Omron Hl-5030 User manual

General-purpose Limit Switch

HL-5000

Economical, Miniature Limit Switch

Boasting Rigid Construction

■The Head, Box, and Cover mate with ridged surfaces to maintain

strength.

■

A unique Head structure provides a large OT for smooth operation.

■Easy-to-wire conduit opening design.

■Ideal for application in printing machines, forming machines, and

light machines.

(High Switches with high sealing characteristics, such as WL or

D4C Switches, in locations subject to oil, water, or precipitation.)

■Models with grounding terminals conform to the CE marking.

■Approved by CCC (Chinese standard).

(Ask your OMRON representative for information on approved

models.)

Be sure to read Safety Precautions on page 4 to 5 and

Safety Precautions for All Limit Switches.

Model Number Structure

Model Number Legend

å`HL-5Å†Å†

(1)(2)

(1) Actuators

000: Roller lever

030: Adjustable roller lever

050: Adjustable rod lever

100: Sealed plunger

200: Sealed roller plunger

300: Coil spring

(2) Ground Terminal Specifications

Blank : Without ground terminal

G : With ground terminal/M5 tapping on the rear side

Ordering Information

* HL-5000 Limit Switches are offered with a choice of ground terminal/M5

tapping on the rear side conforming to various standards. When placing an

order, add the code to the model number to indicate if ground terminal/M5

tapping on the rear side is required.

-G: with ground terminal/M5 tapping on the rear side.

Specifications

Approved Standards

Note: Ask your OMRON representative for information on approved models.

Ratings

Note: 1. The above figures are for steady-state currents.

2. Inductive loads have a power factor of 0.4 min. (AC) and a time

constant of 7 ms max. (DC).

3. Lamp load has an inrush current of 10 times the steady-state current.

4. Motor load has an inrush current of 6 times the steady-state current.

Approved Standard Ratings

CCC (GB14048.5)

Actuator Model

Roller lever HL-5000 *

Adjustable

roller lever HL-5030 *

Adjustable

rod lever HL-5050 *

Sealed

plunger HL-5100 *

Sealed roller

plunger HL-5200

Coil spring HL-5300

HL-5@@ Agency Standard File No.

CCC (CQC) GB14048.5 2003010303077624

Rated

voltage

Non-inductive load (A) Inductive load (A)

Resistive

load Lamp load Inductive

load Motor load

NC NO NC NO NC NO NC NO

125 VAC 5 1.5 0.7 3 2 1

250 VAC 5 1 0.5 3 1.5 0.8

12 VDC 5343

24 VDC 5343

125 VDC 0.4 0.2 −−−

250 VDC 0.4 0.2 −−−

Inrush

current

NC 24 A max.

NO 12 A max.

Applicable category and ratings

AC-15 3 A/250 VAC

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HL-5000

Characteristics

Note: 1. The above figures are initial values.

2. The above characteristics may vary depending on the model. For

further details, contact your OMRON sales representative.

* The values are calculated at an operating temperature of +5°C to +35°C, and

an operating humidity of 40% to 70%RH. Contact your OMRON sales

representative for more detailed information on other operating environments.

Engineering Data

Electrical Durability (cos dia. =1)

(Operating temperature: +5°C to +35°C,

Operating humidity: 40% to 70%RH)

Structure and Nomenclature

Structure Contact Form

Degree of protection IP65

Durability

*Mechanical 10,000,000 operations min. (under

rated conditions)

Electrical See the following Electrical Durability.

Operating speed 5 mm/s to 0.5 m/s

Operating

frequency

Mechanical 120 operations/min

Electrical 30 operations/min

Insulation resistance 100 MΩmin. (at 500 VDC)

Contact resistance 25 mΩmax. (initial value)

Dielectric strength

1,000 VAC, 50/60 Hz for 1 min between

terminals of the same polarity

1,500 VAC, 50/60 Hz for 1 min between

current-carrying metal parts and ground

1,500 VAC, 50/60 Hz for 1 min between

each terminal and non-current-carrying

metal part

Rated frequency 50/60 Hz

Vibration

resistance

Malfunction 10 to 55 Hz, 1.5-mm double amplitude

Shock

resistance

Destruction 1,000 m/s2min.

Malfunction 300 m/s2min.

Ambient operating

temperature −5°C to +65°C (with no icing)

Ambient operating

humidity 35% to 95%RH

Weight Approx. 130 to 190 g

1,000

500

012 34 56

Switching current (A)

Operating frequency:

30 operations/min

125 VAC (cos dia. = 1)

Durability (x 104operations)

Cover

Resin roller

Lever

Head

Built-in switch

Connector

3 (NO)

2 (NC)

(NO) 4

(NC) 1

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HL-5000

Dimensions and Operating Characteristics (Unit: mm)

Switches (Dimensions not shown are the same as roller lever models.)

Note: Unless otherwise specified, a tolerance of ±0.4 mm applies to all dimensions.

* Measured with the types of the 31.5-mm arm or rod length.

OF and RF measured at the arm length of 75 mm for HL-5030, and 145 mm for HL-5050 (reference values).

Operating

characteristics Model HL-5000 HL-5030 *HL-5050 *HL-5100 HL-5200 HL-5300

Operating force

Release force

Pretravel

Overtravel

Movement Differential

OF max.

RF min.

PT max.

OT min.

MD max.

7.35 N

0.98 N

20°

50°

12°

7.35 N

0.98 N

20°

50°

12°

7.35 N

0.98 N

20°

50°

12°

8.83 N

1.47 N

1.5 mm

4 mm

1 mm

8.83 N

1.47 N

1.5

1.47 N

−

30 mm

−

Operating position OP −−−30±0.8 mm 40±0.8

−

HL-5030 HL-5050

OF 3.09 N 1.60 N

RF 0.41 N 0.22 N

17.5 dia. ×6.6

resin roller *1

4.1

60.6

21.4

58 ±0.8

53±0.8

15.5

Three, M3

Rubber

connector

31.5R

(19)

16.5

18.5

39.5±0.8

40.3±0.8

M5 ×12

Allen-head

bolt

(110)

50±0.2

24±0.2

*1. The lever can be mounted anywhere in 360°.

*2. The head can be mounted in any of the four directions.

Two, 5.2 dia.

+0.2

mounting holes

Roller Lever

HL-5000

Adjustable

up to 30R

to 75R

4.1

60.6

21.4

65.7±0.8

60.3±0.8

51.3±0.8

15.5

Three, M3 (19)

16.5

39.5±0.8

17.5 dia. ×6.6 *1

M5 ×12

Allen-head

bolt

M5 ×16

Allen-head

bolt

50±0.2

*1. Resin roller

*2. The head can be mounted in any of the four directions.

Adjustable Roller Lever

HL-5030

4.1

60.6

21.4

62.8±0.8

53.4±0.8

15.5

145 max.

(19)

16.5

3 dia. ×160 *1

M5 ×12

Allen-head

bolt

M5 ×16

Allen-head

bolt

50±0.2

*1. Stainless steel rod

*2. The head can be mounted in any of the four directions.

39.5±0.8

5.4

Three, M3

Adjustable Rod Lever

HL-5050

60.6

20.2

(19)

16.5

50±0.2

4.1

PT 8 dia. *

* Stainless steel plunger

Two, M 3

Three, M3

Sealed Plunger

HL-5100

60.6

20.2

(19)

16.5

50±0.2

4.1

12.7 dia. ×4.8 *1

*1. Stainless sintered alloy roller

*2. The head can be mounted in either of the two directions.

Two, M 3

Three, M3

Sealed Roller Plunger

HL-5200

60.6

20.2

(19)

16.5

110±2.5

50±0.2

4.1

*1. Resin rod

*3. The operating range of the dog or cam is the top third (i.e. from the tip of the

rod) of the whole actuator.

Two, M 3

Three, M3

38±0.2

42±0.2

30 *2

PT 3.2 dia.

6.6 dia. *2

*2. The coil spring may be operated from any directions except axial directions ( ).

Coil Spring

HL-5300

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HL-5000

Safety Precautions

For details, be sure to read Safety Precautions for All Limit Switches.

Operating Environment

•Seal material may deteriorate if a Switch is used outdoor or where

subject to special cutting oils, solvents, or chemicals. Always

appraise performance under actual application conditions and set

suitable maintenance and replacement periods.

•Install Switches where they will not be directly subject to cutting

chips, dust, or dirt. The Actuator and Switch must also be protected

from the accumulation of cutting chips or sludge.

•Constantly subjecting a Switch to vibration or shock can result in

wear, which can lead to contact interference with contacts,

operation failure, reduced durability, and other problems.

Excessive vibration or shock can lead to false contact operation or

damage. Install Switches in locations not subject to shock and

vibration and in orientations that will not produce resonance.

•The Switches have physical contacts. Using them in environments

containing silicon gas will result in the formation of silicon oxide

(SiO2) due to arc energy. If silicon oxide accumulates on the

contacts, contact interference can occur. If silicon oil, silicon filling

agents, silicon cables, or other silicon products are present near the

Switch, suppress arcing with contact protective circuits (surge

killers) or remove the source of silicon gas.

Wiring

Wiring Procedure

1. Loosen the cover mounting screws and remove the cover.

2. Disconnect the rubber connector from the box conduit and pressfit

a solderless terminal. The following solderless terminals are

available.

3. After inserting the solderless terminal into the Switch, tighten the

terminal screws securely.

4. After wiring the Limit Switch, insert the rubber connector into the

groove of the box securely.

5. Tighten the three mounting screws evenly. The optimum tightening

torque for each screw is 0.49 to 0.59 N·m.

Applicable Lead Wires

Note: Do not use wires containing silicone, otherwise a contact failure may

result.

Applicable Solderless Terminal

The following solderless terminals are available. Do not use fork or

any other type of terminals, otherwise an accidental disconnection

resulting in a ground fault may result.

Appropriate Tightening Torque

A loose screw may result in a malfunction. Be sure to tighten each

screw to the appropriate tightening torque as shown below.

Note: If the head direction has been changed, check the torque of each screw

and make sure that the screws are free of foreign substances, and that

each screw is tightened to the proper torque.

Precautions for Correct Use

Not Suitable Suitable

Cover

Cover mounting screw

Rubber connector

Terminal

Wire name

Applicable wire

Number of

conductors

Conductor

size

External

size

Vinyl cabtire cord

(VCTF)

40.75 mm2

Round, 6 to 9

dia.

Flat, 9.4

max.

Vinyl cabtire cable

(VCT) 2 0.75 mm2

600-V vinyl-insulated

sheath cable (VVF)

21 dia./1.2 dia./

1.6 dia.

Terminal with insulated grip

No. Type Appropriate

tightening torque

1Head mounting screw 0.49 to 0.59 N·m

2Cover mounting screw 0.49 to 0.59 N·m

3Allen-head bolt 4.90 to 5.88 N·m

4Terminal screw (M3 screw) 0.49 to 0.59 N·m

5Switch mounting screw

(M5 Allen-head bolt) 4.90 to 5.88 N·m

6.4 max.

