It changed an industry…

There are many reasons why the PCS-100 has become the number one sensor choice at so many facilities in North America and now, worldwide. We kept it simple, it works, it’s tough and it’s affordable. The PCS-100 is mechanically adjustable, which allows you to easily set or change the sensing needle sweep from 5° – 175° in either CW or CCW direction. We’ve also eliminated the need to use a miniature reversing gear box, subject to constant wear and tear. With a capability of over 80 cycles per minute, the PCS-100 will keep pace with your fastest machine.

Settings and Diagnostics

After mounting, set-up of the PCS-100 tool sensor is simple. Simply set the desired swing angle and swing direction for your application using the patented adjustment feature on the PCS-100 Sensor. Make sure the tool or object to be checked is located between the start and end position of the swing angle selected.

Now flick the selector switch on the SCU-100 Sensor Control Unit to correspond with the CW or CCW swing direction selected. If the sensing needle is allowed to travel to its end, indicating a broken tool (or missing object), a fault output is generated by the SCU-100 Sensor Control Unit, causing the machining to cycle stop or to be put in a feed hold. The SCU-100 Sensor Control Unit monitors the set-up of the PCS-100 System, and will indicate a System Fault if you have incorrectly set swing direction or if electronic failures occur between the PCS-100 Positive Contact Sensor and the SCU-100 Sensor Control Unit such as in the case of a cable disconnect or short.

The design of the PCS-100 System is such that it does not fault if the sensing needle is held back from contacting the tool or object being monitored. It will only fault when the tool breaks or the object is missing. This can avoid expensive nuisance faults in many applications.

One such application example is a chip nest condition that builds around the tool, where you don’t want the machine to stop until both the chip nest and tool actually break away. The PCS-100 System design is also great for CNC lathes or machining centers because it ignores common and significant tool-to-tool diameter differences. If you prefer a fault output when any deviation from the normal sensor swing occurs, the PCS-250 System is available.

The same PCS-100 System can be used to monitor free space, rather than object presence. In this scenario, simply moving the selector switch on the SCU-100 Sensor Control Unit to “RL” sets the system to operate in “Reverse Logic” mode, meaning the SCU-100 Sensor Control Unit will generate a fault output if there is an obstruction.

Control Box

One compact SCU-100 Sensor Control Unit is required for each PCS-100 Positive Contact Sensor utilized. The required supply voltage is 24VDC (250mA), and an optional 110-240VAC power supply is available for installations whereby 24VDC is not available. Separate ok and fault “dry contact” relay outputs are each rated at 2A, 250VAC. Mounting can be accomplished via the incorporated 35mm DIN Rail connector, or by using the two mounting holes.

Sensor Specifications

  • Object Presence Monitoring or Free Space Monitoring
  • Blue Anodized Aluminum Body
  • 5-175° mechanically adjustable swing range
  • Direct Drive (no gear box) High Precision DC Motor
  • CW or CCW swing direction by selector switch
  • Disregards tool-to-tool diameter differences
  • Completely sealed against liquid and solid contaminants (IP-67).
  • Speeds exceeding 80 cycles/minute
  • Maxi Life needle in standard or special length
    • Standard: 140mm (5.5 in.)
  • 90° or straight, molded 4 pin connector/cable
    • Cable lengths to 50m (164′)
    • Standard length is 5m (16′)
  • Micro tool and micro drill sensor capability

U.S. Patent #5,307,916

PCS-100 System Specifications: