Limitswitch IOM LS

DNL / DXL RANGE
VERSATILE LIMIT SWITCH
Installation
Operation and
Maintenance
Manual
RTX-IOM-LS-R02-0416 Page 1 of 42
www.rotexautomation.com
Table of Contents
1. Introduction ............................................................................................................. 5
1.1. Definitions .............................................................................................................. 6
2. Operation principal ................................................................................................. 6
3. Identification of limit switch ..................................................................................... 7
3.1. DNLF SERIES........................................................................................................ 7
3.2. DXLW SERIES....................................................................................................... 7
4. Installation procedure ............................................................................................. 8
4.1. Cam setting .......................................................................................................... 10
4.1.1. Cam setting for switch 1A .............................................................................. 11
4.1.2. Cam setting for switch 2A .............................................................................. 12
4.1.3. Cam Settings for switch 3A............................................................................ 13
4.1.4. Cam settings for switch 4A ............................................................................ 14
4.2. Termination details ............................................................................................... 17
4.2.1. Termination details for switch 1A ................................................................... 17
5. Testing of micro switches ..................................................................................... 23
5.1. Initial check up before testing micro switches ...................................................... 23
5.2. Testing of micro switches (by using multi-meter) ................................................. 23
6. Testing of proximity sensors ................................................................................. 23
6.1. Initial check up before testing proximity sensors .................................................. 23

6.2. Testing of proximity sensors (by measuring voltage) ........................................... 23
6.3. Testing of proximity sensors (by measuring current) ............................................ 24
7. Maintenance ......................................................................................................... 24
8. Trouble shooting ................................................................................................... 25
8.1. Trouble shooting for micro switches ..................................................................... 25
8.2. Trouble shooting for proximity sensors ................................................................ 25
9. Tool kit .................................................................................................................. 25
10. Disassembly ......................................................................................................... 26
10.1. Cover disassembly ........................................................................................ 26
10.2. Shaft disassembly ......................................................................................... 27
10.2.1. Shaft disassembly for switch 1A .................................................................... 28
10.3. Switch disassembly ....................................................................................... 30
10.3.1. Disassembly of Switch 1A ............................................................................. 30
11. Assembly .............................................................................................................. 33
12. Dimentional details ............................................................................................... 35
13. 35
14. Assembly details................................................................................................... 36
14.1. Assembly details for DNLF 1A ....................................................................... 36
14.4. ............................................................................................................................ 37
15. Certificates............................................................................................................ 39
16. 41
17. Packaging & store ................................................................................................ 42
18. Assistance ............................................................................................................ 42
1. Introduction
Thank you for choosing ROTEX product. Each product is fully inspected after the
production to offer you the highest quality. In order to fully utilize the product, we
strongly recommend users to read this manual carefully and understood.
 This manual provides information on installation, operation and maintenance