3.0 to

3.7 dia.

14 max.

6.4 max.

14 max.

3.0 to

3.7 dia.

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HL-5000

Mounting

To mount the Limit Switch securely, be sure to use two M5 Allenhead

bolts and washers.

The tightening torque applied to each bolt is 4.90 to 5.88 N·m. To

mount the Limit Switch more securely, use two M5 screw holes on the

rear panel and rear holes for positioning if the model is the HL-

5@@@G-Series Limit Switches.

Only the HL-5@@@G has M5 x 0.8 screw holes on the rear side.

Others

•Do not use the Limit Switch outdoors, otherwise the Limit Switch will

become damaged by rust or ozone.

•The Limit Switch is not suitable in places exposed to the spray of

rainwater, seawater, or oily water. Consult your OMRON

representative for models resisting rainwater, seawater, and oily

water.

•If high-sealing performance is required along with shielded wiring or

conduit wiring, use the D4C or WL.

Using the Switches

Actuator Position Change

(HL-5000, HL-5030, HL-5050)

To change the angle of the actuator, loosen the Allen-head bolt on the

side of the actuator lever. Then the actuator can be set at any angle.

Head Direction Change

(HL-5000, HL-5030, HL-5050, HL5200)

To change the head direction, loosen the two mounting screws. Then

the head can be changed at 90°increments in one of four directions.

The head of the HL-5200 can be mounted in two directions only.

(Refer to the following illustration.)

24±0.15

50±0.15

Two, 5.2-dia. holes (located

diagonally for securing the rear side)

Two, M5 screws or 5.2-dia. holes (located

diagonally for securing the front side)

Mounting holes

Loosen the

Allenhead

bold

Head mounting

screw (Small white

screw that can be

turned with either

a Phillips-head or

flat-blade screw-

driver)

Head mounting screw

(Black non-removable

torque screw)

Head mounting screw

(Black non-removable

torque screw)

Head mounting screw

(Small white screw that

can be turned with either

a Phillips head or

flat-blade screwdriver)

HL-5000

HL-5030

HL-5050

Head mounting screw (white)

HL-5200

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Precautions for All Limit Switches

(Not including Safety Switches)

Note: Refer to the Precautions section for each Switch for specific precautions applicable to each Switch.

•If the Switch is to be used as a switch in an emergency stop circuit

or in a safety circuit for preventing accidents resulting in injuries or

deaths, use a Switch with a direct opening mechanism, use the NC

contacts with a forced release mechanism, and set the Switch so

that it will operate in direct opening mode.

For safety, install the Switch using one-way rotational screws or

other similar means to prevent it from easily being removed. Protect

the Switch with an appropriate cover and post a warning sign near

the Switch in order to ensure the safety.

•Do not supply electric power when wiring. Otherwise electric shock

may result.

•Keep the electrical load below the rated value.

•Be sure to evaluate the Switch under actual working conditions

after installation.

•Do not touch the charged switch terminals while the Switch has

carry current, otherwise electric shock may result.

•If the Switch has a ground terminal, be sure to connect the ground

terminal to a ground wire.

•Do not disassemble the Switch while electric power is being supply.

Otherwise electric shock may result.

•The durability of the Switch greatly varies with switching conditions.

Before using the Switch, be sure to test the Switch under actual

conditions. Make sure that the number of switching operations is

within the permissible range.

If a deteriorated Switch is used continuously, insulation failures,

contact weld, contact failures, switch damage, or switch burnout

may result.

•Maintain an appropriate insulation distance between wires

connected to the Switch.

•Some types of load have a great difference between normal current

and inrush current. Make sure that the inrush current is within the

permissible value. The greater the inrush current in the closed

circuit is, the greater the contact abrasion or shift will be.

Consequently, contact weld, contact separation failures, or

insulation failures may result. Furthermore, the Switch may become

broken or damaged.

Wiring

Pay the utmost attention so that each terminal is wired correctly.

If the terminal is wired incorrectly, the Switch will not function.

Furthermore, not only will the Switch have a bad influence on the

external circuit, the Switch itself may become damaged or burnt.

Mounting

•Do not modify the actuator, otherwise the operating characteristics

and performance of the actuator will change.

•Do not enlarge the mounting holes of the Switch or modify the

Switch. Doing so may result in insulation failures, housing damage,

or physical injuries.

•Be sure to evaluate the Switch under actual working conditions

after installation.

•Do not apply oil, grease, or other lubricants to the moving parts of

the actuator, otherwise the actuator may not operate correctly.

Furthermore, intrusion of oil, grease, or other lubricants inside the

Switch may reduce sliding characteristic or cause failures in the

Switch.

•Mount the Switch and secure it with the specified screws tightened

to the specified torque along with flat washers and springs. The

actuator of a Pushbutton Limit Switch mounted to a panel with

excessive tightening torque may not operate correctly.

•Be sure to wire the Switch so that the conduit opening is free of

metal powder or any other impurities.

•If glue or bonding agent is applied, make sure that it does not

adhere to the movable parts or intrude inside the Switch, otherwise

the Switch may not work correctly or cause contact failure. Some

types of glue or bonding agent may generate a gas that may have

a bad influence on the Switch. Pay the utmost attention when

selecting the glue or locking agent.

•Do not drop or disassemble the Switch, otherwise the Switch will

not be capable of full performance. Furthermore, the Switch may

become broken or burnt.

•Some models allow changes in head directions. When changing

the head of such a model, make sure that the head is free of any

foreign substance. Tighten each screw of the head to the rated

torque.

