Table of Contents

Introduction ............................................................................. 2
Sensors ................................................................................... 4
Limit Switches ......................................................................... 8
International Limit Switches .................................................. 18
North American Limit Switches ............................................. 22
BERO Sensors ....................................................................... 27
Inductive Proximity Sensors Theory of Operation .................. 28
Inductive Proximity Sensor Family ......................................... 40
Capacitive Proximity Sensors Theory of Operation ................ 54
Capacitive Proximity Sensor Family ....................................... 57
Ultrasonic Proximity Sensors Theory of Operation ................. 59
Ultrasonic Proximity Sensor Family ....................................... 68
Photoelectric Sensors Theory of Operation ............................ 80
Photoelectric Family of Sensors ............................................ 93
Sensor Applications ............................................................... 99
Review Answers .................................................................. 107
Final Exam ........................................................................... 108

Introduction

Welcome to another course in the STEP 2000 series, Siemens

Technical Education Program, designed to prepare our
distributors to sell Siemens Energy & Automation products
more effectively. This course covers Sensors and related
products.
Upon completion of Sensors you should be able to:

Describe advantages, disadvantages, and applications of

limit switches, photoelectric sensors, inductive sensors,
capacitive sensors, and ultrasonic sensors

Describe design and operating principles of mechanical

limit switches

Identify components of International and North American

mechanical limit switches

Describe design and operating principles of inductive,

capacitive, ultrasonic, and photoelectric sensors and
describe differences and similarities

Apply correction factors where appropriate to proximity

sensors

Identify the various scan techniques of photoelectric

sensors

Identify ten categories of inductive sensors and sensors in

each category

Describe the effects of dielectric constant on capacitive

proximity sensors

Identify environmental influences on ultrasonic sensors

Identify types of ultrasonic sensors that require manual

adjustment, can be used with SONPROG, and require the
use of a signal evaluator

Describe the difference between light operate and dark

operate modes of a photoelectric sensor

Describe the use of fiber optics and laser technology used

in Siemens photoelectric sensors

Select the type of sensor best suited for a particular

application based on material, sensing distance, and
sensor load requirements

This knowledge will help you better understand customer

applications. In addition, you will be better able to describe
products to customers and determine important differences
between products. You should complete Basics of Electricity
and Basics of Control Components before attempting
Sensors. An understanding of many of the concepts covered in
Basics of Electricity and Basics of Control Components is
required for Sensors.
If you are an employee of a Siemens Energy & Automation
authorized distributor, fill out the final exam tear-out card and
mail in the card. We will mail you a certificate of completion if
you score a passing grade. Good luck with your efforts.
BERO, SIMATIC, SONPROG, and SIGUARD are registered
trademarks of Siemens Energy & Automation, Inc.
National Electrical Code and NEC are registered trademarks
of the National Fire Protection Association, Quincy, MA 02269.
Portions of the National Electrical Code are reprinted with
permission from NFPA 70-1999, National Electrical Code
Copyright, 1998, National Fire Protection Association, Quincy,
MA 02269. This reprinted material is not the complete and
official position of the National Fire Protection Association on
the referenced subject which is represented by the standard in
its entirety.
Underwriters Laboratories, Inc. is a registered trademark of
Underwriters Laboratories, Inc., Northbrook, IL 60062. The
abbreviation UL is understood to mean Underwriters
Laboratories, Inc.
National Electrical Manufacturers Association is located at 2101
L. Street, N.W., Washington, D.C. 20037. The abbreviation
NEMA is understood to mean National Electrical
Manufacturers Association.
Other trademarks are the property of their respective owners.
3

Sensors

One type of feedback frequently needed by industrial-control

systems is the position of one or more components of the
operation being controlled. Sensors are devices used to provide
information on the presence or absence of an object.

Siemens Sensors

Siemens sensors include limit switches, photoelectric ,

inductive, capacitive, and ultrasonic sensors. These products
are packaged in various configurations to meet virtually any
requirement found in commercial and industrial applications.
Each type of sensor will be discussed in detail. At the end of
the course an application guide is provided to help determine
the right sensor for a given application.

Technologies

Limit switches use a mechanical actuator input, requiring the

sensor to change its output when an object is physically
touching the switch. Sensors, such as photoelectric, inductive,
capacitive, and ultrasonic, change their output when an object is
present, but not touching the sensor.
In addition to the advantages and disadvantages of each of
these sensor types, different sensor technologies are better
suited for certain applications. The following table lists the
sensor technologies that will be discussed in this course.
Sensor

Advantages

Disadvantages

Applications

Limit Switch High Current

Capability
Low Cost
Familiar "LowTech" Sensing

Requires Physical Interlocking

Contact with
Basic End-ofTarget
Travel Sensing
Very Slow
Response
Contact Bounce

Photoelectric Senses all Kinds of

Materials
Long Life
Longest Sensing
Range
Very Fast
Response Time

Lens Subject to Packaging

Contamination
Material
Sensing Range
Handling
Affected by Color Parts Detection
and Reflectivity
of Target

Inductive

Resistant to Harsh Distance

Environments
Limitations
Very Predictable
Long Life
Easy to Install

Capacitive

Detects Through
Some Containers
Can Detect
Non-Metallic
Targets

Very Sensitive to Level Sensing

Extreme
Environmental
Changes

Ultrasonic

Senses all
Materials

Resolution
Repeatability
Sensitive to
Temperature
Changes

Industrial and
Machines
Machine Tool
Senses MetalOnly Targets

Anti-Collision
Doors
Web Brake
Level Control

Contact Arrangement

Contacts are available in several configurations. They may be

normally open (NO), normally closed (NC), or a combination of
normally open and normally closed contacts.
Circuit symbols are used to indicate an open or closed path of
current flow. Contacts are shown as normally open (NO) or
normally closed (NC). The standard method of showing a
contact is by indicating the circuit condition it produces when
the contact actuating device is in the deenergized or
nonoperated state. For the purpose of explanation in this text a
contact or device shown in a state opposite of its normal state
will be highlighted. Highlighted symbols used to indicate the
opposite state of a contact or device are not legitimate symbols.
They are used here for illustrative purposes only.

Mechanical limit switches, which will be covered in the next

section, use a different set of symbols. Highlighted symbols are
used for illustrative purposes only.

Circuit Example

In the following diagram a mechanical limit switch (LS1) has

been placed in series with a Run/Stop contact and the M
contactor coil. The Run/Stop contact is in the Run condition and
the motor is running a process. This could be a conveyor or
some other device. Note that the M contacts and the Run/
Stop are shown highlighted, indicating they are normally open
contacts in the closed position. LS1 is a normally closed contact
of the mechanical limit switch.

When an object makes contact with the mechanical limit switch

the LS1 contacts will change state. In this example the normally
closed contacts of LS1 open. The mechanical limit switch
symbol is highlighted. The M contactor coil is deenergized,
returning the normally open contacts of the M contactor to
their normal position, stopping the motor and the process.

Limit Switches

A typical limit switch consists of a switch body and an operating

head. The switch body includes electrical contacts to energize
and deenergize a circuit. The operating head incorporates some
type of lever arm or plunger, referred to as an actuator.
The standard limit switch is a mechanical device that uses
physical contact to detect the presence of an object (target).
When the target comes in contact with the actuator, the
actuator is rotated from its normal position to the operating
position. This mechanical operation activates contacts within the
switch body.

Principle of Operation

A number of terms must be understood to understand how a

mechanical limit switch operates.
The free position is the position of the actuator when no
external force is applied.
Pretravel is the distance or angle traveled in moving the actuator
from the free position to the operating position.
The operating position is where contacts in the limit switch
change from their normal state (NO or NC) to their operated
state.
Overtravel is the distance the actuator can travel safely beyond
the operating point.
Differential travel is the distance traveled between the operating
position and the release position.
The release position is where the contacts change from their
operated state to their normal state.
Release travel is the distance traveled from the release position
to the free position.

