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EAO – Your Expert Partner for Human Machine Interfaces
www . eao.com/catalogues
Product Information
Series 04 | Lever Switches
Lever switches S41 to S45 - Technical Documentation
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Industrial Controllers
Lever switches
S41 to S45 S41 S42 S43
S44 S45
Revision: - 11 -
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Industrial Controllers
Modification Report
Revision Date Modifications Page(s)
1 08.03.2004 First edition all
2 16.03.2004 Definition of dimensioned drawings and connecting diagrams
in appendix checked and revised – thus automatic change of
table of content.
11 and 12
2
3 06.05.2004 • § 4.4 – specification for minimal current added
• § 4.5 – specification for 72 VDC and 110 VDC added
8
9
4 24.06.2004 • § 4.3 – specification for minimal current and specification
for 72 VDC and 110 VDC added
• § 4.4 – Designation AC-12, 60VAC / 1,0A changed to DC-
12, 60VDC / 1,0A
• § 4.5 and 4.6 – specification for minimal current added
8
8
9
5 23.08.2004 • § 4.3 and § 4.5 – specification for minimal current
changed from 4mA to 8mA in 0,5mA to 8mA
8 and 9
6 30.11.2005 • § 5.1 drawing added (anti-twist device)
• § 6 type key enhanced
• § 7 drawing numbers revised
10
11
12
7 01.04.2010 revised all
8 15.09.2010 Attached documents deleted, grip shapes added all
9 29.09.2010 Revised §7 detents and switching sequences added 13
10 05.01.2011 Document revised construction changed all
11 10.01.2011 Document revised (T604) all
12
13
14
15
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Table of Contents1 Illustrations .............................................................................................................................. 6
2 Application .............................................................................................................................. 7
3 Design ...................................................................................................................................... 83.1 GripsForAllUnits(S41–S45)................................................................................................10
4 Technical Data ........................................................................................................................114.1 CompleteDevice......................................................................................................................114.2 Micro-SwitchwithoutPositiveOpeningOperation....................................................................114.3 Micro-SwitchwithPositiveOpeningOperation.........................................................................12
5 Installation ..............................................................................................................................135.1 LeverSwitchInstallation...........................................................................................................135.2 HandleDisassembly.................................................................................................................14
6 Type Key ..................................................................................................................................14
7 Appendix .................................................................................................................................15
8 Order, Detents and Switching Sequences (T604) ................................................................16
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Industrial Controllers
1 Illustrations
S41 S42 S43
S44 S45
Figure 1: Lever switches S41 to S45
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Industrial Controllers
2 Application
The lever switches in Figure 1 – types S41 to S45 – are switches, which generate digital output signals depending on the position of the operator handle (1). For this purpose, each switch has a maximum of 5 (S41 to S43) or 4 (S44 and S45) micro-switches (2) with varying switching pro-grams, thus providing for adaptability to the customer’s demands. Besides the switching pro-gram, the micro-switch type, the electric interface, the colour of the centering rings (4), and the mechanical features (angle of deflection of the operator handle, form of the grips, and its detent and spring return functions) are variable as well.
Due to these variable features, the lever switches can be employed anywhere, where switching levers are to carry out operating functions. Since the centering rings (4) of the lever switches have formally been adjusted to the pushbuttons of the EAO type series 04, one can design op-erating units with pleasant looks using these components (hand-activated auxiliary switches and lever switches).
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Industrial Controllers
3 Design
Figure 2: Design
Figure 2 provides information on the lever switch’s basic design features. As one can see, it basically consists of an operator handle (1), which is supported by a flange plate (2). The form of the operator handle can vary. See the dimension drawings of the units (S41 – S45).
Below the flange plate, the operator handle is connected with a detent disk (3), which is oper-ated by a spring loaded roller lever (4). This is the operating principle behind the mechanical detent and spring return functions. All of the default detent and spring return functions are in-cluded in the technical specification no. T 604 (also in Gessmann catalogue 5/101). Other de-tent and spring return functions are available on request.
