D4CC - Position Sensors OMRON - Free user manual and instructions

Product type	Position sensor (miniature limit switch)
Brand	OMRON
Model	D4CC
Rated voltage	125 VAC or 30 VDC
Rated current	1 A (resistive load)
Protection rating	IP67
Mechanical life	10,000,000 operations min.
Electrical life	200,000 operations min. (1 A, 125 VAC)
Ambient temperature	-10°C to 70°C (no freezing)
Ambient humidity	95% max.
Weight	Approx. 120 g (D4CC-1002 model)
Body material	Molded resin
Available actuator	Plunger, roller, lever, plastic rod, central lever
Operation indicator	Built-in LED (optional, turns off when actuated)
Connection	M12 connector, 4-conductor cable
Mounting	Via 5.2 mm holes or M5 screws
Group mounting	Up to 6 switches (with mounting guide)
Insulation resistance	100 MΩ min. (500 VDC)
Dielectric strength	1000 VAC 1 min between terminals, 1500 VAC 1 min live parts/ground
Shock resistance	Destruction: 1000 m/s² min., Malfunction: 500 m/s² min.
Vibration resistance	Malfunction: 10 to 55 Hz, 1.5 mm double amplitude

Frequently Asked Questions - D4CC OMRON

How to choose the right D4CC model for my application?

The model is selected based on voltage (AC/DC), presence of LED indicator, and actuator type (plunger, roller, lever, etc.). For example, D4CC-1001 is a plunger 1 A 125 VAC without indicator, D4CC-4001 is the same with LED indicator in 30 VDC. Refer to the model table in the manual.

What do the codes in the D4CC reference mean?

The first digit indicates the load type: 1=1A 125VAC without indicator, 2=1A 125VAC with indicator, 3=1A 30VDC without indicator, 4=1A 30VDC with indicator. The next two digits correspond to the actuator (e.g., 01=plunger, 02=roller, 24=lever).

How to wire the D4CC switch?

Use a 4-pin M12 connector. The standard pinout is: pin 1 (brown) = COM, pin 2 (white) = NO, pin 3 (blue) = NC, pin 4 (black) = ground. Follow the contact diagram provided in the manual.

What is the recommended tightening torque for mounting screws?

For M5 Allen screws, tighten to 4.90-5.88 N·m. For the M3.5 head screw, tighten to 0.78-0.88 N·m. Respect these torques to ensure sealing and avoid damaging the switch.

Can I mount multiple D4CC side by side?

Yes, up to 6 switches can be mounted in a group. Use the concave/convex mounting guides on the housing to align them. The panel thickness must be at least 6 mm.

How to properly install the lever actuator?

Adjust the cam or finger so that the lever arrow is between the two convex marks. For the central lever, the concave part (A) must be between the convex parts when the lever is depressed. The cam angle should be ≤30°.

What to do if the LED indicator does not work?

Check that you are using a model with indicator (code 2 or 4 in the reference). The indicator is normally on at rest and turns off when the switch is actuated. Verify the supply voltage and wiring (pin 4 for ground).

What is the lifespan of the D4CC switch?

The mechanical life is 10 million operations minimum, and the electrical life is 200,000 operations minimum (under 1A/125VAC resistive load). These values are measured at 5-35°C and 40-70% humidity.

How to clean and maintain the D4CC?

Do not use aggressive solvents. Wipe with a dry cloth. Regularly check the condition of the seal and the nitrile protective cap. Do not expose to water above 70°C or steam.

Where to find spare parts or accessories?

Cable connectors (XS2F models) and special mounting plates (D4C-P001, D4C-P002, D4C-P020) are available separately. Contact your local OMRON representative to order.

USER MANUAL D4CC OMRON

Many Models Including Roller Lever Switches are Only 16-mm Thick with Connector

• New center roller lever models that enable ganged mounting of up to 6 Switches.
• Cable connectors for easy Switch replacement.
• Triple-seal construction for plungers to provide IEC IP67, UL, and CSA (type 3, 4, 13) degree of protection.
• Operation indicators available for easy monitoring (standard indicator is lit when Switch is not operating).

Two industrial D4CC limit switch devices shown from different angles (no visible text or symbols on the devices themselves)

Model Number Structure

■ Model Number Legend

1. Rated Load

(These codes are different from suffix codes of the D4C)

1: 1 A at 125 VAC
2: 1 A at 125 VAC (with LED indicator)
3: 1 A at 30 VDC
4: 1 A at 30 VDC (with LED indicator)

2. Actuator

01: Pin plunger
02: Roller plunger
03: Crossroller plunger
10: Bevel plunger
24: Roller lever
31: Sealed pin plunger
32: Sealed roller plunger
33: Sealed crossroller plunger
41: Panel mount pin plunger
42: Panel mount roller plunger
43: Panel mount crossroller plunger
50: Plastic rod
60: Center roller lever

Note: With standard models, the operation indicator turns OFF when the switch operates. If models with operation indicators that turn ON when the switch operates are required, add "-B" to the end of the model number.

Ordering Information

■ List of Models

Limit Switches

Actuator	1 A at 125 VAC		1 A at 30 VDC
	Without indicator	With indicator	Without indicator	With indicator
Pinplunger	D4CC-1001	D4CC-2001	D4CC-3001	D4CC-4001
Roller[76GB]plunger	D4CC-1002	D4CC-2002	D4CC-3002	D4CC-4002
Crossroller[SS83]plunger	D4CC-1003	D4CC-2003	D4CC-3003	D4CC-4003
Bevel[GB/T]plunger	D4CC-1010	D4CC-2010	D4CC-3010	D4CC-4010
High-sensitivitroller lever	D4CC-1024	D4CC-2024	D4CC-3024	D4CC-4024
Sealedpin[8'5B]plunger	D4CC-1031	D4CC-2031	D4CC-3031	D4CC-4031
Sealed rollerplunger	D4CC-1032	D4CC-2032	D4CC-3032	D4CC-4032
Sealedcrossroller[32SW]plunger	D4CC-1033	---	D4CC-3033	D4CC-4033
Panel mountpin plunger	D4CC-1041	D4CC-2041	D4CC-3041	D4CC-4041
Panel mount[5X03]roller plunger	D4CC-1042	D4CC-2042	D4CC-3042	D4CC-4042
Panel mountcrossroller[4A4TZ]plunger	D4CC-1043	---	D4CC-3043	D4CC-4043
Plasticrod[22C8]	D4CC-1050	D4CC-2050	D4CC-3050	D4CC-4050
Centerroller[4H3C3]	D4CC-1060	D4CC-2060	D4CC-3060	D4CC-4060

Note: 1. The meaning of suffix codes in the D4CC model numbers is different from that in the D4C model numbers.
2. Refer to the following table for cable plugs.

Accessories (Order Separately)

Plugs

Type	Appearance	No. of conductors	Cable length	Model
VAC	Straight	4	1 m	XS2F-A421-C90-A
			2 m	XS2F-A421-D90-A
			5 m	XS2F-A421-G90-A
			10 m	XS2F-A421-J90-A
VDC			1 m	XS2F-D421-C80-A
			2 m	XS2F-D421-D80-A
			5 m	XS2F-D421-G80-A
			10 m	XS2F-D421-J80-A

Note: Please contact your local OMRON sales office for details.

Special Mounting Plate

It is possible to replace an WL Limit Switch with a D4CC Limit Switch mounted on this plate without changing the position of the dog or cam.

The following is the conversion table:

WL	D4C	Plate model
Top plunger: WLD	Plunger: D4CC-☐001	D4C-P001
Top roller plunger: WLD2	Roller plunger: D4CC-☐002	D4C-P002
Roller lever: WLG2	Roller lever: D4CC-☐024	D4C-P020

Example

Remarks

There is no difference in mounting pitch between the Mounting Plate and the WL. The mounting depth of the D4CC with the Mounting Plate attached is, however, shorter than that of the panel-mounted WL.

Specifications

■ Approved Standards

Agency	Standard	File No.
UL	UL508	E76675
CSA	CSA C22.2 No. 14	LR45746

■ Approved Standard Ratings

UL-CSA

D4CC-1, D4CC-2

D150

Rated voltage	Carry current	Current		Volt-amperes
		Make	Break	Make	Break
120 VAC	1.0 A	3.6 A	0.6 A	432 VA	72 VA

■ Ratings

Rated voltage	Non-inductive load				Inductive load
	Resistive load		Lamp load		Inductive load		Motor load
	NC	NO	NC	NO	NC	NO	NC	NO
125 VAC	1 A	1 A	1 A	0.7 A	1 A	1 A	1 A	1 A
30 VDC	1 A	1 A	1 A	1 A	1 A	1 A	1 A	1 A

Note: 1. The above current ratings are for steady-state current.
2. Inductive loads have a power factor of 0.4 min. (AC) and a time constant of 7 ms max. (DC).
3. Lamp loads have an inrush current of 10 times the steady-state current.
4. Motor loads have an inrush current of 6 times the steady-state current.

D4CC-3, D4CC-4, 1 A at 30 VDC

Inrush current	NC	5 A max.
	NO	2.5 A max.

