In order to reduce service calls and maintain a high standard of quality and consistency, it is important to ensure that the gap between the safety interlock keys and their corresponding key-slots does not exceed 1/8”, and that the key does not impact the switch. Gaps of 3/16” or larger can lead to machine vibration breaking the contact, such that the machine stops running without any error message to alert the machine operator of the nature of the problem. Both of the interlock contacts have to be broken for an error message to appear, but breaking a single contact does not cause an error message to appear.
The photo to the right shows a correctly calibrated switch, while the photo on the left shows a switch in which the key does not engage the interlock properly, rendering the machine inoperable until the problem has been corrected. This problem is only prevalent with OMRON D4NS-3CF door switches, as pictured below.
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