procedures and related instructions for the ROTEX make versatile limit switch.
 The aim of this literature is to support the use of products in correct manner,
and all the technical information provided in the catalogue.
 The manual should be given to the end user.
 The manual can be changed or revised without any prior notice. Any changes
in product's specification, structure, and/or any components may not result
immediate revised version of the manual.
 The manual should not be duplicated or reproduced for any purpose without
any consent of Rotex Manufacturers & Engineers Private Limited, INDIA.
Manufacturer Warranty
 For the safety, it is vital to follow instructions in the manual. It is not ROTEX’s
liability for any damages which caused by users' negligence.
 It is not ROTEX's liability for any damages or accidents which resulted by any
alteration or modification of the product and parts. If alteration or modification
is necessary, please contact the ROTEX directly.
 ROTEX warrants the product from the date of original retail purchase of the
product for one (1) year, except as otherwise stated.
 ROTEX warranty will not cover the products that the product have been
subjected to abuse, accident, alteration, modification, tampering, negligence,
misuse, faulty installation, lack of reasonable care, repair or service in any way
that is not contemplated in the documentation for the product, or if the model
or serial number has been altered, tampered with, defaced or removed;
damages that occurs in shipment, failure due to power surge, and cosmetic
damage. Improper or incorrectly performed maintenance or report voids this
Limited Warranty.
 For detailed warranty information, please contact :
ROTEX MANUFACTERURS & ENGINEERS PRIVATE LIMITED, Manapada road,
Dombivli (e), Maharashtra, India, Pin – 421204.
1.1. Definitions
WARNING:
 If not observed, user incurs a high risk of severe damage to product
and/or fatal injury to personnel.
CAUTION:
 If not observed, user may incur damage to product and/or injury to
personnel.
NOTE:
 Advisory and information comments provided to assist maintenance
personnel to carry out maintenance procedures.
2. Operation principal
Limit switch box mounts to an actuator via mounting bracket, usually sold
separately. The unit shaft directly couples to actuator shaft via NAMUR adaptation,
or via coupling provided in mounting kit.
As actuator rotates the unit shaft, adjustable cam on the shaft actuate mechanical
or proximity switches inside the unit enclosure, at the limits of rotary travel set by
the customer.
The switches are prewired to terminal strip in the enclosure, permitting easy
connection of switch output to external electrical monitoring system or indication
devices.
The visual indicator on the enclosure cover indicates 900 rotary travel between
OPEN & CLOSED valve position, unless ordered optionally for other angular
strokes or 3-way valve application.
3. Identification of limit switch
3.1. DNLF SERIES
DNLF 1 A 2 4 R # # # # # M1
MODEL
SWITCH OF SWITCH
NO OF SWITCH
CABLE ENTRY SIZE
BODY AND COVER MATERIAL
COLOUR
INIDICATOR
TEMPERATURE RANGE
CABLE ENTRY
BRACKET
3.2. DXLW SERIES
DXLW 1 A 2 4 R # # # # M1
MODEL
SWITCH OF SWITCH
NO OF SWITCH
CABLE ENTRY
BODY AND COVER MATERIAL
COLOUR
INIDICATOR
TEMPERATURE RANGE
BRACKET
4. Installation procedure
The equipment must be installed in the accordance with the laws, guide lines and
rules applicable within the country.
WARNING:
 Ensure that Supply Voltage should not exceed more than > 20 % of Rated
voltage. (for current and voltage ratings refer catalogue)
 No mechanical rework allowed by customer. Mechanical rework will increase
clearance will increase between Housing and cover.
 Do not open cover / cable gland when limit switch is under operation or in
energized condition.
CAUTION:
 The current and voltage limitation has to be observed as per the tag
plate.
 The wiring and connection should be carried out with proper gland
and care should be taken to avoid water seepage.
 Confirm the area is non-hazardous before opening the cover of the
enclosure for making electrical connections.
 The plugs given along with box are to be removed and metallic plug
to be used.
 Ensure cable gland is properly fitted using sound engineering
practice ensuring that rain water / other fluids do not enter in the
limit switch box.
 The person who operates the limit switch should have enough
knowledge of electrical engineering.
CAUTION IP67 / IP68:

limit switch box.
to be used.
 Tighten the cover bolts fully to avoid water seepage inside the limit
switch box.
 Use UCIL SYNCHEM make GRIP SEAL CABLE JOINING COMPOUND
or equivalent to seal cable gland. For precaution & application of
sealing compound use original manufacturers operational manual.
NOTE:
 The box should be left in the original packing until it is required for the use.
 It should be stored in the enclosed area with temperature limit 4 o to 40 o C.
 Operating temperature range -20°C to +80°C
The limit switch box is installed on the supplied bracket with fastener and left loose.
The box is then mounted on the actuator while taking care that the shaft enters in
the slot of the actuator pinion.
Assembly of limit switch and actuator should allow the play between shaft and
pinion and never between actuator body and bracket. For that while assembling
keep a clearance ‘C’ between shaft and pinion. Where 0.2mm < C < 0.5mm
Connect the wiring through the cable gland required by the cable diameter. And
connect the wires to the terminal strip. Take care to check the symbols on the PCB.
The switch 1 is at the bottom and switch 2 is at the top. Correspondingly the COM1,
NO1, NC1 are corresponding to the switch1
COM: - Common terminal.
NC: - Normally closed contact open when actuated.
NO: - Normally open contact closes when actuated.
4.1. Cam setting
The setting of cam is crucial operation. The cams