Momentary Operation

One type of actuator operation is momentary. When the target

comes in contact with the actuator, it rotates the actuator from
the free position, through the pretravel area, to the operating
position. At this point the electrical contacts in the switch body
change state. A spring returns the actuator lever and electrical
contacts to their free position when the actuator is no longer in
contact with the target.

Maintained Operation

In many applications it is desirable to have the actuator lever

and electrical contacts remain in their operated state after the
actuator is no longer in contact with the target. This is referred
to as maintained operation. With maintained operation the
actuator lever and contacts return to their free position when a
force is applied to the actuator in the opposite direction. A forkstyle actuator is typically used for this application.

10

Snap-Action Contacts

There are two types of contacts, snap-action and slow-break.

Snap-action contacts open or close by a snap action regardless
of the actuator speed. When force is applied to the actuator in
the direction of travel, pressure builds up in the snap spring.
When the actuator reaches the operating position of travel, a set
of moveable contacts accelerates from its normal position
towards a set of fixed contacts.
As force is removed from the actuator it returns to its free
position. When the actuator reaches the release position the
spring mechanism accelerates the moveable contact back to its
original state.
Since the opening or closing of the contacts is not dependent
on the speed of the actuator, snap-action contacts are
particularly suited for low actuator speed applications. Snapaction contacts are the most commonly used type of contact.

11

Slow-Break Contacts

Switches with slow-break contacts have moveable contacts that

are located in a slide and move directly with the actuator. This
ensures the moveable contacts are forced directly by the
actuator. Slow-break contacts can either be break-before-make
or make-before-break.

In slow-break switches with break-before-make contacts, the

normally closed contact opens before the normally open
contact closes. This allows the interruption of one function
before continuation of another function in a control sequence.
In slow-break switches with make-before-break contacts, the
normally open contact closes before the normally closed
contact opens. This allows the initiation of one function before
the interruption of another function.

Contact State Break-Before-Make

NO
NC
Free Position Open
Closed
Transition
Open
Open
Operated State Closed
Open

12

Make-Before-Break
NO
NC
Open
Closed
Closed
Closed
Closed
Open

Contact Arrangements

There are two basic contact configurations used in limit

switches: single-pole, double-throw (SPDT) and double-pole,
double-throw (DPDT). This terminology may be confusing if
compared to similar terminology for other switch or relay
contacts, so it is best just to remember the following points. The
single-pole, double-throw contact arrangement consists of one
normally open (NO) and one normally closed (NC) contact. The
double-pole, double-throw (DPDT) contact arrangement consists
of two normally open (NO) and two normally closed (NC)
contacts. There are some differences in the symbology used in
the North American and International style limit switches. These
are illustrated below.

Electrical Ratings

Contacts are rated according to voltage and current. Ratings are

generally described as inductive ratings. A typical inductive load
is a relay or contactor coil. There are three components to
inductive ratings:
Make

The load a switch can handle when the

mechanical contacts close. This is associated
with inrush currents. This is typically two cycles
or less.

Break

The load a switch can handle when the

mechanical contacts are opened. This is the
maximum continuous switch current.

Continuous

The load that a switch can handle without

making or breaking a load.

13

The following ratings are typical of Siemens International and

North American style limit switches.
Inductive AC
Contact Ratings

AC Volts
120
240

Inductive DC
Contact Ratings

DC Volts
120
240

DC Volts
120
240

Load Connection

14

International and North American Style

Make
Break
Amp
VA
Amp
VA
60
7200
6
720
30
7200
3
720

International Style
Make
Break
Amp
VA
Amp
VA
0.55
69
0.55
69
0.27
69
0.55
69

North American Style

Make
Break
Amp
VA
Amp
VA
0.22
0.22
0.11
0.11
-

Care must be made to ensure that multiple loads on one switch

are properly connected. The correct way to wire a switch is so
that the loads are connected to the load side of the switch.
Loads should never be connected to the line side of the switch.

