MR221 Heavy Duty Geared Limit Switches

Product Overview

Product Description

The MR221/MR222 Heavy Duty Geared Limit Switches are designed
for industrial applications where precise positioning and control
are required. These limit switches provide accurate position
feedback and are suitable for use in harsh environments.

Schematic Diagram

The schematic diagram of the MR221/MR222 Heavy Duty Geared Limit
Switches illustrates the internal components and their connections.
This diagram can be used as a reference for troubleshooting and
understanding the switch’s functionality.

Ordering Code

The MR221/MR222 Heavy Duty Geared Limit Switches can be ordered
using the following codes:

• MR221 Aluminum Housing Model
• MR222 Aluminum Housing Model
• MR221 Stainless Steel Housing Model
• MR222 Stainless Steel Housing Model

Initial Preparation

Unpacking and Inspection

When you receive the MR221/MR222 Heavy Duty Geared Limit
Switches, carefully unpack and inspect them for any damage that may
have occurred during shipment. If any damage is found, contact the
manufacturer or supplier for assistance.

Damage in Shipment

If the MR221/MR222 Heavy Duty Geared Limit Switches are damaged
during shipment, it is important to document the damage and contact
the shipping carrier immediately. They will guide you through the
necessary steps for filing a claim.

Standard Contents

The standard contents of the MR221/MR222 Heavy Duty Geared Limit
Switches package include:

• MR221/MR222 Geared Limit Switch
• Mounting hardware
• User manual

Warranty Information

The MR221/MR222 Heavy Duty Geared Limit Switches come with a
warranty. Please refer to the warranty information provided by the
manufacturer for details on coverage and terms.

Specifications

Here are the specifications of the MR221/MR222 Heavy Duty Geared
Limit Switches:

Electrical, Mechanical and Environmental

The electrical, mechanical, and environmental specifications of
the MR221/MR222 Heavy Duty Geared Limit Switches are detailed in
the user manual. Please refer to the manual for a comprehensive
overview of these specifications.

-1 Position Output Option, MR265 Loop-Powered Based

The MR221/MR222 Heavy Duty Geared Limit Switches offer a
position output option that is loop-powered based on the MR265
technology. This option provides accurate position feedback using a
4-20mA output signal. Refer to the user manual for more information
on how to utilize this feature.

-E Position Output, Absolute Encoder-Based

Another position output option available for the MR221/MR222
Heavy Duty Geared Limit Switches is the absolute encoder-based
output. This option provides precise position feedback using an
encoder-based mechanism. Consult the user manual for instructions
on configuring and utilizing this feature.

Test Summary

A test summary is provided in the user manual, which outlines
the performance and functionality tests conducted on the
MR221/MR222 Heavy Duty Geared Limit Switches. The summary provides
valuable information on the switch’s capabilities and
limitations.

Installation Guidelines

Mounting The Enclosure

MR221/MR222 Aluminum Housing Models

For MR221/MR222 Heavy Duty Geared Limit Switches with aluminum
housing, follow the mounting instructions provided in the user
manual. These instructions will guide you through the proper
installation process to ensure secure and stable mounting of the
switch.

MR221/MR222 Stainless Steel Housing Models

If your MR221/MR222 Heavy Duty Geared Limit Switches have a
stainless steel housing, refer to the user manual for specific
instructions on mounting the switch. Stainless steel models may
have different mounting requirements compared to aluminum housing
models.

Coupling To Customer Equipment’s Shaft(s)

The MR221/MR222 Heavy Duty Geared Limit Switches need to be
properly coupled to the shaft(s) of the customer’s equipment.
Consult the user manual for detailed instructions on how to achieve
a secure and reliable coupling between the switch and the
equipment’s shaft(s).

Wiring To The Limit Switch

Proper wiring is crucial for the correct operation of the
MR221/MR222 Heavy Duty Geared Limit Switches. Follow the wiring
instructions provided in the user manual to ensure the switch is
connected correctly to the power source and other relevant
components.

Programming The Cams

The MR221/MR222 Heavy Duty Geared Limit Switches can be
programmed to control the position and movement of the cams. The
user manual contains step-by-step instructions on how to program
the cams for precise positioning and control.

Connecting and Programming the 4-20mA Position Output

Options

If you are utilizing the 4-20mA position output options of the
MR221/MR222 Heavy Duty Geared Limit Switches, refer to the user
manual for guidance on connecting and programming these options.
The manual will provide detailed instructions on how to configure
and utilize the 4-20mA position output.

MR221 / MR222 Heavy Duty
Geared Limit Switches User Guide
Document No. 98-0221-02 Revision D
MICRONOR SENSORS, INC. 2085 Sperry Ave, Suite A-1
Ventura, CA 93003 USA +1-805-389-6600
[email protected] www.micronor.com
Notice of Proprietary Rights
The design concepts and engineering details embodied in this manual, which are the property of MICRONOR SENSORS, are to be maintained in strict confidence; no element or detail of this manual is to be spuriously used, nor disclosed, without the express written permission of MICRONOR AG or MICRONOR SENSORS. All rights are reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from MICRONOR SENSORS.
© COPYRIGHT 2022, MICRONOR SENSORS, INC. VENTURA, CA, USA

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

Revision History

Revision Date

A

12-Sep-2007

A1

24-Mar-2022

B

13-Apr-2015

C

20-Oct-2015

D

06-Dec-2022

Technical Contact DNH DNH
DNH
DNH
DNH

Revision Notes
Initial release, Micronor Inc. · Minor Update, 24-March-2011 · Updated Micronor Inc. address only
· Deleted UL/cUL logo as listing was discontinued
· Add CE mark · Minor Updated, 20-Oct-2015 · Added new Camarillo address and tel/fax · Updated contact info for Micronor Sensors
and manufacturer Micronor AG · Added Position Sensor documentation ­
MR265 and Encoder-based 4-20mA outputs