•Be sure to take measures so that no foreign material, oil, or water

will penetrate into the Switch through the conduit opening. Be sure

to attach a connector suited to the cable thickness and tighten the

connector securely to the rated torque.

•Do not impose shock or vibration on the actuator while it is fully

pressed. Otherwise, the actuator will partially abrade and an

actuation failure may result.

Wiring

•If the wiring method is incorrect, the wires may get caught on

objects or the lead wires may be pulled excessively. Make sure that

the lead wires are sufficiently long and secure them along the wiring

path.

•Pay the utmost attention so that each terminal is wired correctly. If

a terminal is wired incorrectly, the Limit Switch will not function

properly. Furthermore, not only will the Limit Switch have an

adverse influence on external circuits, the Limit Switch itself may

become damaged or burnt.

For details, refer to Precautions for Correct Use in the

Technical Guide for Limit Switches.

Precautions for Safe Use

i (Inrush current)

(A)

io (Constant current)

Precautions for Correct Use

CorrectIncorrect

Terminal boxTerminal box

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Technical Guide for Limit Switches

Precautions for Correct Use

Switch Operation

•The Switch in actual operation may cause accidents that cannot be

foreseen from the design stage. Therefore, the Switch must be

practically tested before actual use.

•When testing the Switch, be sure to apply the actual load condition

together with the actual operating environment.

•All the performance ratings in this catalog are provided under the

following conditions unless otherwise specified.

Inductive load:

A minimum power factor of 0.4 (AC) or a maximum time constant

of 7 ms (DC)

Lamp load:

An inrush current 10 times higher than the normal current

Motor load:

An inrush current 6 times higher than the normal current

(1) Ambient temperature: +5°C to +35°C

(2) Ambient humidity: 40% to 70%RH

Note: An inductive load causes a problem especially in DC circuitry. Therefore,

it is essential to know the time constants (L/R) of the load.

Mechanical Characteristics

Operating Force, Stroke, and Contact Characteristics

•The following graph indicates the relationship between operating

force and stroke or stroke and contact force. In order to operate the

Limit Switch with high reliability, it is necessary to use the Limit

Switch within an appropriate contact force range. If the Limit Switch

is used in a normally closed condition, the dog must be installed so

that the actuator will return to the FP when the actuator is actuated

by the dog. If the Limit Switch is used in a normally open condition,

the actuator must be pressed to 70% to 100% of the OT (i.e., 60%

to 80% of the TT) and any slight fluctuation must be absorbed by

the actuator.

•If the full stroke is set close to the OP or RP, contact instability may

result. If the full stroke is set to the TTP, the actuator or switch may

become damaged due to the inertia of the dog. In that case, adjust

the stroke with the mounting panel or the dog.

Refer to page 11, Dog Design, page 12, Stroke Settings vs. Dog

Movement Distance, and page 12, Dog Surface for details.

•The following graph shows an example of changes in contact force

according to the stroke. The contact force near the OP or RP is

unstable, and the Limit Switch cannot maintain high reliability.

Furthermore, the Limit Switch cannot withstand strong vibration or

shock.

•If the Limit Switch is used so that the actuator is constantly pressed,

it will fail quickly and reset faults may occur. Inspect the Limit Switch

periodically and replace it as required.

Mechanical Conditions for Switch Selection

•The actuator must be selected according to the operating method.

(Refer to page 9.)

•Check the operating speed and switching frequency.

1. If the operating speed is extremely low, the switching of the

movable contact will become unstable, thus resulting in incorrect

contact or contact weld.

2. If the operating speed is extremely high, the Switch may break due

to shock. If the switching frequency is high, the switching of the

contacts cannot catch up with the switching frequency. Make

sure that the switching frequency is within the rated switching

frequency.

•Do not impose excessive force on the actuator, otherwise the

actuator may become damaged or not operate correctly.

•Make sure that the stroke is set within the suitable range specified

for the model, or otherwise the Switch may break.

Electrical Characteristics

Electrical Characteristics for Switch Selection

•The switching load capacity of the Switch greatly varies between

AC and DC. Always be sure to apply the rated load. The control

capacity will drastically drop if it is a DC load. This is because a DC

load has no current zero-cross point, unlike an AC load. Therefore,

if an arc is generated, it may continue comparatively for a long time.

Furthermore, the current direction is always the same, which

results in a contact relocation phenomena whereby the contacts

easily stick to each other and do not separate when the surfaces of

the contacts are uneven.

•If the load is inductive, counter-electromotive voltage will be

generated. The higher the voltage is, the higher the generated

energy will be, which will increase the abrasion of the contacts and

contact relocation phenomena. Be sure to use the Switch within the

rated conditions.

•If the load is a minute voltage or current load, use a dedicated

Switch for minute loads. The reliability of silver-plated contacts,

which are used by standard Switches, will be insufficient if the load

is a minute voltage or current load.

Solenoid

(Approximately

10 to 20 times higher)

Incandescent lamp

(Approximately

10 to 15 times higher)

Motor

(Approximately

5 to 10 times higher)

Relay

(Approximately

4 to 5 times higher)

Operating forceContact force

Stroke

OTP

Changes to opposite side

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Technical Guide for Limit Switches

Contact Protective Circuit

Apply a contact protective circuit to increase the contact durability,

prevent noise, and suppress the generation of carbide or nitric acid.

Be sure to apply the contact protective circuit correctly, otherwise an

adverse effect may occur.

The following provides typical examples of contact protective circuits.

If the Switch is used in an excessively humid location for switching a

load that easily generates arcs, such as an inductive load, the arcs

may generate NOx, which will change into HNO3if it reacts with

moisture.