Actuators

Several types of actuators are available for limit switches, some

of which are shown below. There are also variations of actuator
types. Actuators shown here are to provide you with a basic
knowledge of various types available. The type of actuator
selected depends on the application.

Roller Lever

The standard roller is used for most rotary lever applications. It

is available in various lengths. When the length of the roller lever
is unknown, adjustable length levers are available.

Fork

The fork style actuator must be physically reset after each

operation and is ideally suited for transverse movement control.

15

Mounting Considerations

Limit switches should be mounted in locations which will

prevent false operations by normal movements of machine
components and machine operators. An important aspect of
limit switch mounting is cam design. Improper cam design can
lead to premature switch failure.
For lever arm actuators it is always desirable to have the cam
force perpendicular to the lever arm. For applications in which
the cam is traveling at speeds less than 100 feet per minute a
cam lever angle of 30 degrees is recommended.

Overriding and
Non-Overriding Cams

In overriding cam applications it is necessary to angle the

trailing edge of the cam in order to prevent the lever arm from
snapping back. Snapping back of the lever arm can cause shock
loads on the switch which will reduce the life of the switch.

Non-Overriding cams are cams which will not overtravel the

actuating mechanism.

16

Flexible Loop and

Spring Rod

Flexible loop and spring rod actuators can be actuated from all
directions, making them suitable for applications in which the
direction of approach is constantly changing.

Plungers

Plunger type actuators are a good choice where short,

controlled machine movements are present or where space or
mounting does not permit a lever type actuator. The plunger can
be activated in the direction of plunger stroke, or at a right angle
to its axis.

Mounting Considerations

When using plain and side plunger actuators the cam should be
operated in line with the push rod axis. Consideration should be
given so as not to exceed the overtravel specifications. In
addition, the limit switch should not be used as a mechanical
stop for the cam. When using roller top plunger the same
considerations should be given as with lever arm actuators.

17

International Limit Switches

International mechanical limit switches are widely used in many

countries, including North America. The International
Electrotechnical Commission (IEC) and the National Electrical
Manufacturers Association (NEMA) develop standards for
electrical equipment. Siemens international mechanical
switches are built to IEC and NEMA standards. In addition, they
are UL listed and CSA certified. International style switches
consist of two major components, the operating head and
switch body.

International Limit
Switch Family

18

A large family of mechanical limit switches is available in the

international style to meet virtually any mechanical limit switch
application.

Operating Heads

Depending on the switch, Siemens international style limit

switches can be fitted with any of several interchangeable
operating heads and actuators. Overtravel plunger, roller plunger,
roller or angular roller lever, plain or adjustable length roller lever,
plain or spring rod, fork lever, or coded sensing heads are
available.

The actuator head can be rotated so that the switching direction

of limit switches with roller crank, adjustable-length roller crank
or rod actuators can operate from any side of the switch body.
In addition, roller cranks can be repositioned to the left or right
around the operating shaft.

19

Open-Type
Limit Switches

Open-type limit switches are intended for use as auxiliary

switches in cabinets, large enclosures, or locations where they
are not exposed to dust and moisture. A miniature version is
available for limited space applications such as automatic door
interlocking. Open-type switches use a plunger actuator.

Miniature Formed Housing

Limit Switches

Miniature formed housing limit switches are used in

applications where space is restricted. The glass-reinforced
fiber, flame-retardant molded plastic enclosure resists most
shocks, impacts, cutting oils, and penetration from dust and
water.

20

Replaceable Contact Block

Limit Switches

Siemens has developed two limit switch models with

replaceable contact blocks, one with a formed plastic enclosure
and one with a metal enclosure. The formed plastic version is in
an enclosure similar to the miniature limit switches discussed
previously. The metal version is enclosed in die-cast aluminum.
It is impervious to most mechanical shocks.

