal.

Polarized Retroreflective Sensing Visible light from the emitter of a retroreflective photoelectric sensor that is filtered so as to be projected in only one plane. The receiver of a polarized unit is filtered to accept only light that is reflected perpendicular to the emitted light. Corner cube reflectors are required to properly rotate the emitted light source.

PNP Transistor output that provides a path to "plus" for current passing through the load (sourcing). When the transistor is turned on, current can then pass from Positive, through the PNP transistor, through the load, and to ground, completing the circuit.

Retroreflective Sensing Detection method where light from the emitter is aimed at, and reflected back to the receiver, from a retroreflective target.

Sensing Distance The maximum distance at which, under specifications, a sensor can detect a target.

Shielded Sensor A sensor which senses only to the front of its face and ignores metals to its side.

Switching Frequency The maximum number of complete on-off cycles that the control output is capable of in one second, usually expressed in Hz (Hertz, cycles per second).

Through-Beam Sensing Sensor where the emitter and receiver are in separate housings and arranged facing each other. The target would be detected passing between the emitter and receiver, interrupting the beam.

Ultrasonic Sensing

Operating mode for photoelectric sensors where the output is turned on when light is received.

Ultrasonic proximity mode sensors can measure the time delay between the emitted sound and the returned echo, and produce an accurate measurement of sensing distance. Analog Ultrasonic Sensors produce an output that has a highly linear relationship to sensing distance.

Limit Switch

Unshielded Sensor

A switch positioned such that it is actuated by a moving part, in order to shut off or reverse the power to the motor driving the part when it reaches the limit set for it's travel.

Refers to inductive-type proximity sensors that do not have an internal metallic ring to reduce interference from surrounding metals and other inductive sensors. Non-shielded sensors cannot be flush mounted in metal and must be spaced further away from other inductive sensors than shielded types of sensors.

Light Activated

Magnetic Sensing A sensing device that is activated when brought into the influence of a magnetic field generated by either a permanent magnet or an electromagnet.

NEMA National Electrical Manufacturer's Association; Industrial trade organization that publishes testing standards, including enclosure ratings.

61 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Index to Part Numbers Part Number 325-1003-221 325-1003-222 325-1003-223 325-1003-224 325-1003-225 325-1003-226 325-1004-219 325-1004-220 325-1103-234 325-1103-236 413-9100-228 413-9100-230 413-9100-248 413-9100-249 413-9100-250 413-9100-261 413-9100-263 413-9100-266 413-9100-278 413-9100-279 413-9100-280 413-9100-281 596-0223-040 596-0223-041 596-0223-069 596-0223-070 601-1411-856 601-1411-868 601-1431-857 601-1431-869 601-1811-133 601-1831-134 601-2431-877 601-2441-907 601-2811-029 601-2831-022 601-2831-023 601-3812-075 601-3832-076 601-4735-001 601-5735-002 601-6119-016 601-6119-040 601-6119-041 601-6169-026 601-6169-039 601-6169-063 601-6169-064 601-6169-065 601-6409-060 601-6419-059 601-6469-066 601-6469-067 601-6809-057

Descriptive Code AN-KAB-SHS - 2M DC AN-KAB-SHS - 5M DC AN-KAB-SHS - 10M DC AN-KAB-SHS - 2M DC AN-KAB-SHS - 5M DC AN-KAB-SHS - 10M DC AN-KAB-SHS - 5M AC AN-KAB-SHS - 5M AC AN-KAB-SHS - 5M AC AN-KAB-SHS - 5M GDK-R06US/S00-2.5PU WDK-R06US/S00-2.5PU GDK-M12AS/S00-2 GDK-M12AS/S00-5 WDK-M12AS/S00-2 GDK-M08US/S00-2.5PU GDK-M08US/S00-5PU WDK-M12UA/S00-2.5PU WDK-M08US/S00-2.5PU WDK-M08US/S00-5PU WDK-M12US/S00-2 WDK-M12US/S00-5 BKS-D22PA BKS-D34PA BKB-D04PA BKS-D05PA SD-U1 SD-U1/LATCH SiD-UV1Z SiD-UV1Z/LATCH SEK-U1Z SiEK-UV1Z SiD-UV1Z SiD-UV2Z/LATCH SEM2-U1Z SiEM2-UV1Z SiEM2-UV1Z/LATCH SI-U1Z SiI-UV1Z Si1-UV1ZAK/LATCH Si2-UV1AK/LATCH SK-U1Z M SK-U1Z MRV SK-U1Z MRH SK-UV15Z M SKC-A1Z M SK-UV15Z F SK-UV15Z MRH SK-UV15Z MRV SKT-SU1Z M3 SKT-U1Z M3 SKT-A2Z M3 SKT-SA2Z M3 SKI-SUIZ M3