are self-locking due to the male and female gears
perfectly matching.
The top cam is red in colour and is to be used for closed position this red cam has
to be rotated clock wise to actuate the switch for closed indication.
Similarly, the bottom cam is yellow in colour and is to be used for open position
cam has to be rotated counter clock wise to actuate the switch for open indication.
Actuate the assembly so as the valve closes.
4.1.1. Cam setting for switch 1A
Operate the actuator to bring the valve in closed condition. Use the red cam to set
the closed position. The cam has to be depressed and rotated (clock wise) till the
click on the micro switch is heard.
Operate the actuator to bring the valve in open condition. Use the yellow cam to set
the open position. The cam has to be lifted and rotated (counter clock wise) till the
click from micro switch is heard.
4.1.2. Cam setting for switch 2A
multimeter gives sensation for fully closed valve position.
Operate the actuator to bring the valve in open condition. The red cam has to be lifted
and rotated (counter clock wise) in 900 so that the multimeter gives sensation for fully
open valve position.
4.1.3. Cam Settings for switch 3A
multimeter gives sensation for fully open valve position.
4.1.4. Cam settings for switch 4A
First loosen the locking screw. Now rotate the valve to ensure that cam rotation is
right, If not adjust the cam accordingly.
Operate the actuator to bring the valve in closed condition. Cam has to be rotated
(clock wise) till the multimeter gives sensation for fully closed valve position.
First loosen the locking screw. Now rotate the valve to ensure that cam rotation is
right, If not adjust the cam accordingly.
Operate the actuator to bring the valve in open condition. Cam has to be rotated
(counter clock wise) till the multimeter gives sensation for fully closed valve
position.
click on the micro switch is heard.
click from micro switch is heard.
multimeter gives sensation for fully open valve position.
4.2. Termination details
4.2.1. Termination details for switch 1A
5. Testing of micro switches
5.1. Initial check up before testing micro switches
1. Ensure voltage is 8 v / 24v in open wire (PLC/DCS output) before connecting to
COM & NO terminals.
2. Connect both wires to COM & NO terminal. There should not be any loose
connection.
3. Ensure target (metal) should be in front of the switch sensing area (adjust both cam
accordingly with respect to valve operation).
5.2. Testing of micro switches (by using multi-meter)

1. Connect multi-meter (ohm-meter) across COM & NO terminal.
2. Check micro switch operation with continuity test.
6. Testing of proximity sensors

6.1. Initial check up before testing proximity sensors
1. Ensure voltage is 8 v / 24v in open wire (PLC/DCS output) before connecting to
COM & NC terminals.
2. Connect both wires to COM & NC terminal with right polarity. There should not be
any loose connection.
3. Ensure target (metal) should be in front of the switch sensing area (adjust both cam
accordingly with respect to valve operation).
4. Ensure distance between target & switch sensing area should be as specified (max.
1 to 3 mm)
6.2. Testing of proximity sensors (by measuring voltage)

1. Connect multi-meter (voltmeter) across COM & NC terminal.
2. For NO switch –Ensure voltage should be 8 volt / 24 volt when target is far away.
Voltage should be dropped when target in front of the switch.
3. For NC switch – Ensure Voltage should be dropped when target is far away.
Voltage should be 8 / 24 volt when target is in front of the switch.
NO sensors – When target is far away, voltage NO sensors – When target in front of switch,
shows 24 volt voltage drops
6.3. Testing of proximity sensors (by measuring current)
1. Connect multi-meter (Mili-ameter) in series with COM/NC terminal
2. For NO switch – Ensure current should be low (or zero) when target is away.
When target in front of switch, full load current should be there.
3. For NC switch – current should be low when target is in front of the switch.
When target is far away, full load current should be there.
NO sensors – When target is far away, current NO sensors – When target is in front of the
shows 0 mA switch, current value is 33.3 mA (as per load)
7. Maintenance
CAUTION for IP67 / IP68:
 Ensure cable gland is properly fitted using sound engineering practice
ensuring that rain water / other fluids do not enter in the limit switch
box.
 The plugs given along with box are to be removed and metallic plug to
be used.
switch box.
 Use UCIL SYNCHEM make GRIP SEAL CABLE JOINING COMPOUND or
equivalent to seal cable gland. For precaution & application of sealing
compound use original manufacturers operational manual.
 NOTE:
 The limit switch must be removed from installation prior to maintenance.
 All the wiring and supply has to be disconnected prior to disassembly.
 All the spares used or replaced must be original from Rotex.
It is important to verify the model/version of limit switch box and spares to be
replaced. In case of difficulty consult Rotex distributor.
1. The Rotex limit switch is designed to operate for one million cycles without
servicing. Call Rotex when you are approching this milestone for a preventive
maintenance kit and instructions.
2. Install, operate and maintain as per the instructions and recommendations of
this manual.
3. Any deviation from the above will cease the responsibilities of ROTEX.
8. Trouble shooting
8.1. Trouble shooting for micro switches
Failure Check list Corrective action
No feedback Check voltage & current Correct DCS output /
correct loose connection
Check cam position Adjust Cam properly
PCB soldering issue / PCB tack issue Re-solder it / replace PCB
due to corrosion
Faulty micro switches Replace micro switch
8.2. Trouble shooting for proximity sensors