File Reference
98-0221-02_D_MR221-MR222_Manual_DRAFT_06-Dec-2022

Page 2 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

Table of Contents
Revision History ………………………………………………………………………………………………. 2
File Reference …………………………………………………………………………………………………. 2
1. Product Overview ………………………………………………………………………………………. 5
1.1 Product Description……………………………………………………………………………… 5 1.2 Schematic Diagram……………………………………………………………………………… 7 1.3 Ordering Code……………………………………………………………………………………… 8
2. Initial Preparation………………………………………………………………………………………. 9
2.1 Unpacking and Inspection ……………………………………………………………………. 9 2.2 Damage in Shipment …………………………………………………………………………… 9 2.3 Standard Contents ………………………………………………………………………………. 9 2.4 Warranty Information …………………………………………………………………………… 9
3. Specifications…………………………………………………………………………………………..11
3.1 Electrical, Mechanical and Environmental ……………………………………………11 3.2 -1 Position Output Option, MR265 Loop-Powered Based ………………………12 3.3 -E Position Output, Absolute Encoder-Based…………………………………………12 3.4 Test Summary…………………………………………………………………………………….13
4. Installation Guidelines ………………………………………………………………………………14
4.1 Mounting The Enclosure ……………………………………………………………………..14 4.1.1 MR221/MR222 Aluminum Housing Models ………………………………….14 4.1.2 MR221/MR222 Stainless Steel Housing Models …………………………..14
4.2 Coupling To Customer Equipment’s Shaft(s) ………………………………………..15 4.3 Wiring To The Limit Switch…………………………………………………………………..16 4.4 Programming The Cams………………………………………………………………………18 4.5 Connecting and Programming the 4-20mA Position Output Options ………19
4.5.1 Programming the -1 MR265 4-20mA Position Output Option ………….20 4.5.2 Programming the -E Encoder-based 4-20mA Position Output Option.22 4.6 Closing and Sealing the Enclosure……………………………………………………….22
5. Maintenance and Service………………………………………………………………………….23
5.1 Replaceable Parts ………………………………………………………………………………23 5.2 Replacing Microswitches …………………………………………………………………….23 5.3 Lubricating Bevel Gear Junction (MR222 Only) …………………………………….25 5.4 Lubricating Cam Switch Gear Junction …………………………………………………26
6. Reference Drawings………………………………………………………………………………….27

Page 3 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

List of Figures
Figure 1. Features of the MR221 One-Ended Geared Limit Switch…………………….. 6 Figure 2. Features of the MR222 Two-Ended Geared Limit Switch…………………….. 6 Figure 3. MR221-MR222 Schematic Diagram ………………………………………………….. 7 Figure 4. Mounting Hole Pattern for Aluminum Housings…………………………………14 Figure 5. Mounting Hole Pattern for Stainless Steel Housings ………………………….14 Figure 6. Reference Dimensions For Shaft ………………………………………………………15 Figure 7. Wiring to the Phoenix COMBICON Terminal Blocks ……………………………16 Figure 8. Cam Programming Examples for <180° (A) and 180° (B)………………..18 Figure 9. How to Program Cams with the PSN Programming Tool …………………….18 Figure 10. How to wire MR22X-1 MR265 Position Output…………………………………20 Figure 11. How to set 4mA/20mA points and Direction of MR265 Output ………..21 Figure 12. How to set 4mA point for -E Encoder Position Output ……………………….22 Figure 13. Micronor P/N 6099.22.846 Replacement Switch……………………………23 Figure 14. How to replace Microswitch ……………………………………………………………24 Figure 15. Location of the Bevel Gears and Cam Switch Gear Junctions …………..25
List of Tables
Table 1. Wiring Table Template ………………………………………………………………………17

Page 4 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

1. Product Overview
1.1 Product Description
MICRONOR MR221/MR222 series Heavy Duty Geared Limit Switches are designed for use in machine applications requiring the highest quality, industrial-grade CE approved limit switches. These heavy duty switches can be used in applications with side loads as high as 200 lbf (890 N) and axial loads up to 80 lbf (360 N). Enclosure options include NEMA 4 (watertight) or NEMA 4X (watertight and corrosion resistant), ensuring the best product match for the operating environment. This new product line draws upon Micronor’s 30+ years expertise in electromechanical control and sensor design ­ including custom engineered feedback units, motorized potentiometers, encoders, resolvers and proprietary stepless CAM-switch technology.
Rotary limit switches are used in machinery and mechanisms where motion is expressed in rotary motion. The primary purpose of a rotary limit switch is to control the intermediate or end limits of linear or rotary motion. The switch is often used as a safety device to protect against accidental damage to the equipment. Applications range from machine tools in factory environments to cranes and hoists operating in the harsh environments of rail yards and sea ports.
Features: · Combines gear reducer, coupling and cam switches into one compact unit · Limit switches mechanically decoupled from heavy duty drive shaft ­ provides reliability and accuracy · One-ended (MR221) or two-ended (MR222) models · NEMA 4-rated die cast aluminum enclosure or NEMA 4X stainless steel enclosure · Standard 1/2″ stainless steel shaft with #404 Woodruff Key slot. · Industrial grade, heavy duty bearings · Protective shaft cover provided for installations where only one end is used · 2, 4, 6 or 8 cam switch channels · Easy to replace, heavy duty limit switches · Two conduit wiring connections tapped for ½” NPT · 4-20mA position output options ­ Transducer or Encoder based

Page 5 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

Two ½” NPT Conduit Hubs and Cover Plugs
Are Pre-Installed
Ground Points. One Copper Grounding Lug Screw Provided.
Internal Storage Holder For PSN Cam
Programming Tool

Heavy Duty NEMA/UL Type 1/4/4X
Enclosures: Aluminum or Stainless

One-Ended High Strength Stainless
Steel Shaft – ½” with #404 Woodruff Key Slot. One Woodruff Key Supplied With Unit.

