Testing the Clamp Proximity Sensors

The proximity sensors on the moving clamp detect material when the clamps are holding material in
place.

NOTE: If the clamp cylinder or bearings are not in good working order, then operation could result in
inconsistent results

X2:

X1:

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ORIGINATED BY: TG EQUIPMENT TYPE: PythonX Structural Fabrication System Page 1 of 4
REVIEWED BY: TG JB JH SUBJECT: Proximity sensor, clamp sensor, clamp fault
APPROVED BY: Rod Sluser
 Clamp Proximity Faults

Test the proximity sensors as per the preventive maintenance schedule or if the following faults are
highlighted in VersaFab:

• FltInClampPP1 / FltInClamp1PP1 (Infeed Clamp 1 fault)

• FltInClamp2PP1 (Infeed Clamp 2 fault)

• FltOutClampPP1 (Outfeed Clamp fault)

Physical Inspection

The LED light on the proximity sensor, near the sensor wire connector, should come on when the sensor
detects metal and off when not detecting metal. The proximity sensors should be set 1.5mm (1/16”)
back from the clamp face. For X2 customers, the sensors are enclosed inside the clamp housing and can
be accessed by removing the top cover.

Sensor Not Detecting Metal Sensor Detecting Metal

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REVIEWED BY: TG JB JH SUBJECT: Proximity sensor, clamp sensor, clamp fault
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 Multiport block when sensor is not detecting metal Multiport block when sensor is detecting metal

The above are located under the gold triangular cover at the back of the cutting area.

NOTE:

• Ensure the face of the sensor is free of metallic dust or slag buildup.
• A sensor with the LED consistently on or off could indicate a damaged sensor
• Refer to the electrical drawings for the corresponding multiport port number

Testing the Digital Inputs

X1:

• On the teach pendant go to the top left corner drop down menu-> Inputs/Outputs-> View->
Digital Inputs (Alternatively: In VersaFab go to Management-> Robots-> Variables-> Status Bits->
Value Column)

Sensor Input Name Test

Infeed Clamp 1 Proximity
Sensors
Infeed Clamp 2 Proximity
Sensors
** Dual Robot Systems only**
di28_InFeedPP1 Input should be High (1) when metal is on sensor,
Low (0) when sensor is not detecting metal
di44_InFeed2PP1 Input should be High (1) when metal is on sensor,
Low (0) when sensor is not detecting metal

Outfeed Clamp 2 Proximity di31_OutFeedPP1 Input should be High (1) when metal is on sensor,
Sensor Low (0) when sensor is not detecting metal
X2:

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duplicated, communicated to other parties or used for any purpose without the express written permission of Burlington Automation.
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REVIEWED BY: TG JB JH SUBJECT: Proximity sensor, clamp sensor, clamp fault
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 • On the teach pendant go to the top left corner drop down menu-> Inputs/Outputs-> View->
digital Inputs (Alternatively: In VersaFab go to Management-> Machine-> Robots-> Variables->
Status Bits)

Sensor Input Name Test

Infeed Clamp 1 Proximity diInClmp1PP Input should be High (1) when metal is on sensor,
Sensors Low (0) when sensor is not detecting metal
Infeed Clamp 2 Proximity diInClmp2PP Input should be High (1) when metal is on sensor,
Sensors Low (0) when sensor is not detecting metal
Outfeed Clamp 2 Proximity diOtClmp1PP Input should be High (1) when metal is on sensor,
Sensor Low (0) when sensor is not detecting metal

NOTE:
• If there are two proximity sensors on the clamp face, the sensors are connected by a ‘y’ cable;
the input will be triggered if either proximity sensor detects metal.

Troubleshooting Tips

• Only test one sensor at a time to help identify the faulty component

• Check the connections from the proximity sensor through the ‘Y’ cable (part # PPY-1; if two
sensors are installed), through the proximity wire (part # PPC-1), to the multiport block. Refer to
the electrical drawings for the proper path and connection to the block.
• The ‘Y’ cable can be removed and the straight cable can be connected directly to one proximity
sensor

• Swap the sensor with a new sensor or with a known working proximity on a different clamp

• Swap the ‘Y’ and/or straight cable with a new or known working cable

• Ensure the cabling or sensors do not have visible damage

PROPRIETARY & CONFIDENTIAL: This document contains proprietary information owned by Burlington Automation and may not be
duplicated, communicated to other parties or used for any purpose without the express written permission of Burlington Automation.
ORIGINATED BY: TG EQUIPMENT TYPE: PythonX Structural Fabrication System Page 4 of 4
REVIEWED BY: TG JB JH SUBJECT: Proximity sensor, clamp sensor, clamp fault
APPROVED BY: Rod Sluser