Failure Check list Corrective action
No feedback Check polarity Correct it
Check voltage & current Correct DCS output / correct loose
connection
Check target position & its distance Adjust Cam properly (adjust target
towards sensing area position as specified by max. 1 to 3
mm distance)
PCB soldering issue / PCB tack issue Re-solder it / replace PCB
due to corrosion
Faulty proximity sensors Replace sensors
9. Tool kit
Tool Tool specification

1. Screw driver (tip style - sloted) for switch 3 mm
2. Screw driver (tip style - sloted) for plug 6-8 mm
3. Screw driver (tip style - phillips) for dome indicator 4 mm
4. Allen key for cover 5 mm
10. Disassembly
WARNING:
 All electric and pneumatic connections should be removed before
starting disassembly.
CAUTION:
 Do not place dismantled part on any diary/work bench but keep it on
clean paper/cloth in same sequence as you have dismantled it.
NOTE:
 It is advisable to replace all the rubber parts using genuine ROTEX spare kit.
10.1. Cover disassembly
The cover bolts are loosen and then rotated till

they are free.
Pull out the cover vertically, note that the shaft

is still in housing.
To disassembal the top dome indicator remove the screw. Observe the o-ring for
weathering effect. Replace the parts as required. It is advisable to replace all the
rubber part together. All parts are included in the set of kit
10.2. Shaft disassembly

For all shafts listed below, after dismanteling, observe the o-ring damage and cam
damage. Replace shaft or o-ring as required.
10.2.1. Shaft disassembly for switch 1A
Circlip should be removed to bring the shaft out from the box. Use screwdriver to
remove the circlip.
remove the circlip.
remove the circlip.
remove the circlip.
remove the circlip.
emove the circlip.
10.3. Switch disassembly
10.3.1. Disassembly of Switch 1A
Dismantle the screw to take out the PCB. Dismantle the screw to take out microw
switch cover. Now you can acces the micro switches. Use multimeter to locate the
error by using the zero resistence method. The ohmic value should be less than 0.2
ohms. Incase of burnt contact the contacts may show open contact. Replace the
PCB completely with the switches .
Dismantle the screw to take out sensor mounting plate. Dismantle the screw to take
out cylindrical proximity sensor.
Dismantle the screw to take out the PCB. Dismantle the screw to take out microw
switch cover. Now you can acces the proximity switches. Incase of burnt contact
the contacts may show open contact. Replace the PCB completely with the
switches.
Dismantle the screw to take out the PCB. Incase of burnt contact the contacts may
show open contact. Replace the PCB completely with the switches.
Dismantle the screw to take out microw switch cover with micro switches. Take out
the PCB. Incase of burnt contact the contacts may show open contact. Replace the
PCB completely with the switches.
Dismantle the screw to take out the PCB. Dismantle the screw to take out the
hermatically sealed microw switch. Incase of burnt contact the contacts may show
open contact. Replace the PCB completely with the switches.
11. Assembly
CAUTION for IP67 / IP68:
limit switch box.
to be used.
switch box.
 Use UCIL SYNCHEM make GRIP SEAL CABLE JOINING COMPOUND
or equivalent to seal cable gland. For precaution & application of
sealing compound use original manufacturers operational manual.
NOTE:
 Follow the sequences as given below to ensure proper assembly.
 ROTEX recommends “ROTEX V09” grease for greasing. Apply the grease
with soft brush or similar.
1. Install the shaft in housing with grease as a lubricant. Install the circlip. Check
the rotation by hand and check for the play. The play should be less than
0.05mm. If play is more it is not safe to install the box.
2. Install the PCB/ switch/ sensor and switch cover, fasten the screw to ensure the
no movement of PCB is possible. This may cause the faulty signal. Rotate the
cam to ensure that the cam is showing the valve positions correctly. Check the
mating surface of cover and housing there should not be any mark within the
flame path area. It is important if the surface is found faulty must be consulted
with expert on EN norms to certify the usage.
3. Insert cover on the shaft. The shaft has

to be lightly lubricated. Take care that
gasket is in the position and all
fasteners are on the cover. Insert the
top end of the shaft in cover so that it
touches the indicator. Now rotate the
cover till the cover slides down. Align
the cover and body and tighten the bolts
fully. Tighten all the bolts and check with
slip gauge of size 0.05 mm. It should not
enter from any face joint area. In case it
does, the box cannot be used. Repack
the limit switch box to safe storage.
12. Dimentional details
13.
14. Assembly details
14.1. Assembly details for DNLF 1A
14.4.
15. Certificates
1. CCOE 2. BIS
3. ERDA 4. CMRI
5. DGMS 6. KL
7. ATEX 8. INMETRO
16.
9. IECEX 10. CUTR
11. UL
17. Packaging & store
1. When not in use, LIMIT SWITCH BOX should be kept in a sealed plastic bag in
a cardboard box to prevent moisture or dust from contacting product.
2. LIMIT SWITCH BOX should be stored in a dry place free from water and dust.
3. Store at temperature between 40°F and 120°F (4°C and 49°C).
4. Locate in an area to avoid damage by impact.
18. Assistance
For technical questions or assistance, contact any authorized distributor