Consequently, the internal metal parts may corrode and the Switch

may fail. Be sure to select the ideal contact preventive circuit from the

following.

Also, load operating times may be delayed somewhat if a contact

protective circuit (a surge killer) is used.

Typical Examples of Contact Protective Circuits

Do not apply contact protective circuits (surge killers) as shown below.

Using Switches for Micro Loads

Contact faults may occur if a Switch for a general-load is used to

switch a micro load circuit. Use switches in the ranges shown in the

diagram on the right. However, even when using micro load models

within the operating range shown here, if inrush current occurs when

the contact is opened or closed, it may increase contact wear and so

decrease durability. Therefore, insert a contact protection circuit

where necessary. The minimum applicable load is the N-level

reference value. This value indicates the malfunction reference level

for the reliability level of 60% (λ60).

The equation, λ60 = 0.5 ×10–6/operations indicates that the estimated

malfunction rate is less than 1/2,000,000 operations with a reliability

level of 60%.

Circuit example

Applicable

current Feature and details Element selection

AC DC

CR circuit

Condi-

tional *O* When AC is switched, the load impedance must

be lower than the CR impedance.

C: 1 to 0.5 μF×switching current (A)

R: 0.5 to 1 Ω×switching voltage (V)

The values may change according to the charac-

teristics of the load.

The capacitor suppresses the spark discharge of

current when the contacts are open. The resistor

limits the inrush current when the contacts are

closed again. Consider the roles of the capacitor

and resistor and determine ideal capacitance and

resistance values through testing.

Generally, use a capacitor that has a dielectric

strength of between 200 and 300 V. Use an AC ca-

pacitor for an AC circuit, i.e., a capacitor that has no

polarity.

If, however, the arc shutoff capacity between the con-

tacts is a problem at high DC voltages, it may be more

effective to connect a capacitor and resistor across

the contacts rather than the load. Performing testing

to determine the most suitable method.

The operating time will be greater if the load is a re-

lay or solenoid.

Connecting the CR circuit in parallel to the load is

effective when the power supply voltage is 24 or 48

V and in parallel to the contacts when the power

supply voltage is 100 to 200 V.

Diode

method ×O

Energy stored in the coil is changed into current by

the diode connected in parallel to the load. Then

the current flowing to the coil is consumed and

Joule heat is generated by the resistance of the in-

ductive load. The reset time delay with this method

is longer than that in the CR method.

The diode must withstand a peak inverse voltage

10 times higher than the circuit voltage and a for-

ward current as high or higher than the load cur-

rent.

Diode and

Zener diode

method ×OThis method will be effective if the reset time delay

caused by the diode method is too long.

If a suitable Zener voltage is not used, the load may

fail to operate depending on the environment. Use

a Zener diode with a Zener voltage that is about 1.2

times the power supply voltage.

Varistor

method OO

This method makes use of constant-voltage char-

acteristic of the varistor so that no high voltage is

imposed on the contacts. This method causes a re-

set time delay.

Connecting a varistor in parallel to the load is effec-

tive when the supply voltage is 24 to 48 V and in

parallel to the contacts when the supply voltage is

100 to 200 V.

Select a varistor with a cut voltage Vc that satisfies

the following formula. For AC, the voltage must be

multiplied by the square root of 2.

Vc > Power supply voltage ×1.5

If Vc is set too high, effectiveness will be reduced

because high voltages will not be cut.

This circuit effectively suppresses arcs when

the contacts are OFF. When the contacts are

open, capacity is stored in the capacitor, and

short-circuit current of the capacitor will flow

when the contacts are turned ON, which may

cause contacts to weld.

This circuit effectively suppresses arcs when

the contacts are OFF. When the contacts are

ON again, however, charge current will flow to

the capacitor, which may result in contact weld.

Inductive

load

Power

supply

Inductive

load

Power

supply

Inductive

load

Power

supply

Inductive

load

Power

supply

Inductive

load

Power

supply

Load

Power

supply

CCLoad

Power

supply

01 10 100 1,0000.1

1 mA

Operating range

for micro-load

models

26 mA0.16 mA

800 mW5 mW

100 mA 160 mA

Unusable

range

Voltage (V)

Current (mA)

Operating range

for standard

models

http://www.ia.omron.com/ C-3

Technical Guide for Limit Switches

Connections

•Do not connect a Single Limit Switch to two power supplies that are

different in polarity or type.

•Do not design a circuit where voltage is imposed between contacts,

otherwise contact welding may result.

•Do not use a circuit that will short-circuit if an error occurs,

otherwise the charged part may melt and break off.

•Application of Switch to a Low-voltage, Low-current Electronic

Circuit.

1. If bouncing or chattering of the contacts results and causes

problems, take the following countermeasures.

(a)Insert an integral circuit.

(b)Suppress the generation of pulse from the contact bouncing

or chattering of the contacts so that it is less than the noise

margin of the load.

2. Conventional silver-plated contacts are not suited to this

application. Use gold-plated contacts, which are ideal for

handling minute voltage or current loads.

3. The contacts of the Switch used for an emergency stop must be

normally closed with a positive opening mechanism.

•In order to protect the Switch from damage due to short-circuits, be

sure to connect a quick-response fuse with a breaking current 1.5

to 2 times larger than the rated current to the Switch in series. When

complying with EN approved ratings, use a 10-A IEC 60269-

compliant gI or gG fuse.

Operating Environment

•Do not use the Switch by itself in atmospheres containing

flammable or explosive gases. Arcs and heating resulting from

switching may cause fire or explosion.