Item (5) shows a stop pin, which will be employed, if the operator handles’ maximum angle of deflection (25°-0-25°) is to be limited. Its position and the number of stop pins is optional, which allows for a great variety of types with reduced angles of deflection (see T 604 or in Gessmann catalogue 5/101).
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Industrial Controllers
The micro-switches (6) are activated by cam discs (7). Basically, there are two types of micro-switches available:
1. Micro-switch without positive opening operation
These micro-switches are used in the lever switches S41, S42, and S43. Each lever switch includes a maximum of 5 micro-switches. The technical data of these micro-switches is listed in chapter 4.
2. Micro-switch with positive opening operation
These micro-switches are used in the lever switches S44 and S45. Each lever switch in-cludes a maximum of 4 micro-switches. The technical data of these micro-switches is listed in chapter 4.
By varying the cam discs, the switching sequences may be adjusted to individual customer re-quirements. All the default switching sequences are listed in the technical specification no. T 604. Other switching programs are available on request.
The electric interface (8) differs from one lever switch type to the other. More detailed informa-tion on these interfaces is given in table 1. In addition, the relevant connection diagrams are listed, too, which can be found attached.
Type S41 S42 S43 S44 S45
Electric Inter-face
cage clamp
1 – 1.5 mm²
JST connector up to 0.2mm², counter plug is supplied. Re-
quired crimping tool, JST WC
240
blade terminal 6.3 x 0.8 mm
cage clamp
1 – 1.5 mm²
screw terminal or blade termi-nal 6.3 x 0.8
mm
Connection diagram, 1-2 contacts
EK / 87-10 EK / 90 –10 EK / 94 – 10 EK / 96 –10 EK / 106 –10
Connection diagram, 3-4 contacts
EK / 89 – 10 EK / 91 –10 EK / 95 –10 EK / 102 –10 EK / 106 –10
Connection diagram, 5 contacts
EK / 105-10 EK / 107-10 EK / 108-10 - -
Table 1: Electric interfaces
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Industrial Controllers
3.1 Grips for all units (S41 – S 45)
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4 Technical Data
4.1 Complete device
• Mechanical product life - 5 million cycles
• Protection class (front side) - IP 54
• Standards and approbations*:
Fire behaviour: DIN 5510 - pending
NFF 16-101 - pending
NFF 16-102 - pending
Design: VDE 0660
*further standards and approbations on request
4.2 Micro-switch without positive opening operation
(S = silver contacts)
• Mechanical product life - 5 million cycles
• Temperature range - -40°C to +85°C
• Switching category - DC-13, 24VDC / 2,0 A
- DC-13, 60 VDC / 0,5 A
- DC-13, 72 VDC / 0,35 A
- DC-13, 110 VDC / 0,2 A
- AC-13, 230 VAC / 1,5
• Minimal current - ≤ 30 VDC / 20mA
Micro-switch without positive opening operation (G = gold plated silver contacts) • Mechanical product life - 5 million cycles
• Temperature range - -40°C to +85°C
• Switching category - DC-12, 12 to 30 VDC / 10mA
• Minimal current - ≤ 30 VDC / 0,5mA to 8mA
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Industrial Controllers
4.3 Micro-switch with positive opening operation
(S = silver contacts)
• Solder-hook terminated contact - with lever switch S44
• Contact with screw terminal - with lever switch S45
• contact with blade terminal - with lever switch S45
• Mechanical product life - 10 million cycles
• Temperature range - -40°C to +85°C
• Switching category - AC-12, 250 VAC / 10A
- DC-12, 24 VDC / 6,0 A
- DC-12, 60 VAC / 1,0 A
- DC-12, 72 VAC / 0,7 A
- DC-12, 110 VAC / 0,35 A
- DC-12, 250 VDC / 0.2 A
• Minimal current - ≤ 30 VDC / 20mA
Micro-switch with positive opening operation (G = gold plated silver contacts) • Solder-hook terminated contact - for lever switch S44
• Contact with screw terminal - with lever switch S45
• contact with blade terminal - with lever switch S45
• Mechanical product life - 10 million cycles
• Temperature range - -40°C to +85°C
• Switching category - DC-12, 12 to 30 VDC / 10mA
• Minimal current - ≤ 30 VDC / 0,5mA to 8mA
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Industrial Controllers
5 Installation
5.1 Lever switch installation
With anti-twist device Without anti-twist device
Figure 3: Installation
Figure 3 shows the installation of the lever switch. As one can see, the lever switch (1) is in-serted into the port (2) from below, and the centering ring (3) is placed upon it from the top. Fix the entire unit by tightening the two attachment screws (4) evenly (NOTE: Max. Torque 50 Ncm!!). Make sure to remove the cylindrical handles (handles 13 and 14) before inserting the lever switch into the port. You will find a detailed instruction for the disassembly of the handles in chapter 5.2.