SIGUARD Mechanical
Interlock Switches

Sensitivity to safety is an increasing priority for the workplace.

Most sensors cannot be used in safety circuits, including
proximity sensors and photoelectric sensors which will be
covered in later sections. Sensors used in safety circuits must
meet stricter design and test standards specified by DIN and
IEC. The SIGUARD line of International style switches is
designed for safety circuits. SIGUARD mechanical interlock
switches have triple coded actuators that act as a key. These
devices can be used to control the position of doors, machine
guards, gates, and enclosure covers. They can also be used to
interrupt operation for user safety. They are available in miniature
formed housing and metal housing models.

21

North American Limit Switches

North American mechanical limit switches are specifically

designed to meet unique requirements of the North American
market. These switches are comprised of three interchangeable
components; contact block, switch body, and sensing head.
North American limit switches meet UL (Underwriters
Laboratory) and CSA (Canadian Standards Association).

Actuators

22

Like the International limit switches, Siemens North American

limit switches also accept a variety of operating heads and
actuators.

NEMA Type 6P Submersible

The housing for North American NEMA Type 6P submersible

limit switch is die-cast metal with an epoxy finish for harsh
industrial environments. In addition, the Siemens 6P
submersible switch can be used for watertight applications.

Class 54, Rotating Type

Class 54 rotating limit switches are used to limit the travel of

electrically operated doors, conveyors, hoists, and similar
applications. The contacts are operated when the external shaft
is rotated sufficiently. Siemens rotating switches employ a
simple reduction worm and gear(s) to provide shaft-to-cam
ratios of 18 to 1, 36 to 1, 72 to 1, or 108 to 1. In addition, long
dwell cams are available which keeps contacts closed for longer
periods of time. This may be necessary in hoist or similar
applications. A fine adjustment cam is also available to increase
the accuracy of the number of shaft turns required to cause the
contacts to operate.

23

Miniature, Prewired,
Sealed Switches

Miniature, prewired, sealed switches allow for miniaturization

of the electrical connection. The switch is prewired and the
terminals and connection are encapsulated in epoxy. The switch
uses a single-pole, double-throw contact. The contact can be
wired either normally open (NO) or normally closed (NC).
Depending on the load voltage, the contact can make up to 7.5
amps and break up to 5 amps.

3SE03 Hazardous
Locations, Type EX

Type EX limit switches are designed for extreme environmental

service in locations where there exists a danger of an internal or
external explosion of flammable gasses, vapors, metal alloy, or
grain dust. EX switches are designated by the catalog number
3SE03-EX.

24

Enclosed Basic Switches

North American limit switches are also available in an enclosed

basic version. These switches are designated by the catalog
number 3SE03-EB. Enclosed basic switches are preconfigured
with a plunger actuator, booted plunger, roller lever, booted roller
lever, roller plunger, or a booted roller plunger.

25

Review 1
1)

A ____________ ____________ is a type of sensor that

requires physical contact with the target.

2)

Which of the following symbols identifies a Normally

Closed, Held Open limit switch?

3.

____________ is the distance or angle traveled in

moving the actuator from the free position to the
operating position.

4.

The ____________ ____________ is where contacts in

the limit switch change from their normal state to their
operated state.

5.

In slow-break switches with ____________ ____________ - ____________ contacts, the normally

closed contact opens before the normally open contact
closes.

6.

____________ defines the load a switch can handle

when the mechanical contacts are opened. This is the
maximum continuous switch current.

7.

For applications in which the cam is travelling at speeds

less than 100 feet per minute a cam lever angle of
____________ degrees is recommended.

8.

An International switch consists of an ____________

____________ and switch body.

9.

____________ is the trade name for a type of

International switch suitable for safety circuits.

10. The Siemens ____________ submersible switch can be

used for watertight applications.

26