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:
TÉCNICA
TEC-023

Electrical Control Modules Electrification

- “WEE” Equipment + Dinefer Mod. 3 Test cards-

Rev. Rev. Date Revision Motive

01 11/09/08 Revision of the items 1.1.1.; 1.1.2.; 1.1.3.;

Elaborated Approved

Table of Contents

1. Introduction..................................................................................................... 2
1.1. WEE Electrification / Dinefer Mod. 3 test cards ....................................... 2
1.1.1. Electrification sequence .................................................................... 2
1.1.2. Test points’ electrification .................................................................. 2
1.1.3. Module’s power supply electrification (+24V DC) .............................. 3
1.1.4. Connection of the module’s cable to the table’s test cards mesa...... 4
1.2. Electrical Schemes symbology ................................................................ 5
1.2.1. Modules’ generic electrical schemes................................................. 6
1.2.2. Specific modules’ electrical schemes .............................................. 14

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 1/15

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TEC-023

1. Introduction
The electrification of an electrical control module changes depending on the table test
cards and test equipment used.
The combination between Test equipment / test cards originates different
electrifications.

WEE test equipment with Dinefer Mod.3 test cards;

1.1. WEE Electrification / Dinefer Mod. 3 test cards

This electrification is Dinefer’s Standard Electrification, all the others are particular
cases based on the specifications of some clients.

1.1.1. Electrification sequence

The modules which are destined to WEE equipments respect the sequences established
on points 2.1. (for the ways and detections) and 2.2. (for the colours) of TEC-022
(general rules).

1.1.2. Test points’ electrification

To electrify the module’s test points we use female plugs (colour black) of 2, 4, 6, 8 and
10 terminals with pitch 2.54mm. The connection of these plugs to the cables (2, 4, 6, 8
and 10 wires) is established through a “male connector”.

Representative example of the module’s test points connection to the table’s test cards,
using connection cables.
For this example we will consider a module with 12 test points (10 ways + 1 detection).
To establish the connection two cables are used, one with 10 conductors and the other
with 2 conductors.

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 2/15

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TEC-023

Module Plug Cable Plug

Grey/Rose White Brown

1 1
Red/Blue 2 Brown 2 2 White
1

TABLE TEST CARDS

White 1 White Violet
1
Brown 2 Brown Black
Green Green Red
3
Yellow 4 Yellow Blue
Grey Grey Rose
5
Rose
6
Rose 1 1 Grey
Blue Blue Yellow
7
Red Red Green
8
Black Black Brown
Violet 9 Violet White 1
10

First Test point

Plugs Connection - Pitch 2.54

Sch.1 – Connection of the module’s test points to the cables

1.1.3. Module’s power supply electrification (+24V DC)

The module’s power supply is made through a lined female plug (colour black) and
pitch 2.54mm. The plug has four ways and obeys the following electrification sequence:

Black: 0V 1
Red: 24V
2
Brown: 0/24V 3
Green: 0V Led
4

Sch. 2 – Module’s power supply plug

1 – Black wire: 0V (Module’s ground);

2 – Red wire: 24V (Module’s positive);
3 – Brown wire: 0 or 24V – Special input, used only when necessary;
4 – Green wire: 0V Led.

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 3/15

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The connection between the module’s power supply plug (command) and the table’s
test cards is a 4 conductor with the identification “POWER”. The colour sequence for
the cable is: 1 – Blue; 2 – Red; 3 – Yellow; 4 – Grey.

TABLE TEST CARDS

Black 1 Blue Grey
1 Red
Red 2 Yellow
Yellow POWER POWER Red
3
Green 4 Grey Blue
1

Brown - Special Input when necessary

Sch. 3 – Connection of the module’s power supply plug to the cable

1.1.4. Connection of the module’s cable to the table’s test cards mesa

The cables which concern the test points as well as the modules’ power supply cables
(command) are connected on the table’s test cards, as indicated on the photo.

Module’s test point

cables

Module’s power supply cables

(command)

Fig. 1 – Connection of the module’s cables to the table’s Dinefer Mod. 3 test cards

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 4/15

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TEC-023

1.2. Electrical Schemes symbology

• K1 – Relay 24V DC

• K2 – Relay 24V DC

• K3 – Relay 24V DC

• Y1 – 5/2 Electro valve's coil

• Y2 – 5/2 Electro valve's coil

• S1 – Activation micro switch

• LD2 –Bicolour Led for leak test

• R1 – Limitation resistance for the led (2.2 KOhms)

• D1 – Diode (1N4148)

• PS1 – Pressure switch

• MS1 = MS2 – Magnetic position sensor

• MR1 – Magneto-resistant position sensor

• PCI1 – Dinefer Mod. Plate with 1 relay

• PCI2 – Dinefer Mod. Plate prepared for 2 relays.