Attention ! The surface of the assembly position of the switch has to be very flat without any barrier.
The positioning of the lever switch with anti-twist device (2) is given by an arbor.
The dimensioned drawings listed in table 2 provide information on the outside dimensions of the various lever switch types and the port designs. All dimensioned drawings are attached.
Type S41 S42 S43 S44 S45
Dimensioned drawing
M 4650 M 4651 M 4652 M 4653 M 4654
Table 2: Dimensioned drawings
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Industrial Controllers
5.2 Handle disassembly
The handles 02, 03, 05, 13, 14, and 15 are put over the switching lever and then fixed axially by a hex-socket set screw (M3 DIN 916). Upon the loosening of this set screw, the handles can be removed upwards. For the handles 13 and 14, a cover must be removed first (see fig. 4), before one can access the set screws.
When tightening the set screws, make sure not to exceed the max. torque of 20 Ncm.
Figure 4: Handle disassembly
6 Type Key
Sample:S 4X - 11 - 2 - MS.../xy/xy - 4 - 8 - V
type handle design number of contacts
Ms = detent see T 604
type of connection
colour of centering ring
lock against rotation
x = switching sequence see T
604
1 = screw terminal
0 = black anodized
not specified = without anti-twist
device
y = G = goldcontact S = silvercontact
2 = blade terminal 6,3x0,8
8 = aluminium coloured anodized
V =with anti-twist
device
3 = cage clamp 1-1,5mm2
4 = connector JST max 0,2mm²
contact 2contact 1
grip
cover
set screw
handle
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Industrial Controllers
8 Appendix
This appendix includes all and any documents, to which reference was made in the previous chapters.