Page Number 47 47 47 47 47 47 47 47 47 47 57 57 24 24 24 20, 24 20, 24 57 20, 24 20, 24 20 20 23 13, 15, 23 23 23 58 58 58 58 58 58 58 58 58 58 58 58 58 60 60 44 44 44 44 44 44 44 44 42 42 42 42 42

Part Number 601-6819-052 601-6869-056 601-6869-058 601-7119-020 601-7119-023 601-7119-032 601-7119-033 601-8119-001 601-8119-002 601-8119-003 601-8119-004 601-9261-009 601-9261-010 601-9261-011 601-9261-014 601-9261-015 601-9261-016 601-9261-017 601-9261-018 601-9291-013 606-1100-001 606-1300-011 606-1600-002 606-1800-012 606-2330-021 606-2830-022 606-3111-025 606-3833-045 608-1102-001 608-1117-002 608-1135-003 608-1136-012 608-1137-011 608-1152-007 608-1167-008 608-1185-009 608-1186-018 608-1187-017 608-1190-045 608-5103-001 608-5117-002 608-5137-007 608-5153-008 608-5167-009 608-5171-017 608-5185-012 608-5186-013 608-5190-015 608-6100-093 608-6100-094 608-6100-095 608-6103-008 608-6117-017 608-6121-021

Descriptive Code SKI-U1Z M3 SKI-A2Z M3 SKI-UV15Z M3 SLM-FVTW24DC-55-AR SLM-MVTW24DC-55 SLM-FVTW120AC-55-AR SLM-MVTW120AC-55 SLK-FVTU24UC-55-AR SLK-FVTU24-230MC-55-AR SLK-MVTU24UC-55 SLK-MVTU24-230MC-55 SHS-A1Z-SA SHS-A1Z-SR SHS-A1Z-KA5 SHS-A1Z-KR5 SHS-A1Z-SA SHS-A1Z-SR SHS-A1Z-SA-BG SHS-A1Z-SR-BG SHS-OZ F1-U1Y F1-SU1Z F1-U1Y UN F1-SU1Z UN F2-SU1Z-SU1Z F2-SU1Z-SU1Z UN F3-U1Z-U1Z-U1Z F3-SU1Z-SU1Z-SU1Z UN ENK-U1Z iw ENK-U1Z Riw ENK-U1Z AHS-V ENK-U1 AV ENK-U1Z AD ENK-SU1Z iw ENK-SU1Z Riw ENK-SU1Z AHS-V ENK-SU1 AV ENK-SU1Z AD ENK-SU1 FF Bi-U1Z w Bi-U1Z Riw Bi-U1 AD Bi-SU1Z w Bi-SU1Z Riw Bi-SU1Z Hw Bi-SU1Z AH Bi-SU1 AV Bi-SU1 FF I88-U1Z VKS I88-U1Z VKW RE I88-U1Z VKW LI I88-U1Z w I88-U1Z RiwK I88-U1Z Hw

62 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

Page Number 42 42 42 55 55 55 55 54 54 54 54 46, 52 46, 51 46, 50 46, 50 46, 51 46, 52 46, 49 46, 49 46 39 39 39 39 39 39 39 39 35 35 35 35 35 35 35 35 35 35 35 31 31 31 31 31 31 31 31 31 53 53 53 33 33 33


Index to Part Numbers Part Number 608-6135-033 608-6136-037 608-6139-054 608-6153-012 608-6167-018 608-6171-022 608-6185-034 608-6187-042 608-7102-001 608-7117-004 608-7121-007 608-7127-010 608-7135-013 608-7136-016 608-7137-018 608-7352-002 608-7367-005 608-7371-008 608-7377-011 608-7385-014 608-7386-017 608-7387-019 608-8103-001 608-8117-007 608-8121-015 608-8135-021 608-8137-027 608-8153-002 608-8167-008 608-8171-016 608-8185-022 608-8190-040 610-8002-001 612-1100-555 616-1000-203 616-1300-327 616-1800-328 616-1800-482 618-6100-267 6210-448-003 630-1167-054 630-1262-039 630-2111-047 630-2121-030 630-2142-049 630-2145-048 631-1208-596 631-1211-541 631-1230-571 631-1245-539 631-4212-217 631-4223-268 631-4242-533 639-2702-301