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 5/15

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1.2.1. Modules’ generic electrical schemes

Components which characterize the electrification prepared for WEE test equipment
with Dinefer Mod.3 test cards.

EAO button – Led (Harness’s errors signaller) / Deactivation;

Fig. 2 – EAO button with Led (Cod. 21103000) Sch. 4 – EAO button’s scheme

Modules’ activation plate

Relé 24 VDC
1 29 28 27 26 25 24 23 22

NO NO
2 21

3 C C

4
NC K1 NC

5
- +

6 20

7 8 9 10 11 12 13 14 15 16 17 18 19

Fig. 3 – Activation plate Sch. 5 – Activation plate’s scheme

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 6/15

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TEC-023

The following schemes represent some typical electrical schemes of the modules
produced by Dinefer. This way we have:

1. Module only with activation;

The activation system used by Dinefer is characterized by the fact that the relay of the
activation plate remains self-power supplied. This way, it’s possible to avoid problems
with the consecutive activation and deactivation caused by the component’s oscillation
inside the module.
Notice that the electrical part of the activation system is independent from the electrical
part of the module’s detections, meaning that the effect of the self-power supply affects
exclusively the module’s activation. This way, in order for a detection to be OK it’s
required that the micro switch of that detection is pressed continuously.

Relay 24 VDC
0V 1 29 28 27 26 25 24 23 22

NO NO
2 21

3 C C R1
D1
4
NC K1 NC

5
- +

S1 6 20

7 8 9 10 11 12 13 14 15 16 17 18 19

Y1
24 VDC

Button

0V LED

Sch. 6 – Module only with activation

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 7/15

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2. Module with activation and detection on the 2nd relay;

This scheme is common on the electrification of clip modules and is characterized by

the fact that the micro switch which makes the module’s activation is the same as the
one which detects the clip.
A second relay is used in order to separate electrically the module’s activation from the
clip’s detection, this way, the module’s activation is self-power supplied but in order for
the detection signal to be OK it is required to press continuously the micro switch.

51

50

46
49
53

52

48
54

47

45
55

44
56

43
57

42
58
Relay 24 VDC

59
0V 1 29 28 27 26 25 24 23 22
Relay 24 VDC

60
NO NO
2 21

Detection
NO NO

61

41
3 C C R1
D1

62

40
C C
4
NC K1 NC

K2
63

39
5
- + NC NC

64

38
36
6 20
-
S1

33

34

37
30

31

35
32
7 8 9 10 11 12 13 14 15 16 17 18 19

Y1
24 V DC

Button

0V LED

Esq. 7 - Module with activation and detection on the 2nd relay

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 8/15

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3. Module with activation and leak test detection;

The leak test scheme is characterized by the pressure switch (output of electrical signal
depending on the pressure inside the module’s leak test’s chamber) and the bicolour Led
which gives visual information regarding the leak test (colour red – leak test NOK;
colour green – leak test OK).

51

50

46
49
53

52

48
54

47

45
55

44
56

43
57

42
58
Relay 24 VDC

59
0V 1 29 28 27 26 25 24 23 22
Relay 24 VDC

Leak Test Detection

60
NO NO
2 21
NO NO

61

41
3 C C R1
D1

62

40
C C
4
NC K1 NC

LD2

K2
63

39
5
- + NC NC

S1

64

38
36
6 20
-

33

34

37
30

35
31

32
7 8 9 10 11 12 13 14 15 16 17 18 19

Y1

24 V DC PS1

Botton

0V LED

Sch. 8 - Module with activation and leak test

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 9/15

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4. Module with activation and magnetic position sensor;

The Magnetic sensors are applied on the modules’ pneumatic cylinders, this way it’s
possible to detect some elements of the components by adjusting the sensor for the
intended cylinder’s stroke.
Frequent application: It’s common to use this type of sensors on the modules with
spacer closing. In these cases a sensor is placed on the spacer closing cylinder in order
to detect the spacer closing position.

Blue 1 (-)
1 (-) 2
Blue 2

Sch. 9 – Magnetic position sensor

51

46
50

49
53

52

48
54

47

45
55

44
56

43
57

42
58

Relay 24 V DC
59

0V

End of Stroke
1 29 28 27 26 25 24 23 22
Relay 24 VDC
NO NO
60

2 21
NO NO
61

41
C
3 C R1
D1
62

40
C C
4
NC K1 NC
K2
63

39
5
- + NC NC

S1
64

38
36

6 20
-
33
30

34

37
31

35
32

7 8 9 10 11 12 13 14 15 16 17 18 19

1 2

MS1
24 V DC
Y1

Button

0V LED

Sch. 10 - Module with activation and magnetic position sensor

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 10/15

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5. Module with activation and magneto-resistive position sensor;

This type of sensor has precisely the same function as the magnetic position sensor;
however, it is used for situations in which a higher precision is required.
These sensors use a PNP connection (positive output).