of ROTEX or:
ROTEX MANUFACTURERS AND ENGINEERS PRIVATE LIMITED

Manpada Road, Dombivli (East)-421204
Maharastra, INDIA.
Tel: +91 251 2871033/ 2871390/ 2871196/ 2871989
Fax: +91 251 2871191
aftersales@rotexautomation.com
To find your local ROTEX representative:
For more information about ROTEX and its network, Please visit

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Limitswitch IOM LS

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DNL / DXL RANGE

VERSATILE LIMIT SWITCH

1.1. Definitions .............................................................................................................. 6

2. Operation principal ................................................................................................. 6

3. Identification of limit switch ..................................................................................... 7

3.1. DNLF SERIES........................................................................................................ 7

3.2. DXLW SERIES....................................................................................................... 7

4. Installation procedure ............................................................................................. 8

4.1. Cam setting .......................................................................................................... 10

4.1.1. Cam setting for switch 1A .............................................................................. 11

4.1.2. Cam setting for switch 2A .............................................................................. 12

4.1.3. Cam Settings for switch 3A............................................................................ 13

4.1.4. Cam settings for switch 4A ............................................................................ 14

4.1.5. Cam settings for switch 5A ............................................................................ 15

4.1.6. Cam settings for switch 6A ............................................................................ 16

4.2. Termination details ............................................................................................... 17

4.2.1. Termination details for switch 1A ................................................................... 17

4.2.2. Termination details for switch 2A ................................................................... 18

4.2.3. Termination details for switch 3A ................................................................... 19

4.2.4. Termination details for switch 4A ................................................................... 20

4.2.5. Termination details for switch 5A ................................................................... 21

4.2.6. Termination details for switch 6A ................................................................... 22

5. Testing of micro switches ..................................................................................... 23

5.1. Initial check up before testing micro switches ...................................................... 23

5.2. Testing of micro switches (by using multi-meter) ................................................. 23

6. Testing of proximity sensors ................................................................................. 23

6.1. Initial check up before testing proximity sensors .................................................. 23

6.3. Testing of proximity sensors (by measuring current) ............................................ 24

8. Trouble shooting ................................................................................................... 25

8.1. Trouble shooting for micro switches ..................................................................... 25

8.2. Trouble shooting for proximity sensors ................................................................ 25

9. Tool kit .................................................................................................................. 25

10. Disassembly ......................................................................................................... 26

10.1. Cover disassembly ........................................................................................ 26

10.2. Shaft disassembly ......................................................................................... 27

10.2.1. Shaft disassembly for switch 1A .................................................................... 28

10.2.2. Shaft disassembly for switch 2A .................................................................... 28

10.2.3. Shaft disassembly for switch 3A .................................................................... 28

10.2.4. Shaft disassembly for switch 4A .................................................................... 29

10.2.5. Shaft disassembly for switch 5A .................................................................... 29

10.2.6. Shaft disassembly for switch 6A .................................................................... 29

10.3. Switch disassembly ....................................................................................... 30

10.3.1. Disassembly of Switch 1A ............................................................................. 30

10.3.2. Disassembly of Switch 2A ............................................................................. 30

10.3.3. Disassembly of Switch 3A ............................................................................. 31

10.3.4. Disassembly of Switch 4A ............................................................................. 31

10.3.5. Disassembly of Switch 5A ............................................................................. 32

10.3.6. Disassembly of Switch 6A ............................................................................. 32

11. Assembly .............................................................................................................. 33

12. Dimentional details ............................................................................................... 35

14. Assembly details................................................................................................... 36

14.2. Assembly details for DNLF 2A ....................................................................... 36

14.3. Assembly details for DNLF 3A ....................................................................... 37

14.5. Assembly details for DNLF 4A ....................................................................... 37

14.6. Assembly details for DNLF 5A ....................................................................... 38

14.7. Assembly details for DNLF 6A ....................................................................... 38

17. Packaging & store ................................................................................................ 42

18. Assistance ............................................................................................................ 42

 This manual provides information on installation, operation and maintenance

3.2. DXLW SERIES

CAUTION IP67 / IP68:

COM: - Common terminal.

NC: - Normally closed contact open when actuated.

NO: - Normally open contact closes when actuated.