•Use protective covers to protect Switches that are not specified as

waterproof or airtight whenever they are used in locations subject

to splattering or spraying oil or water, or to accumulation of dust or

dirt.

•The materials of Limit Switch may change in quality or deteriorate

if the Limit Switch is used outdoors or any other location where the

Limit Switch is exposed to special machining oil. Consult your

OMRON representative before selecting the model.

•Be sure to install the Switch so that the Switch is free from dust or

metal powder. The actuator and the switch casing must be

protected from the accumulation of dust or metal powder.

•Do not use the Switch in locations where the Switch is exposed to

hot water at a temperature greater than 60°C or steam.

•Do not use the Switch under temperatures or other environmental

conditions not within the specified ranges.

The rated permissible ambient temperature range varies with the

model. Refer to the specifications in this catalog. If the Switch is

exposed to radical temperature changes, the thermal shock may

deform the Switch and the Switch may malfunction.

•Be sure to protect the Switch with a cover if the Switch is in a

location where the Switch may be actuated by mistake or where the

Switch is likely cause an accident.

•If vibration or shock is continuously imposed on the Switch, contact

failure, malfunction, or decrease in service life may be caused by

abrasive powder generated from the internal parts. If excessive

vibration or shock is imposed on the Switch, the contacts may

malfunction or become damaged. Make sure to install the Switch in

locations free of constant vibration or shock.

•Do not use the Switch with silver-plated contacts for long periods if

the switching frequency of the Switch is comparatively low or the

load is minute. Otherwise, sulfuric film will be generated on the

contacts and contact failures may result. Use the Switch with gold-

plated contacts or use a dedicated Switch for minute loads instead.

Incorrect

Correct

Connect the load to the same polarities.

Power Connection Examples

(Connection of Different Polarities)

Incorrect

Incorrect Power Connection Example

(Connection of Different Power Supplies)

There is a risk of AC and DC mixing.

Incorrect

100 V

200 V

Correct

Incorrect

Terminal box Terminal box

Incorrect Correct

Separate the Switch

from hot water.

Incorrect Correct

(Malfunction prevented)

Correct

Incorrect

http://www.ia.omron.com/ C-4

Technical Guide for Limit Switches

•Do not use the Switch in locations with corrosive gas, such as

sulfuric gas (H2S or SO2), ammonium gas (NH3), nitric gas (HNO3),

or chlorine gas (Cl2), or high temperature and humidity. Otherwise,

contact failure or corrosion damage may result.

•If the Switch is used in locations with silicone gas, arc energy may

create silicon dioxide (SiO2) on the contacts and a contact failure

may result. If there is silicone oil, silicone sealant, or wire covered

with silicone close to the Switch, attach a contact protective circuit

to suppress the arcing of the Switch or eliminate the source of

silicone gas generation.

Regular Inspection and Replacement

•If the Switch is normally closed with low switching frequency (e.g.,

once or less than once a day), a reset failure may result due to the

deterioration of the parts of the Switch. Regularly inspect the Switch

and make sure that the Switch is in good working order.

•In addition to the mechanical durability or electrical durability of the

Switch described previously, the durability of the Switch may

decrease due to the deterioration of each part, especially rubber,

resin, and metal. Regularly inspect the Switch and replace any part

that has deteriorated in order to prevent accidents from occurring.

•If the Switch is not turned On or OFF for a long time, oxidation of

the contacts may decrease contact reliability. Faulty continuity may

result in accidents.

•Be sure to mount the Switch securely in a clean location to ensure

ease of inspection and replacement. The Switch with operation

indicator is available, which is ideal if the location is dark or does

not allow easy inspection or replacement.

Storage of Switch

•When storing the Switch, make sure that the location is free of

corrosive gas, such as H2S, SO2, NH3, HNO3, or Cl2, or dust and

does not have a high temperature or humidity.

•Be sure to inspect the Switch before use if it has been stored for

three months or more.

Weather Resistance, Cold Resistance, and Heat

Resistance

Silicon rubber is used to increase resistance to weather, cold, and

heat. Silicon rubber, however, can generate silicon gas. (This can

occur at room temperature, but the amount of silicon gas generated

increases at higher temperatures.) Silicon gas will react as a result of

arc energy and form silicon oxide (SiO2). If silicon oxide accumulates

on the contacts, contact interference can occur and can interfere with

the device. Before using a Switch, test it under actual application

conditions (including the environment and operating frequency) to

confirm that no problems will occur in actual.

Outdoor Use

•If the Limit Switch is used in places with sludge or dust powder

spray, make sure that the mechanical parts are sealed with a

rubber cap.

•The rubber materials exposed to ozone may deteriorate. Check

that the rubber parts are made of environment-resistive materials,

such as chloroprene, silicone, or fluorine rubber.

•Due to capillary attraction, rainwater may enter the Limit Switch

through the lead wires or sheath. Be sure to cover the wire

connections in a terminal box so that they are not directly exposed

to rainwater.

•If the Limit Switch is used outdoors, the steel parts of the Limit

Switch (such as the screws and plunger parts) may corrode.

Models with resistance against climatic conditions have been

added to the series. Consider using outdoor models, such as the

WL-@P1 or D4C-@P.

•"Limit Switch is used outdoors" refers to an environment where the

Limit Switch is exposed directly to rainwater or sunlight (e.g.,

multistory parking facilities) excluding locations with corrosive gas

or salty breezes. A Limit Switch used outdoors may not release due

to icing and may not satisfy specified standards.