Type of drawing Drawing No. Description
Data sheet T 604 Order, Detents and switching sequences S4, S41 to S45
Dimensioned drawing M 4650 Dimensioned drawing S41
Data sheet EK / 87-10 Connection diagram 1 to 2 contacts (S41)
Data sheet EK / 89-10 Connection diagram 3 to 4 contacts (S41)
Data sheet EK / 105-10 Connection diagram, 5 contacts (S41)
Dimensioned drawing M 4651 Dimensioned drawing S42
Data sheet EK / 90-10 Connection diagram 1 to 2 contacts (S42)
Data sheet EK / 91-10 Connection diagram 3 to 4 contacts (S42)
Data sheet EK / 107-10 Connection diagram, 5 contacts (S42)
Dimensioned drawing M 4652 Dimensioned drawing S43
Data sheet EK / 94-10 Connection diagram 1 to 2 contacts (S43)
Data sheet EK / 95-10 Connection diagram 3 to 4 contacts (S43)
Data sheet EK / 108-10 Connection diagram, 5 contacts (S43)
Dimensioned drawing M 4653 Dimensioned drawing S44
Data sheet EK / 96-10 Connection diagram 1 to 2 contacts (S44)
Data sheet EK / 102-10 Connection diagram 3 to 4 contacts (S44)
Dimensioned drawing M 4654 Dimensioned drawing S45
Data sheet EK / 106-10 Connection diagram 1 to 4 contacts (S45)
Table 3: Appendix
Lever switches S41 to S45 - Technical Documentation
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Industrial Controllers
7 Order, Detents and Switching Sequences (T604)
purchase order offer
Purchaser: Date
Company:
Name:
Street
Zip code: Location:
Phone:
Fax:
E-Mail:
Delivery address
Company:
Name:
Street
Zip code: Location:
Phone:
Fax:
E-Mail:
Requested delivery date:
Delivery / and shipping instruction:
Remarks:
FAX: +49(0)7131 4067-10 E-Mail: gessmann@gessmann.com
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Industrial Controllers
7 Order, Detents and Switching Sequences (T604)
purchase order offer
Purchaser: Date
Company:
Name:
Street
Zip code: Location:
Phone:
Fax:
E-Mail:
Delivery address
Company:
Name:
Street
Zip code: Location:
Phone:
Fax:
E-Mail:
Requested delivery date:
Delivery / and shipping instruction:
Remarks:
FAX: +49(0)7131 4067-10 E-Mail: gessmann@gessmann.com
Lever switches S41 to S45 - Technical Documentation
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Industrial Controllers
8 Appendix
This appendix includes all and any documents, to which reference was made in the previous chapters.
Type of drawing Drawing No. Description
Data sheet T 604 Order, Detents and switching sequences S4, S41 to S45
Dimensioned drawing M 4650 Dimensioned drawing S41
Data sheet EK / 87-10 Connection diagram 1 to 2 contacts (S41)
Data sheet EK / 89-10 Connection diagram 3 to 4 contacts (S41)
Data sheet EK / 105-10 Connection diagram, 5 contacts (S41)
Dimensioned drawing M 4651 Dimensioned drawing S42
Data sheet EK / 90-10 Connection diagram 1 to 2 contacts (S42)
Data sheet EK / 91-10 Connection diagram 3 to 4 contacts (S42)
Data sheet EK / 107-10 Connection diagram, 5 contacts (S42)
Dimensioned drawing M 4652 Dimensioned drawing S43
Data sheet EK / 94-10 Connection diagram 1 to 2 contacts (S43)
Data sheet EK / 95-10 Connection diagram 3 to 4 contacts (S43)
Data sheet EK / 108-10 Connection diagram, 5 contacts (S43)
Dimensioned drawing M 4653 Dimensioned drawing S44
Data sheet EK / 96-10 Connection diagram 1 to 2 contacts (S44)
Data sheet EK / 102-10 Connection diagram 3 to 4 contacts (S44)
Dimensioned drawing M 4654 Dimensioned drawing S45
Data sheet EK / 106-10 Connection diagram 1 to 4 contacts (S45)
Table 3: Appendix
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Industrial Controllers
Figure 5: Detents and switching sequences (T 604)
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sid
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ccor
ding
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switc
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seq
uenc
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cord
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604
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WA
GO
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1v.1
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115
S1
S2
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S5
"0"
- po
sitio
n m
icro
switc
h
X1=
30po
l.
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cont
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1
42
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1
42
42
1
4
12
34
56
78
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1315
1720
2224
2527
29
1630
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1
1012
1416
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2123
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30
top
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0 po
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defin
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ccor
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X1
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"0"-position
microsw
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X1
09.03.04
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5 co
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EK
/108
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S
defin
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26.08.03
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11
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(14) (12)
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(31)
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(34) (32)
11
14
S2 S4
1v.1
NC/12
bottomside
14
topside
(21) (24)
11
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(22)
11
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(41) (44) (42)
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C/11
NO/14 microswitch
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Notes
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