Descriptive Code I88-U1Z AH I88-U1 AV I88-SU1 AF I88-SU1Z w I88-SU1Z RiwK I88-SU1Z Hw I88-SU1Z AH I88-SU1 AD ENM2-U1Z iw ENM2-U1Z Riw ENM2-U1Z DG Hw ENM2-U1Z DG Kw ENM2-U1Z AHS-V ENM2-U1 AV ENM2-U1Z AD ENM2-SU1Z iw ENM2-SU1Z Riw ENM2-SU1Z DG Hw ENM2-SU1Z DG Kw ENM2-SU1Z AHS-V ENM2-SU1 AV ENM2-SU1Z AD Ti2-U1Z w Ti2-U1Z Riw Ti2-U1Z Hw Ti2-U1Z AH Ti2-U1 AD Ti2-SU1Z w Ti2-SU1Z Riw Ti2-SU1Z Hw Ti2-SU1Z AH Ti2-SU1Z FF RTS-082KK GC-U1Z VT 90째 F1-SU1Z/UV1 D UN F1-SU1 Mi RG F1-SU1 Mi RG UN F1-SU1Z AT UN I88-U1Z AHDB MCS-149/814 T67 N/S T-62 N/S TK-11-11 TK-21-12 TK-42 TK-45 MAN-0812-B MAK-1112-B MAK-3012-B MAK-4512-B MAK-1212-F MAM-2312-F MAK-4212-F MUZ-202/D24-UM

Page Number 33 33 33 33 33 33 33 33 37 37 37 37 37 37 37 37 37 37 37 37 37 37 29 29 29 29 29 29 29 29 29 29 4, 5, 6, 7, 8, 9 45 40 39 39 39 53 28 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 26, 27 56

Part Number 639-2706-302 640-2042-301 640-2043-023 640-2052-305 649-0642-301 649-0642-305 649-0652-306 649-0652-309 649-0653-310 649-0653-313 650-2307-135 650-2308-001 650-2316-003 650-2342-004 650-2399-003 650-2399-004 650-2399-018 650-2907-068 650-2908-002 650-2916-003 650-2935-005 650-2939-004 650-2942-006 650-2999-003 650-2999-004 650-2999-020 650-3503-001 650-3504-001 650-3505-004 650-3506-002 650-3507-378 650-3508-246 650-7013-001 650-7013-011 650-7315-001 650-7319-001 650-7321-002 650-7321-723 650-7323-001 650-7915-001 650-7919-001 650-7921-002 650-7921-724 650-7923-727 650-8515-001 650-8521-001 650-8521-004 650-8523-001 651-2101-045 655-1019-001 655-1219-002 655-1219-102 655-1086-01 655-1686-003

Descriptive Code MUZ-602/D24-UM TK-42-CD TK-43-CD TK-52-CD-HF MAK-4236-3 MAK-4236-STK MAK-5236-3 MAK-5236-STK MAK-5336-3 MAK-5336-STK KIB-M30NS/010-KL2 KIN-M30NS/015-KL2 KIN-M08NS/002-KL2 KIN-M08NS/002-KLSM8 KIB-M05NS/001-KL2 KIB-D04NS/0.8-KL2PU KIB-M04NS/0.6-KL2 KIB-M30PS/010-KL2 KIN-M30PS/015-KL2 KIN-M08PS/002-KL2 KIN-M30PS/015-KLS12 KIB-M30PS/010-KLS12 KIN-M08PS/002-KLSM8 KIB-M05PS/001-KL2 KIB-D04PS/0.8-KL2PU KIB-M04PS/0.6-KL2 KIB-M12AS/002-L2 KIN-M12AS/004-L2 KIB-M18AS/005-L2 KIN-M18AS/008-L2 KIB-M30AS/010-L2 KIN-M30AS/015-L2 KCN-T32DP/030-KLP2 KCB-M32DP/015-KLP2 KCN-R34NS/030-KLP2 KCN-T12NS/004-KLP2 KCN-T18NS/008-KLPSM8 KCA-T18NS/008-KLP2 KCN-T30NS/020-KLP2 KCN-R34PS/030-KLP2 KCN-T12PS/004-KLP2 KCN-T18PS/008-KLPSM8 KCA-T18PS/008-KLP2 KCN-T30PS/020-KLP2 KCN-R34AS/030-LP2 KCN-T18AS/008-LP2 KCN-T18AS/008-LPS12A KCN-T30AS/020-LP2 MCS-680-3 OT18SE-D00S-08.0-C OT18EE-DPTN-08.0-CL OT18ES-DPTN-08.0-CL Projector OR20EE-MAR5-20.0-ALET

Page Number 56 57 57 57 57 57 57 57 57 57 18 18 18 20 18 18 18 18 18 18 20 20 20 18 18 18 22 22 22 22 22 22 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 28 9 9 9 4 4

63 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678


Index to Part Numbers Part Number 655-1686-103 655-1819-001 655-1819-101 655-4219-002 655-4686-001 655-4696-001 655-4819-003 655-5219-001 655-5686-001 655-5819-003 655-7219-005 655-7219-006 655-7686-001 655-7686-003 655-7696-001 655-7819-005 655-7819-006 655-8219-001 655-8686-002 655-8696-001 655-8819-001 693-2301-001 693-2303-001 693-2304-001 693-2305-001 693-2305-004 693-2306-001 693-2306-004 693-2342-001 693-2343-001 693-2344-001 693-2901-001 693-2903-001 693-2904-001 693-2905-001 693-2905-004 693-2906-001 693-2906-004 693-2942-001 693-2943-001 693-2944-001 7100-448-002 7105-448-002 7105-448-005 7105-448-007 7105-448-011 7115-448-001 7115-448-003 7115-448-005 7120-448-004 7120-448-015 7125-101-001 7125-448-002 7125-448-003

Descriptive Code OR20ES-MAR5-20.0-ALET OT18EE-DPTP-08.0-CL OT18ES-DPTP-08.0-CL OT18RS-DPTN-03.0-CL OR20RS-MAR5-08.0-ALET OR90RS-MAR5-08.0-CL OT18RS-DPTP-03.0-CL OT18PS-DPTN-02.5-CLE OR20PS-MAR5-06.0-ALET OT18PS-DPTP-02.5-CLE OT18RT-DPTN-0300-CLE OT18RT-DPTN-0500-CLE OR20RT-MAR5-0600-ALET OR20RT-MAR5-01.5-ALET OR90RT-MAR5-0600-CL OT18RT-DPTP-0300-CLE OT18RT-DPTP-0500-CLE OT18FF-DPTN-0040-CL OR20 RH-MAR5-0400-ALET OR90RH-MAR5-0080-CL OT18FF-DPTP-0040-CL KIB-M08NS/1.5-KL2 KIB-M12NS/002-KL2 KIN-M12NS/004-KL2 KIB-M18NS/005-KL2 KIB-M18NS/005-KLS12 KIN-M18NS/008-KL2 KIN-M18NS/008-KLS12 KIB-M08NS/1.5-KLSM8 KIB-M12NS/002-KLS12 KIN-M12NS/004-KLS12 KIB-M08PS/1.5-KL2 KIB-M12PS/002-KL2 KIN-M12PS/004-KL2 KIB-M18PS/005-KL2 KIB-M18PS/005-KLS12 KIN-M18PS/008-KL2 KIN-M18PS/008-KLS12 KIB-M08PS/1.5-KLSM8 KIB-M12PS/002-KLS12 KIN-M12PS/004-KLS12 MCS-159/814 MCS-626 MCS-636 MCS-626-2 MCS-636-2 MCS-637 MCS-627 MCS-629 MCS-144/814 MCS-165/814 BWN-M18ST MCS-625 MCS-635

Page Number 4 9 9 9 4 5 9 9 4 9 9 9 4 4 5 9 9 9 4 5 9 18 18 18 18 20 18 20 20 20 20 18 18 18 18 20 18 20 20 20 20 6 8 8 8 8 8 8 8 6 6 9 8 8

Part Number 7135-488-011 7135-488-012 7150-101-003 7150-101-004 7150-101-013 7150-101-016 7150-101-020 7150-448-003 7150-448-004 7151-101-001 7151-448-001 7400-448-018 7400-448-019 7400-448-020 7400-448-021 7400-448-022 7400-448-024 7400-448-026 7400-448-029 7410-448-008 7420-448-029 7430-448-001 7430-448-003 7430-448-005 7430-448-007 7430-448-010 7500-448-008 7500-448-009 7600-448-001 7600-448-002 7600-448-003 7600-448-004 8010-448-001 8010-448-002 8010-448-003 8010-448-004 8010-448-005 8010-448-006

Descriptive Code MCS-638-3 MCS-638-4 MCS-501-120-CON MCS-500-120-CON MCS-500-120-BAS MCS-850-REL-OUT BWN-MCS-500 MCS-501-01 MCS-500-01 MCS-500P-120-CON MCS-500P-01 MCS-830 MCS-831 MCS-832 MCS-833 MCS-834 MCS-836 MCS-830-1 MCS-836-1 MCS-814 .5 IN. CABLE GLAND BWN-MCS-144-ETC BWN-M30ST BWN-MCS-161A-ETC BWN-MCS-164-ETC OR20 BRACKET MCS-680 MCS-680-1 UT30UP-DCA4-1016-CSI UT30UP-DCA4-2032-CSI UT30UP-DSS5-1016-CSHT UT30UP-DSS5-2032-CSHT 15 ft. Accessory Kit 30 ft. Accessory Kit 75 ft. Accessory Kit 105 ft. Accessory Kit 200 ft. Accessory Kit 250 ft. Accessory Kit

64 For Application Assistance Call 1-800-451-8279 or Fax 1-815-389-6678

Page Number 11 11 7 7 7 7, 28 7 7 7 7 7 6 6, 28 6, 28 6 6 6, 28 6 6, 28 6, 28 7 6 8, 13, 15 4 5 4 28 28 12, 13 12, 13 12, 15 12, 15 58 58 58 60 60 60


Warner Electric engineers, manufactures and markets electromechanical components and systems for controlling motion. Designed to help increase productivity, our products are incorporated into new equipment designs and are to upgrade performance on machines already in service. With an international organization of stocking distributors and sales centers, Warner Electric offers the most extensive network of its kind for locally available products and professional, on-the-spot customer service.

Other Products Packaged Electromagnetic Clutches/Brakes • C-face Compatible •Clutch/Brake Combinations •Washdown Versions •Ceramic High Performance Versions • Shaft and Base Mounted • Electrically Released Brakes • Clutch/Brake Controls Catalog P-1234 Basic Design Clutches/Brakes • Electromagnetic clutches and brakes • Custom design with off-the-shelf components • Maximum mounting versatility • Wide range of sizes, torque ratings, and configurations • Ideal for space restrictive applications Catalog P-1264 Tension Control Systems Up to 21,500 lb. ft. stopping torque • Complete system for unwind applications • Patented, new technology electric brakes • Sophisticated control systems • Load cell controls • Accurate, smooth, long life Catalog P-771 Overrunning Clutches Torque loads to 700,000 lb. ft. (949200 Nm) • Overrunning, indexing and backstopping applications • Instantaneous action, no backlash • More torque, less space • Full sprag complement with infinitely changing wear parts Catalog P-956 ERD • Designed to keep load in position in the event of power failure • Sizes from 3.3 in. to 9.9 in., 4 to 221 ft.lbs. of torque • Stops loads from speeds up to 3600 RPM • Quiet operation • Bi-directional stopping capability • Metric and inch standard bore sizes Catalog P-1083


Warner Electric

Marland Clutch

Electromagnetic Clutches and Brakes - USA

Roller Ramp and Sprag Type Overrunning Clutches and Backstops

South Beloit, IL 61080 815-389-3771 For application assistance: 1-800-825-9050

Electromagnetic Clutches and Brakes - Europe

Allonnes, France +33 (0)2 43 43 63 63 Precision Electric Coils - USA

Burr Ridge, IL 60527 630-455-1752 Nuttall Gear and Delroyd Worm Gear Worm Gear and Helical Speed Reducers

Niagara Falls, NY 14302 716-731-5180

Columbia City, IN 46725 260-244-6183

Wichita Clutch and Industrial Clutch

Boston Gear

Pneumatic and Oil Immersed Clutches and Brakes - USA

Enclosed and Open Gearing, Electrical and Mechanical P.T. Components

Wichita Falls, TX 76302 940-723-3400

Quincy, MA 02171 617-328-3300

Pneumatic Clutches and Brakes - Europe

For Customer Service: 1-888-999-9860

Bedford, UK +44 (0)1234 350311

For Application Assistance: 1-800-816-5608

Ameridrives Couplings

Formsprag Clutch

Gear Couplings, Mill Spindles, Universal Joints

Overrunning Clutches and Holdbacks

Erie, PA 16512 814-480-5000

Warren, MI 48089 586-758-5000 For application assistance: 1-800-927-3262

Stieber Clutch Overrunning Clutches and Holdbacks

Heidelberg, Germany +49 (0)6221 30 47 0

Altra Industrial Motion Asia Pacific China

852 2615 9313

Taiwan

886 2 2577 8156

Singapore

65 487 4464

Thailand

66 2 322 0481

Australia

612 9894 0133

www.warnerelectric.com

Warner Electric 449 Gardner Street • South Beloit, IL 61080 815-389-3771 • Fax: 815-389-2582 www.warnerelectric.com

P-1201-WE

10/05

Printed in USA

Warnerwork  
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