Heavy Duty Sealed Ball-
Bearings

Figure 1. Features of the MR221 One-Ended Geared Limit Switch

Easy Wiring To Phoenix COMBICON Wiring Strips. Also Supplied
With Pre-wired jumper.
0-360° Indicator Dial For Ease Of Cam Programming
Double Cams Are Easily Programmed With Supplied PSN Cam Programming
Tool
Individual Microswitches Are Field Replaceable
Using A Slotted Screwdriver

Two ½” NPT Conduit Hubs and Cover Plugs
Are Pre-Installed
Ground Points. One Copper Grounding Lug Screw Provided.
Internal Storage Holder For PSN Cam
Programming Tool

Heavy Duty NEMA/UL Type 1/4/4X
Enclosures: Aluminum or Stainless

Two-Ended High Strength Stainless Steel Shaft ½” with #404 Woodruff Key Slot. Two Woodruff Keys Supplied With Unit.

Heavy Duty Sealed Ball-
Bearings

Figure 2. Features of the MR222 Two-Ended Geared Limit Switch

Easy Wiring To Phoenix COMBICON Wiring Strips. Also Supplied
With Pre-wired jumper.
0-360° Indicator Dial For Ease Of Cam Programming
Double Cams Are Easily Programmed With Supplied PSN Cam Programming
Tool
Individual Microswitches Are Field Replaceable
Using A Slotted Screwdriver

Page 6 of 36

MICRONOR AG
1.2 Schematic Diagram

MR221/MR222 Series Geared Limit Switch User Guide

Figure 3. MR221-MR222 Schematic Diagram Page 7 of 36

MICRONOR AG
1.3 Ordering Code

MR221/MR222 Series Geared Limit Switch User Guide

MR2221 Alum

MR222 Alum

MR221-X SS

MR222-X SS

Page 8 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

2. Initial Preparation
2.1 Unpacking and Inspection
The unit was carefully inspected mechanically and electrically before shipment. When received, the shipping carton should contain the following items listed below. Account for and inspect each item before the carton is discarded. In the event of a damaged instrument, write or call your nearest MICRONOR office in either the USA. or Switzerland. Please retain the shipping container in case reshipment is required for any reason.
2.2 Damage in Shipment
All instruments are insured when shipped by MICRONOR. If you receive a damaged instrument you should:

1. Report the damage to your shipper immediately. 2) Inform MICRONOR 3) Save all shipping cartons.
   Failure to follow this procedure may affect your claim for compensation.
   2.3 Standard Contents
   The MR221 / MR222 series limit switches consist of the configurations described by the following part number format:
   2.4 Warranty Information
   MICRONOR warrants this product to be free from defects in material and workmanship for a period of twelve (12) months from date of shipment. During the warranty period we will, at our option, either repair or replace any product that proves to be defective.
   To exercise this warranty, write or call MICRONOR SENSORS, or directly contact MICRONOR AG in Switzerland. You will be given prompt assistance and return instructions. Send the instrument, transportation prepaid, to the indicated service facility. Repairs will be made and the instrument returned transportation prepaid. Repaired products are warranted for the balance of the original warranty period, or at least 90 days.
   Limitations of Warranty
   This warranty does not apply to defects resulting from unauthorized modification or misuse of any product or part. This warranty also does not apply to optical interfaces, cable assemblies, fuses or AC line cords.
   Page 9 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

This warranty is in lieu of all other warranties, expressed or implied, including any implied warranty of merchantability of fitness for a particular use. MICRONOR or MICRONOR SENSORS shall not be liable for any indirect, special or consequent damages.

For Sales & Support in North America: Micronor Sensors, Inc. 2085 Sperry Ave, Suite A-1 Ventura, CA 93003 USA

Phone +1-805-389-6600 Email [email protected] URL www.micronor.com

Manufacturer and Worldwide Sales & Support:

Micronor AG

Phone +41-44-843-4020

Pumpwerkstrasse 32

Email [email protected]

CH-8015 Regensdorf

URL www.micronor.ch

SWITZERLAND

Page 10 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

3. Specifications
3.1 Electrical, Mechanical and Environmental

Parameter Enclosure Ratings

Specification

Notes

UL/NEMA Type 1/4/4X Choice of die cast aluminum with powder coat

+ IP66

finish or stainless steel housing

Switch Rating
Cam Programming Mechanical Rating
Wire Range Temperature

Mechanical Life Resistive Load
Inductive Load
Motor Load Temperature 1-2 (COM-NC) 1-3 (COM-NO) Repeatability Max RPM Mechanical Life Max Side Load
Max Axial (Thrust) Load
Bearing Life
24-10 AWG
Storage Temperature Operating Temperature