Brown 1 +
_ 1 (+)
Blue 2
2 (-)
Load
Black 3
3

Sch. 11 – Magneto – Resistive Sensor PNP connection

51

46
50
53

49
52

48
54

47

45
55

44
56

43
57

42
Relay 24V DC 58
59
0V 1 29 28 27 26 25 24 23 22
Relay 24V DC
NO NO
60

End of Stroke
2 21
NO NO
61

41
C C
3 R1
D1
62

40
C C
4
NC K1 NC
K2
63

39
5
- + NC NC

S1
64

38
36
6 20
-
33

37
30

34

35
31

32

7 8 9 10 11 12 13 14 15 16 17 18 19

MR1 1 (+)
24V DC 2 (-)
Y1 3 (+)

Button

0V LED

Esq. 1 - Module with activation and magneto – resistive position sensor

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 11/15

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6. Module with activation and colour or contrast sensor;

The colour or contrast sensors are used when it is only possible to differentiate
components from the same family through the colour/ contrast detection.
These sensors use PNP connections (positive output) or NPN (negative output).

+ 24 V DC
Brown

Output
Sensor Black
0V Blue PNP Load

+ 24 V DC
Brown

Output
Load Sensor Black
0V Blue NPN

Sch. 2 – Colour/contrast sensor with PNP and NPN connection

51

50

46
53

49
52

48
54

47

45
55

44
56

43
57

42
58

Relay 24V DC
59

0V 1 29 28 27 26 25 24 23 22
Relay 24V DC

Det. Colour/Contrast
NO NO
60

2 21
NO NO
61

41
3 C C
R1
D1
62

40
C C
4
NC K1 NC
K2
63

39
5
- + NC NC

S1
64

38
36

6 20
-
33

37
34
30

35
31

32

7 8 9 10 11 12 13 14 15 16 17 18 19

Sensor
Output

24V DC Colour/Contrast

Y1 PNP

Button

0V LED

Sch. 3 - Module with activation and colour or contrast sensor (PNP)

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 12/15

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51

46
50
53

49
52

48
54

47

45
55

44
56

43
57

42
58
Relay 24V DC

59
0V 1 29 28 27 26 25 24 23 22
Relay 24V DC

Det. Colour/Contrast
60
NO NO
2 21
NO NO

61

41
3 C C
R1
D1

62

40
C C
4
NC K1 NC

K2
63

39
5
- + NC NC

S1

64

38
36
6 20
-

33

37
30

34

35
31

32
7 8 9 10 11 12 13 14 15 16 17 18 19

Sensor

Output
-
Colour/Contrast
Y1 -
24V DC NPN

Button

0V LED

Sch. 4 - Module with activation and colour or contrast sensor (NPN)

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 13/15

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TEC-023

1.2.2. Specific modules’ electrical schemes

The modules may combine some of the circuits described previously.

Examples:

1. Module with leak test and spacer closing;

This type of module is used a lot and it’s characterized by making simultaneously the
component’s leak test and its spacer closing through a pneumatic cylinder specific for
this function. The spacer closing cylinder has a magnetic position sensor to assure the
correct closing.

PCI2

51

50

46
53

49
52

48
-

54

47

45

2
End of Stroke
NC NC

K3
55

44

MS1
56

43
C C

57

42
NO NO

58

1
Relay 24V DC
Relay 24 VDC

59
0V 1 29 28 27 26 25 24 23 22
Relay 24V DC
NO NO

60
Leak Test

2 21
61 NO NO

41
3 C C R1
D1
62

40
C C
4
NC K1 NC

K2 LD2
63

39
5
- + NC NC

S1
64

38
36
6 20
-
33

37
34
30

31

35
32

7 8 9 10 11 12 13 14 15 16 17 18 19

PS1
Y1
24 VDC

Botão

0V LED

Sch. 5 - Module with leak test and spacer closing

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 14/15

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2. Module for components “gallette - holders”;

These modules have a specific electrification. The catches’ cylinders have magnetic
position sensors which detect the “gallette(s)” correct closing in the “gallete-holder” and
command at the same time the electrovalve (Y2) of the main cylinder’s (cylinder of the
pins-holder plate).

PCI 1
Relay 24V DC
0V 1 29 28 27 26 25 24 23 22

NO NO
2 21

3 C C R1
D1
4
NC K1 NC

5
- +

S1 6 20

7 8 9 10 11 12 13 14 15 16 17 18 19

Y1 1 2
MS2
24V DC
Y2
Button
2

MS1
1

0V LED

• Y1 – Catches’ electrovalve;
• Y2 – Main cylinders’ electrovalve;
• MS1 – Magnetic sensors installed on catche 1;
• MS2 – Magnetic sensors installed on catche 2.

Sch. 6 - Module for components “gallette-holders”

Mod. 082-Ed. A Rev.: 01 Date: 11/09/08 Pag.: 15/15