Operation

•Carefully determine the position and shape of the dog or cam so

that the actuator will not abruptly snap back, thus causing shock. In

order to operate the Limit Switch at a comparatively high speed,

use a dog or cam that keeps the Limit Switch turned ON for a

sufficient time so that the relay or valve will be sufficiently

energized.

•The method of operation, the shape of the cam or dog, the

operating frequency, and the travel after operation have a large

influence on the durability and operating accuracy of the Limit

Switch. The cam or dog must be smooth in shape.

•Appropriate force must be imposed on the actuator by the cam or

dog in both rotary operation and linear operation.

If the dog touches the lever as shown below, the operating position

will not be stable.

Easy to inspect

Difficult to inspect or install

The cover must be located in the

direction ensuring ease of

maintenance or inspection.

Incorrect Correct

Snapped

back

Abruptly

actuated

Incorrect Correct

Snapped

back Abruptly

actuated

Incorrect

Dog Dog

Correct

http://www.ia.omron.com/ C-5

Technical Guide for Limit Switches

•Unbalanced force must not be imposed on the actuator. Otherwise,

wear and tear on the actuator may result.

•With a roller actuator, the dog must touch the actuator at a right

angle. The actuator or shaft may deform or break if the dog touches

the actuator (roller) at an oblique angle.

•Make sure that the actuator does not exceed the OT (overtravel)

range, otherwise the Limit Switch may malfunction. When mounting

the Limit Switch, be sure to adjust the Limit Switch carefully while

considering the whole movement of the actuator.

•The Limit Switch may soon malfunction if the OT is excessive.

Therefore, adjustments and careful consideration of the position of

the Limit Switch and the expected OT of the operating body are

necessary when mounting the Limit Switch.

•When using a pin-plunger actuator, make sure that the stroke of the

actuator and the movement of the dog are located along a single

straight line.

•Be sure to use the Limit Switch according to the characteristics of

the actuator.

If a roller arm lever actuator is used, do not attempt to actuate the

Limit Switch in the direction shown below.

•Do not modify the actuator to change the OP.

•With the long actuator of an Adjustable Roller Lever Switch, the

following countermeasures against lever shaking are

recommended.

1.Make the rear edge of the dog smooth with an angle of 15°to 30°

or make it in the shape of a quadratic curve.

2.Design the circuit so that no error signal will be generated.

3.Use a switch that is actuated in one direction only. (Alternatively,

set the Switch so that it is operated only in one direction.)

•With a bevel plunger actuator, make sure that the width of the dog

is wider than that of the plunger.

Incorrect Correct

RollerRoller

Dog Dog

CorrectIncorrect

Dog

Operating

body

Install a stopper.

PT (Pretravel)

FP (Free position)

OP (Operating position)

OT (Overtravel)

TTP (Total travel position)

Reference line

70% of

rated OT 100% of

rated OT

Distance to the

optimum setting range.

Optimum setting range

Correct

Stopper

Incorrect Correct

Operating

body

Operating

body

Incorrect

Incorrect Correct

http://www.ia.omron.com/ C-6

Technical Guide for Limit Switches

Dog Design

Speed and Angle of Dog and Relationship with Actuator

Before designing a dog, carefully consider the operating speed and angle of the dog (φ) and their relationship with the shape of the actuator. The

optimum operating speed (V) of a standard dog at an angle of 30°to 45°is 0.5 m/s maximum.

Roller Lever Switches

(1) Non-overtravel Dog

Note: The above y values indicate the ratio ranges based on TT (total travel).

Therefore, the optimum pressing distance of the dog is between 50% and

80% (or 50% and 70%).

(2) Overtravel Dog

If the speed of the overtravel dog is comparatively high, make the rear

edge of the dog smooth at an angle of 15°to 30°or make it in the

shape of a quadratic curve. Then lever shaking will be reduced.

Note: The above y values indicate the ratio ranges based on TT (total travel).

Therefore, the optimum pressing distance of the dog is between 50% and

80% (or 50% and 70%).

Plunger Switches

If the dog overrides the actuator, the front and rear of the dog may be

the same in shape, provided that the dog is not designed to be

separated from the actuator abruptly.

Fork Lever Lock Models

Note: Design the shape of the dog so that it does not come in contact with the

other roller lever when the actuator is inverted.

Dog speed: 0.5 m/s max. (standard speed)

Dog speed: 0.5 m/s ≤V ≤2 m/s (high speed)

θ φ V max. (m/s) y

45°45°0.5 0.5 to 0.8 (TT)

50°40°0.6 0.5 to 0.8 (TT)

60°to 55°30°to 35°1.3 0.5 to 0.7 (TT)

75°to 65°15°to 25°2 0.5 to 0.7 (TT)

Dog speed: 0.5 m/s max.

Dog speed: 0.5 m/s min.

θ φ V max. (m/s) y

45°45°0.5 0.5 to 0.8 (TT)

50°40°0.6 0.5 to 0.8 (TT)

60°to 55°30°to 35°1.3 0.5 to 0.7 (TT)

75°to 65°15°to 25°2 0.5 to 0.7 (TT)

Lever set

vertically

V max. (m/s)

30°

45°

60°

60°to 90°

0.4

0.25

0.1

0.05 (low speed)

0.8 (TT)

80% of to-

tal travel

Change lever set angle (θ)

according to dog angle (φ)

Lever set

vertically

V max. (m/s)

30°

45°

60°

to 90

0.4

0.25

0.1

0.05 (low speed)

0.8 (TT)

80% of to-

tal travel

15 to 30°

60°max.