NOTE: IP rating applies only when unit installed, connected and torqued properly. 10 x 106 cycles (typical) 230 VAC/6 A Continuous/10 A Momentary 24 VDC/6 A Continuous/10 A Momentary 230 VAC/Power Factor 0.7/3 A 125 VDC/0.5 A 80 VDC/0.75 A 40 VDC/1 A 24 VDC/3A 230 VAC/Power Factor 0.85/10 A
-40°C to +85°C
With Cam Valley Profile: 4°…180° (1…50%) With Cam Peak Profile: 4°…356° (1…99%) 1.8° 3000 RPM 10 x 106 cycles (typical) 890 N (200 lbf) to 500 RPM; 445 N (100 lbf) to 1800 RPM 360 N (80 lbf) to 500 RPM; 185 N (40 lbf) to 1800 RPM 10 years (87,660 hours) continuous running with 350 N (78 lbf) side load at 1000 RPM Connections via Phoenix COMBICON Type MKDS 5/3–6,35 (1714968) printed circuit terminal blocks with screw connection
-30°C to +70°C -15°C to +60°C

Specifications subject to change without notice

Page 11 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

3.2 -1 Position Output Option, MR265 Loop-Powered Based

The MR22X-1 (MR265) option is a precision, 2-Wire, potentiometer-based, loop- powered 4-20mA output option.

Parameter MR265
Angular Travel
Ext Burden Resistance Loop Voltage Requirements Linearity/Accuracy Temperature

Specification
Potentiometer-based transducer
355° (equivalent to 98.6% of usable gear ratio) 500

Notes 4mA point programmable via Offset trimpot 20mA point porgrammable via Span trimpot Equivalent to 98.6% of usable gear ratio, rThis represents the 5° dead spot between the two ends of potentiometer.

24-30 V DC, absolute max ratings ±0.5%
0°C to +70°C

Typical 15mA @ 24V DC (no load)
MR22X operating/storage temperature derated due to MR265 electronics rating

Specifications subject to change without notice

3.3 -E Position Output, Absolute Encoder-Based

The MR22X-E is a precision, absolute encoder based, 4-wire interface option (2-Wire power + 2Wire current loop). The single turn, absolute encoder is in series with the cam switches geared to cover the

Parameter Encoder
Angular Travel Ext Burden Resistance Loop Voltage Requirements Linearity Accuracy (INL) Resolution Analog Accuracy

Specification ST Absolute encoder with 4-20mA output
360°C 500
24-30 V DC, absolute max ratings 0.15% ±0.0878° ( 12 bit) 13 Bits ±20 A @ 20mA

Notes Posital UCD-AC105-0013-R060-2TW Type: Magnetic, single turn, absolute encoder Input 1: Set1/Direction Input 2: Set2/Zero Set Continuous
Typical 15mA @ 24V DC (no load)
@ 20 mA = ±20 A at 20 mA (with ideal power supply)

Specifications subject to change without notice

Page 12 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

3.4 Test Summary

Parameter Temperature Test Dielectric Voltage Withstand Test Resistive Load Test

Specification Standard Standard
Standard

AC

DC

Inductive Load Test Standard

Hosedown Test Bending Test Torque Test

AC DC Standard Standard Standard

UL Product Category UL Category

UL Test Report

UL File No.

UL Product Identity UL Control No.

UL ID Code UL Control No.

Notes Per UL 508, Section 43 Per UL 508, Section 49
Per UL 508, Sections 45 (Overload) and 46 (Endurance) Endurance Test at 240 VAC/6 A and Overload Test at 240 VAC/9A Endurance Test at 24 VDC/6 A and Overload Test at 24 VDC/9 A Per UL 508, Sections 45 (Overload) and 46 (Endurance) 240 VAC and 120 VAC (Std Duty B300 Rating) 24 VDC/2 A (Pilot Duty Rating) Per UL 50, Section 35, Type 1/4/4X Per UL 50, Section 46 Per UL 50, Section 46
Auxiliary Devices (NKCR, NKCR7) E302565 (Certified for U.S. and Canada) NOTE: UL/cUL listing was discontinued 1-Jan-2015 and CE mark added in its place. Industrial Control Equipment 37V8

UL General Installation Instructions 1. Use copper conductors rated 60°C 2. Tighten terminal torque is 5-7 in-lbs 3. Unused conduit ports must be properly sealed to prevent moisture and water leakage into the unit.
Specifications subject to change without notice

Page 13 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

4. Installation Guidelines
4.1 Mounting The Enclosure
Use appropriate hardware to mount limit switch enclosure. On the mounting screws, be sure to use caulking or other sealant appropriate for the operating environment and to ensure proper sealing.

4.1.1 MR221/MR222 Aluminum Housing Models The unit is designed to mount to a flat surface using hole pattern shown in Figure 4.

Figure 4. Mounting Hole Pattern for Aluminum Housings 4.1.2 MR221/MR222 Stainless Steel Housing Models The unit is designed to mount to a flat surface using hole pattern shown in Figure 5.
Figure 5. Mounting Hole Pattern for Stainless Steel Housings Page 14 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

4.2 Coupling To Customer Equipment’s Shaft(s)
In general, heavy duty/zero backlash couplings should be used to couple the limit switch’s shaft to the customer’s equipment (usually the drum or overspeed sensor).
When ordering from a particular coupling supplier, be sure to describe the limit switch’s shaft characteristics as “12.7mm (0. 5-inch) with #404 Woodruff Key”. You will NOT need to purchase separate #404 Woodruff Keys as these are already supplied with the unit). A reference drawing of the shaft end is shown in Figure 6 below. .

3.18mm +0.00/-0.05 (0.125″)

Shaft

404 Woodruff Key

12.7 mm +0.00/-0.5 (0.50″)

14.20 mm +0.00/-0.10 (0.559″)

Figure 6. Reference Dimensions For Shaft

8mm (0.315″)
31.5mm (1.24″)

To order a coupling from most suppliers, the process is to select the coupling style (heavy duty/zero backlash) and the shaft dimensions (and any special features) of both sides. Designating Side A for the Micronor limit switch and Side B for the customer’s equipment (typically the drum or over speed sensor):
· Side A (Micronor side) for 12.7mm (0.5-inch) shaft with #404 Woodruff Key · Side B (Customer equipment, specify shaft OD, shape and any key/slot features)
Be sure to follow the coupling manufacturer’s assembly and installation instructions. This includes using the proper tools and torque values for securing all screws and set-screws.
IF YOU ARE NOT USING BOTH SHAFT ENDS of the Limit Switch…
· Be sure to install and secure a protective shaft cover over the unused shaft. · For safety reasons, the unused shaft end should never be left uncovered.

Page 15 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

4.3 Wiring To The Limit Switch
Important wiring notes
· Use copper conductors rated 60°C or higher · Tighten terminal torque is 5-7 in-lbs
· Unused conduit ports must be properly sealed to prevent moisture and water leakage
into the unit.
Electrical connections should be performed consistent with governing electrical code and following these steps:
1. Pre-plan cam programming and wiring by filling in Wiring Table label on inside of cover. Select wire type, color and size consistent with the project requirements and safety codes. Copper conductors should be rated 60°C or higher.
2. According to the wiring table, determine how much of the provided Commons wire jumper will be used. Clip off any unused portion and discard all clippings.
3. Standard ½” NPT conduit can be coupled directly to the supplied conduit hubs.
4. Pull wire through conduit ports.
5. Strip wire ends approximately 5-6mm (0,22″) length. Using a slotted screwdriver, loosen terminal contacts of Phoenix COMBICON wiring block(s), insert wire end and close contact by tightening screw (see Figure 7).
6. If not using one of the conduit hub ports, be sure to properly seal the opening using the supplied threaded plug and proper sealant.

Figure 7. Wiring to the Phoenix COMBICON Terminal Blocks Page 16 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

Table 1. Wiring Table Template

Contact Switch No. No.

Contact Type

1

Switch 1 Common

2

Switch 1 NC

3

Switch 1 NO

4

Switch 2 Common

5

Switch 2 NC

6

Switch 2 NO

7

Switch 3 Common

8

Switch 3 NC

9

Switch 3 NO

10

Switch 4 Common

11

Switch 4 NC

12

Switch 4 NO

13

Switch 5 Common

14

Switch 5 NC

15

Switch 5 NO

16

Switch 6 Common

17

Switch 6 NC

18

Switch 6 NO

19

Switch 7 Common

20

Switch 7 NC

21

Switch 7 NO

22

Switch 8 Common

23

Switch 8 NC

24

Switch 8 NO

25

Encoder

+0V (Gnd)

26

Encoder

+24VDC

27

Encoder

Set1/Direction

28

Encoder

Set2/Zero Set

29

Encoder

I+

30

Encoder

I- (Gnd)

31

No Connection —

32

No Connection —

33

No Connection —

34

No Connection —

35

No Connection —

36

No Connection —

Cam Program (Input shaft degrees
or dial setting)

ON

OFF

Wire Color and Size

Signal Name

Another Note About Foreign Objects and Debris (FOD)
· Do not allow any FOD (including wire clippings) to be left behind in the enclosure.
· FOD could become lodged in the switch mechanism and cause an electrical short or
other system failure

Page 17 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

4.4 Programming The Cams

The Micronor Programmable Cam Switches are designed to be both versatile and easy to operate. However, initial planning is required for cams to be programmed to function as desired. Due to the design of the cam, switches cannot be engaged for more than 180°. If the system requires that the switch does not make contact for more than 180°, the normally closed (NC) contact must be wired.
As shown in Example A, a system might require that the connection for a switch be made from 0° to 70° and there be no connection from 71° to 359°. To accomplish this, the switch must be wired in the normally closed position.
As shown in Example B, a system that requires a connection for 290°, the normally open contact must be wired so that a connection is made when the switch is engaged, and no connection is made when the switch is disengaged.

Example A

Example B

COMMON NC

COMMON NO

Figure 8. Cam Programming Examples for <180° (A) and 180° (B)

Figure 9. How to Program Cams with the PSN Programming Tool Page 18 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

The following instructions may be used to program the start and stop times of each switch using the supplied PSN (black) cam programming tool:

1. Turn external shaft to the desired START position via dial setting. Insert PSN key ith the numbered side away from the cam and the notched side towards the cam.
2. While gently applying pressure against the cam with the key; rotate the cam to the desired position.
3. Turn external shaft to the desired STOP position, flip over the PSN key and repeat steps 1 and 2 on the other side of the cam.
4. Test the unit to confirm that the switches engage (START) and disengage (STOP) at the appropriate positions.

4.5 Connecting and Programming the 4-20mA Position Output Options
The MR221-MR222 Gear Limit Switch family includes two options for continuous position feedback as a 4-20mA analog output:
· -1 MR265 Loop-Powered 4-20mA Output Option · -E Encoder-based 4-20mA Output Option

Page 19 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

4.5.1 Programming the -1 MR265 4-20mA Position Output Option
The MR22X-1 (MR265) 4-20mA Position Output Option is a 2-Wire or loop-power feedback option. That is, the loop is powered in series and provides the advantage that this feedback option can be powered remotely from the PLC location. In contrast, the MR22X-E option is a 4-wire sensor design requiring power be located near the MR22X unit.
The schematic diagram of Figure 10 shows how the I+/I- current outputs are wired. A 24V DC supply must be inserted in series to power the current loop.
The MR265 Transducer option is based on a PCB Controller and an internal single turn potentiometer mounted on the cam shaft. The analog output is adjustable over a mechanical range of 0° to 355° corresponding to the MR22X’s gear ratio less 1.4% (equivalent to 5° not covered by potentiometer) and controller by two accessible trimpots (Offset and Span) and two jumpers (Direction), Offset and Span.
As shown in Figure 11, the analog output may be adjusted anywhere between 4mA to 20mA within the yellow shaded area along with the desired electrical direction (4-20mA or 20-4mA) controlled onboard jumpers.