Roller Plunger

Ball Plunger

Bevel Plunger

φφ

V max. (m/s)

30°

20°

0.25

0.5 0.6 to 0.8 (TT)

0.5 to 0.7 (TT)

φφ

V max. (m/s)

30°

20°

0.25

0.5 0.6 to 0.8 (TT)

0.5 to 0.7 (TT)

Note: The above y values indicate the ratio

ranges based on TT (total travel).

Therefore, the optimum pressing

distance of the dog is between 60%

and 80% (or 50% and 70%).

V max. (m/s)

30°

20°

0.25

0.5 0.6 to 0.8 (TT)

0.5 to 0.7 (TT)

60°

27.6

Dog

45°45°

http://www.ia.omron.com/ C-7

Technical Guide for Limit Switches

Stroke Settings vs. Dog Movement Distance

•The following information on stroke settings is based on the

movement distance of the dog instead of the actuator angle.

The following is the optimum stroke of the Limit Switch.

Optimum stroke: PT + {Rated OT ×(0.7 to 1.0)}

In terms of angles, the optimum stroke is expressed as θ1+θ2.

•The movement distance of the dog based on the optimum stroke is

expressed by the following formula.

Movement distance of dog

φ: Dog angle

θ: Optimum stroke angle

R: Actuator length

X: Dog movement distance

•The distance between the reference line and the bottom of the dog

based on the optimum stroke is expressed by the following formula.

Y = a + b + r (mm)

a: Distance between reference line and actuator fulcrum

b: R cosθ

r: Roller radius

Y: Distance between reference line and bottom of dog

Dog Surface

The surface of dog touching the actuator should be 6.3 S in quality

and a hardness of approximately HV450.

For smooth operation of the actuator, apply molybdenum disulfide

grease to the actuator and the dog touching the actuator. This is ideal

for Limit Switches of drip-proof construction and Multiple Limit

Switches.

Maintenance and Repairs

The user of the system must not attempt to perform maintenance and

repairs. Contact the manufacturer of the system concerning

maintenance and repairs.

Other

•The standard material for the switch seal is nitrile rubber (NBR),

which has superior resistance to oil. Depending on the type of oil or

chemicals in the application environment, however, NBR may

deteriorate, e.g., swell or shrink. Confirm performance in advance.

•The correct Switch must be selected for the load to ensure contact

reliability. Refer to precautions for micro loads in individual product

information for details.

•When using a Limit Switch with a long lever or long rod lever, make

sure that the lever is in the downward direction.

•Wire the leads as shown in the following diagram.

•Reduced ambient temperature tends to result in hardening of the

actuator's rubber seal. Therefore, reset may be delayed or reset

may fail if the Switch is used with the actuator continually pressed

in. Contact your OMRON representative if the Switch is to be used

for this type of environment or application.

X = Rsinθ+ R (1–cosθ)(mm)

tanφ

70% to 100% of rated OT

PT: Pretravel

OT: Overtravel

Dog

Reference line

Mounting hole

Dog

Crimp terminal with insulating sheath

Terminal screw Terminal

screw

TerminalTerminal

Crimped location facing up Lead

Lead

Correct Wiring

Crimp terminal with insulating sheath

Terminal screw Terminal

screw

Terminal Terminal

Too close to maintain dielectric strength

Crimped location facing down Lead

Lead

Incorrect Wiring

http://www.ia.omron.com/ C-8

2007.3

OMRON Corporation

Industrial Automation Company

In the interest of product improvement, specifications are subject to change without notice.

Read and Understand This Catalog

Please read and understand this catalog before purchasing the products. Please consult your OMRON representative if you have any questions or

comments.

Warranty and Limitations of Liability

WARRANTY

OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if

speciﬁed) from date of sale by OMRON.

OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR

FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE

HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL

OTHER WARRANTIES, EXPRESS OR IMPLIED.

LIMITATIONS OF LIABILITY

OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS, OR COMMERCIAL

LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR

STRICT LIABILITY.

In no event shall responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.

IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS

OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT

SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.

Application Considerations

SUITABILITY FOR USE

OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's

application or use of the product.

At the customer's request, OMRON will provide applicable third party certiﬁcation documents identifying ratings and limitations of use that apply to the

products. This information by itself is not sufﬁcient for a complete determination of the suitability of the products in combination with the end product,

machine, system, or other application or use.

The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible

uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:

• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this catalog.

• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety

equipment, and installations subject to separate industry or government regulations.

• Systems, machines, and equipment that could present a risk to life or property.

Please know and observe all prohibitions of use applicable to the products.

NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE

SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND

INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

Disclaimers

CHANGE IN SPECIFICATIONS

Product speciﬁcations and accessories may be changed at any time based on improvements and other reasons.

It is our practice to change model numbers when published ratings or features are changed, or when signiﬁcant construction changes are made.

However, some speciﬁcations of the product may be changed without any notice. When in doubt, special model numbers may be assigned to ﬁx

or establish key speciﬁcations for your application on your request. Please consult with your OMRON representative at any time to conﬁrm actual

speciﬁcations of purchased product.

DIMENSIONS AND WEIGHTS

Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.

ERRORS AND OMISSIONS

The information in this catalog has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical,

typographical, or proofreading errors, or omissions.

PERFORMANCE DATA

Performance data given in this catalog is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent

the result of OMRON’s test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON

Warranty and Limitations of Liability.

PROGRAMMABLE PRODUCTS

OMRON shall not be responsible for the user's programming of a programmable product, or any consequence thereof.

This catalog shall not be copied for sales or promotions without permission.

This catalog is protected by copyright and is intended solely for use in conjunction with the product. Please notify us before copying or reproducing this