Figure 10. How to wire MR22X-1 MR265 Position Output Page 20 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

Figure 11. How to set 4mA/20mA points and Direction of MR265 Output

Page 21 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

4.5.2 Programming the -E Encoder-based 4-20mA Position Output Option
As shown in Figure 12 below, the MR221-MR222 Gear Limit Switch family also includes an option for 4-20mA position feedback via an integrated single-turn absolute encoder. The 4-20mA output is scaled over the full # of turns (gear ratio) of the ordered limit switch. A programmable input (Set2/Zero Set) to the encoder allows the 4.01mA point to be electronically (versus mechanically) set once the unit is installed in the field. It is recommended that the Zero Set point correspond to the 0 point on the internal dial scale.

Figure 12. How to set 4mA point for -E Encoder Position Output
4.6 Closing and Sealing the Enclosure
Apply Proper Sealing Techniques To Prevent Damaging Ingress
· On the mounting screws, be sure to use caulking or other sealant appropriate for the operating environment.
· If not using one of the conduit hub (wiring) ports, be sure to properly seal the opening
using the supplied threaded plug and proper sealant.
· Failure to apply proper sealing techniques voids product warranty.
Page 22 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

5. Maintenance and Service
Under normal operating conditions and use, the MR221/MR222 Limit Switches require no maintenance. The only replaceable component part is the microswitch (consult Section 5.2). Cleaning and re-lubrication of the internal, exposed gears might be necessary if the unit had not been properly sealed and the grease has become contaminated.
Otherwise, it is more practical to replace the entire unit.

5.1 Replaceable Parts
The following replacement accessory part is available from Micronor: · PSN Cam Programming Key, Micronor P/N PSN (consult Section 4.4 for application)
The following replacement component part is available from Micronor: · Microswitch, Micronor P/N 6099.22.846 (consult Section 5.2 for application)
The following replacement gear lubricant is available from Etna-Bechem Lubricants Ltd: · Contact: Etna-Bechem Lubricants Ltd. o 16824 Park Circle Dr, Chagrin Falls, OH 44023 o Tel 440-543-9845, Fax 440-543-1789 o Email [email protected], URL www.etna.com · Type BERULUB FH 28 (Multipurpose synthetic specialty grease for metals and polymers, rated -31°F/320°F or -35°C/160°C, also consult Section 5.2 for application)

5.2 Replacing Microswitches
Age and heavy duty cycles can eventually wear out the microswitches. Replacements can be ordered using Micronor P/N 6099.22.846 (shown in Figure 13 below).

Figure 13. Micronor P/N 6099.22.846 Replacement Switch Page 23 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

To replace a microswitch, follow these steps while consulting Figure 14:
1. Using a large slotted or Phillips screwdriver, remove cover by loosening the 4 mounting screws located on top.
2. Using a slotted screwdriver, loosen (but do not remove) the two screws holding the rear mounting flange of the cam switch subassembly. To gain access to the microswitches, grab subassembly and pull back to disengage from the two mounting screws loosen in the previous step.
3. Remove the two screws holding the microswitch to the frame of the cam switch subassembly. Replace with the new switch and mount using the same screws.
4. Gently pull the FASTON receptacle connections off the terminals of the old switch and insert onto the corresponding terminals of the new switch.
5. Align the cam switch subassembly via the front alignment pins and the two back mounting screws (that were loosened in Step 2). Tighten the two bottom mounting screws.
6. Replace cover and tighten the four mounting bolts.

Figure 14. How to replace Microswitch Page 24 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

5.3 Lubricating Bevel Gear Junction (MR222 Only)
Under normal conditions, it is not necessary to lubricate the bevel gears used on the MR222 models (see Figure 15, couples the main shaft to the cam switch shaft). However, if the inside becomes accidentally contaminated, it would become necessary to clean and lubricate gears. Follow these steps:
1. Disconnect external couplings to both ends of the main shaft. This is done to facilitate manual rotation of the gears in the next step.
2. While manually rotating the main shaft, clean inside case and exposed gears using lintless swabs/wipes and reagent grade IPA (isopropyl alcohol).
3. While rotating the shaft, apply a moderate amount of grease all around and over each gear.

Bevel Gear Junction
Cam Switch Gear Junction
Figure 15. Location of the Bevel Gears and Cam Switch Gear Junctions

Page 25 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

5.4 Lubricating Cam Switch Gear Junction
Under normal conditions, it is not necessary to lubricate the cam gears (see Figure 15, couples from the gear reduction module to the main shaft of the cam switch subassembly). However, if the inside becomes accidentally contaminated, it would become necessary to clean and relubricate the gears. Follow these steps:
1. Disconnect external couplings to both ends of the main shaft. This is done to facilitate manual rotation of the gears in the next step.
2. Using a slotted screwdriver (consult Figure 14), loosen (but do not remove) the two screws holding the rear mounting flange of the cam switch subassembly. To gain access to the microswitches, grab subassembly and pull back to disengage from the two mounting screws loosen in the previous step. This will expose the two gears ­ one that is attached to the gear box and the other attached to the cam switch shaft.
3. Clean inside of case and the two gears using lintless swabs/wipes and reagent grade IPA (isopropyl alcohol).
4. While rotating the shaft, apply a moderate amount of grease all around and over each gear.
5. Align the cam switch subassembly via the front alignment pins and the two back mounting screws (that were loosened in Step 2). Tighten the two bottom mounting screws.

Page 26 of 36

MICRONOR AG

MR221/MR222 Series Geared Limit Switch User Guide

6. Reference Drawings
The following pages provide reference drawings for each model: · Standard MR221 in Aluminum Housing, 925x.xx.xxx 2 pages · Standard MR221-E in Extended Aluminum Housing, 9350.03.373, 1 page · Standard MR222 in Aluminum Housing, 928x.xx.xxx, 2 pages · Special MR221-X in Stainless Steel Housing, 926x.xx.xxx, 2 pages · Special MR222-X in Stainless Steel Housing, 929x.xx.xxx, 2 pages

Page 27 of 36

6 D

5
F

91 (3.583″) 70 (2.756″)

F

4

3

2

3,18

+ –

0 0,05

(0.125″)

30 (1.181″)

P12,7 (0.5″)
F-F ( 1 : 1 )
P14 (0.551″) P7 (0.276″)

45 (1.772″) 14,2 (0.559″)

50 (1.969″)

19 (0.748″) 22,3 (0.878

C

E-E

31,5 (1.240″) 8 (0.315″)

215 (8.465″) 125 (4.921″) 18 (0.709″)

E

B

E

1 D
C
B

110 (4.331″)

160 (6.299″)

0 0,05

A 6

P12,7

+ –

240 (9.449″) 260 (10.236″) 309,6 (12.189″)

5

4

Ersetz durch Ersatz fr g f e d c b 0-Series a Prototype
Modifikation
3

20.10.06 MAZU 20.06.06 MAZU Datum Name

Stcklisten Nr.

Datum Gez. 23.10.2006 Kontr. Frei.

Name M.Zrcher

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39

2

|nderungen vorbehalten / subject to modification

M- aterial Massstab
2:1

Objekt / Bezeichnung
MR221 (Die Cast Aluminum)
Gearded Limit Switch Single Shaft A
Zeichnungs Nr.

1

6

5

4

3

2

1

D

D

10 (0.394″)

240 (9.449″) 220 (8.661″)

10 (0.394″)

C

C

110 (4.331″) 90 (0.394″) 33 (1.299″)

B

B

Ersetz durch Ersatz fr

Stcklisten Nr.

M- aterial

g

Datum

Name

Massstab Objekt / Bezeichnung

f

Gez. 23.10.2006

M.Zrcher

2:1 MR221 (Die Cast Aluminum)

A

e

Kontr.

d

Frei.

Gearded Limit Switch Single Shaft A

c b 0-Series a Prototype
Modifikation

20.10.06 MAZU 20.06.06 MAZU Datum Name

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39

Zeichnungs Nr.

6

5

4

3

2

1

91 (3.582″) 70 (2.755″) 14,2 (0.559″)

6

5

3,18

–

0 0,05

B

(0.125″)

D

P12,7 (0.5″)

B-B ( 1 : 1 )

B

45 (1.771″)

31,6 (1.244″)

18 (0.708″)

C

22 (0.866″)

33 (1.299″)

B 8 (0.314″)

A |nderungen vorbehalten / subject to modification

6

5

4

3

2

1

D

31 (1.220″)

225 (8.858″) 135 (5.314″)

45 (1.771″)

P14 (P0.551″) P7 (P0.275″) C

110 (4.330″) 160 (6.299″)
181 (7.125″) 19 (0.748″) 50 (1.968″)

C

C

C-C ( 1 : 2 )
B

340 (13.385″)

360 (14.173″)

409,6 (16.125″)

Ersetz durch Ersatz f¯r

St¯cklisten Nr.

Material

g

Datum

Name Massstab Objekt / Bezeichnung

f

Gez. 26.04.2019 R. Schubert 1 : 2

e

Kontr.

d

Frei.

c

MICRONOR_

b

CH – 8105 Regensdorf

a

T. 044 843 40 25 / Fax. 044 843 40 39

Aenderungen Datum Name www.micronor.ch

KWG360 L8 U25:1 ESA36 Analog

Zeichnungs Nr.

A

9350.03.373

We reserve all right in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden Wir behalten die Rechte f¯r alle enthaltenen Inforamtionen, die Verwendung oder die Weitergabe an dritte Personen ist strengstens Verboten

Subject for modification / |nderungen vorbehalten

4

3

2

1

6

5

4

3

2

91,00 (3.583″)

3,18

+ –

0,00 0,05

F

D n12,70 (0.5″)

(0.559″)

F-F ( 1 : 1 )

F

+ 0,00 – 0,10

70,00 (3.543″) 45,00 (1.732″)

260 (10.236″)

14,53

n14,00 (0.551″)

E-E

n7,00 (0.276″)

50,00 (1.969″)

C Woodruf Key #404, 2 plcs

215(8.465″)
125 (4.921″) 39 (1.535″)

31,00 (1.22″)

1 D
C

19,00 (0.748″) 22,3 (0.878″)

7 (0.315″)

259 (10.008″) 31,50 (1.240″)
196 (7.677″) 18,00 (0.709″)

B
A 6

E

B

E

110 (4.331″) 160 (6.299″)

n12,70

+ 0,00 – 0,05

(0.5″)

240(9.449″)

5

4

Änderungen vorbehalten / subject to modification

Ersetz durch Ersatz für

Stücklisten Nr.

M- aterial

g

Datum

Name

Massstab Objekt / Bezeichnung

f

Gez. 20.10.2006

M.Zürcher

2:1

e d

Kontr. 01.11.2006

kjo

Frei. 01.11.2006

kjo

MR222 Serie Aluminium

A

c b 0-Series a Prototype
Modifikation

20.10.06 MAZU 22.06.06 MAZU Datum Name

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39

Zeichnungs Nr.
928x.06.000

3

2

1

6

5

4

3

2

1

D

D

3,00 (0.118″)

220,00 (8.661″)

10,00 (0.394″)

C

C

15,00 (0.591″)

110,00 (4.331″) 90,00 (3.543″)

B

B

240,00 (9.44″)

Ersetz durch Ersatz fr

Stcklisten Nr.

M- aterial

g

Datum

Name

Massstab Objekt / Bezeichnung

f

Gez. 20.10.2006

M.Zrcher

2:1

A

e d

Kontr. 01.11.2006

kjo

Frei. 01.11.2006

kjo

MR222 Serie Aluminium

A

c b 0-Series a Prototype
Modifikation

20.10.06 MAZU 22.06.06 MAZU Datum Name

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39

Zeichnungs Nr.
928x.06.000

6

5

4

3

2

1

158 (6.220″)

107 (4.213″) 101 (3.976″) 87 (3.425″) 58,5 (2.283″)

58,5 (2.303″)

100,5 (3.957″)

2 (0.079″)

6
B
D
B
C 18 (0.748″)
31,5 (1.240″) 8 (0.315″)
B
A 6

n12,7

+ –

0 0,05

14,2 (0.559″)

5

4

3

2

260

B-B ( 1 : 1 )

3,18

+ –

0 0,05

(0.125″)

42 (1.654″)

12,7

+ –

0 0,05

(0.5″)

220 (8.661″) 160 (6.299″)
n6,8

1 D
C
B

110 (4.331″)

300 (11.811″) 312 (12.283″)

5

4

Ersetz durch Ersatz für g f e d c b 0-Series a
Modifikation
3

20.10.06 MAZU 20.06.06 MAZU Datum Name

Stücklisten Nr.

Datum Gez. 23.10.2006 Kontr. 01.11.2006 Frei. 01.11.2006

Name M.Zürcher kjo kjo

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39
2

Änderungen vorbehalten / subject to modification

M- aterial

Massstab Objekt / Bezeichnung

2:1

MR221 Serie Edelstahl

A

Zeichnungs Nr.

926x.06.000

1

6

5

4

3

2

1

D

D

6 (0.236″)

312 (12.283″) 300 (11.811″)

C

C

159 (6.260″) 110 (4.331″) 58,5 (2.303″) 34 (1.339″)

B

B

Ersetz durch Ersatz für

Stücklisten Nr.

M- aterial

g

Datum

Name

Massstab Objekt / Bezeichnung

f

Gez. 23.10.2006

M.Zürcher

2:1

A

e d

Kontr. 01.11.2006

kjo

Frei. 01.11.2006

kjo

MR221 Serie Edelstahl

A

c b 0-Series a
Modifikation

20.10.06 MAZU 20.06.06 MAZU Datum Name

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39

Zeichnungs Nr.
926x.06.000

6

5

4

3

2

1

6
39 (1.535″) D

5 260 (8.465″)

107 (4.213″) 101 (3.976″) 87 (3.425″) 56 (2.205″)

220 (8.661″)
170 (6.693″) C
39 (1.535″)

4

3

2

(0.559″)

A-A ( 1 : 1 )

3,18

+ –

0 0,05

(0.125″)

+0 – 0,01

A

14,2

12,7 (0.5″)
A

8 (0.315″) 2 (0.079″)

22,3 (0.878″)

P6,8 B

42 (1.654″)

1 D
C
B

110 (4.331″) 158 (6.220″)

259 (10.008″) 196 (7.677″)

19 (0.748″)

A 6

31,5 (1.240″)

Woodruf Key #404, 2 plcs

P12,7

+ –

0 0,05

(0.5″)

300 (11.811″)

5

4

Ersetz durch Ersatz fr g f e d c b 0-Series a Prototype
Modifikation
3

20.10.06 MAZU 22.06.06 MAZU Datum Name

Stcklisten Nr.

Datum Gez. 28.09.2006 Kontr. Frei.

Name M.Zrcher

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39

2

|nderungen vorbehalten / subject to modification
M- aterial Massstab Objekt / Bezeichnung
2:1 MR222 Series (Stainless Steel)
Geared Limit Switch Double Shaft A
Zeichnungs Nr.
1

6

5

4

3

2

1

312 (12.283″)

D 6 (0.236″)

300 (11.811″)

D

65 (2.559″)

24,5 (0.965″)

C

C

159 (6.260″) 110 (4.331″)

B

B

Ersetz durch Ersatz fr

Stcklisten Nr.

M- aterial

g

Datum

Name

Massstab Objekt / Bezeichnung

f

Gez. 28.09.2006

M.Zrcher

2:1 MR222 Series (Stainless Steel)

A

e

Kontr.

d

Frei.

Geared Limit Switch Double Shaft A

c b 0-Series a Prototype
Modifikation

20.10.06 MAZU 22.06.06 MAZU Datum Name

MICRONOR AG
CH – 8105 Regensdorf T. 044 843 40 25 / Fax. 044 843 40 39

Zeichnungs Nr.

6

5

4

3

2

1

References

• Metalworking Fluids, Coolants and Cutting Lubricants | ETNA Products
• Micronor: Faseroptische & Mechanische Sensoren - Micronor
• Micronor: Faseroptische & Mechanische Sensoren - Micronor
• Products - Micronor Sensors Inc.
• Products - Micronor Sensors Inc.

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