■ Characteristics

Degree of protection	IP67
Durability (see note 2)	Mechanical: 10,000,000 operations min.Electrical: 200,000 operations min. (1 A at 125 VAC, resistive load)
Operating speed	Plunger: 0.1 mm to 0.5 m/sRoller lever: 1 mm to 1 m/s
Operating frequency	Mechanical: 120 operations/minElectrical: 30 operations/min
Rated frequency	50/60 Hz
Insulation resistance	100 MΩ min. (at 500 VDC)
Contact resistance (initial)	100 mΩ max.
Dielectric strength	1,000 VAC, 50/60 Hz for 1 min between terminals of same polarity1,500 VAC, 50/60 Hz for 1 min between current-carrying metal parts and ground, and between each terminal and non-current-carrying metal part
Vibration resistance	Malfunction: 10 to 55 Hz, 1.5-mm double amplitude (see note 3)
Shock resistance	Destruction: 1,000 m/s2 min.Malfunction: 500 m/s2 min.
Ambient temperature	Operating: -10°C to 70°C (with no icing)
Ambient humidity	Operating: 95% max.
Weight	Approx. 120 g (in the case of D4CC-1002)

Note: 1. The above figures are initial values.
2. The values are calculated at an operating temperature of 5^ C to 35^ C, and an operating humidity of 40% to 70%. Contact your OMRON sales representative for more detailed information on other operating environments.
3. Excluding plastic rod models.

Leakage Current (for Switches with Indicators)

The leakage current and resistance of Switches with indicators are as follows:

Item	D4CC-2□□□	D4CC-4□□□
Voltage	125 VAC	30 VDC
Leakage current	1.0 mA	1.0 mA
Resistive value	150 kΩ	30 kΩ

■ Operating Characteristics

Model	D4CC-□001	D4CC-□002	D4CC-□003	D4CC-□010	D4CC-□024
OF max.	11.77 N	11.77 N	11.77 N	11.77 N	5.69 N
RF min.	4.41 N	4.41 N	4.41 N	4.41 N	1.47 N
PT max.	1.8 mm	1.8 mm	1.8 mm	1.8 mm	10 ± 3^
OT min.	3 mm	3 mm	3 mm	3 mm	50^
MD max.	0.2 mm	0.2 mm	0.2 mm	0.2 mm	3^
OP	15.7 ± 1 mm	28.5 ± 1 mm	28.5 ± 1 mm	28.5 ± 1 mm	---

Model	D4CC-□031	D4CC-□032	D4CC-□033	D4CC-□041	D4CC-□042	D4CC-□043
OF max.	17.65 N	17.65 N	17.65 N	11.77 N	11.77 N	11.77 N
RF min.	4.41 N	4.41 N	4.41 N	4.41 N	4.41 N	4.41 N
PT max.	1.8 mm	1.8 mm	1.8 mm	1.8 mm	1.8 mm	1.8 mm
OT min.	3 mm	3 mm	3 mm	3 mm	3 mm	3 mm
MD max.	0.2 mm	0.2 mm	0.2 mm	0.2 mm	0.2 mm	0.2 mm
OP	24.9±1 mm	34.3±1 mm	34.3±1 mm	31.2±1 mm	36.8±1 mm	36.8±1 mm
TT (reference value)	(5) mm	(5) mm	(5) mm	(5) mm	(5) mm	(5) mm

Model	D4CC-□050	D4CC-□060
OF max.	1.47 N	6.67 N
RF min.	---	1.47 N
PT max.	15°	10±3°
OT min.	---	50°
MD max.	---	3°

■ Contact Form

AC Switches (D4CC-10□□, 20□□)

Note: The indicators of these models are lit when the Switches are not actuated. When the Switches are actuated, the indicator are off.
Note 1. "Lights when operated" means that when the actuator is turned or pushed and the Limit Switch contact leaves the NC side, the indicator lights.
2. "Lights when not in operation" means that when the actuator is in the free position, the indicator is lit, and when the actuator is turned or pushed and the contact comes into contact with the NO side, the indicator turns OFF.

DC Switches (D4CC-30□□, 40□□)

With LED Indicator (lights when operated)

Note: The indicators of these models are lit when the Switches are not actuated. When the Switches are actuated, the indicator are off.
Note 1. "Lights when operated" means that when the actuator is turned or pushed and the Limit Switch contact leaves the NC side, the indicator lights.
2. "Lights when not in operation" means that when the actuator is in the free position, the indicator is lit, and when the actuator is turned or pushed and the contact comes into contact with the NO side, the indicator turns OFF.

Plugs

Nomenclature

Dimensions

Note: 1. All units are in millimeters unless otherwise indicated.

1. The □ in each model number is replaced with the code expressing the rated load of the model. Refer to Ordering Information.
2. Unless otherwise specified, a tolerance of ±0.4 mm applies to all dimensions.

Limit Switches

Pin Plunger
D4CC-□001

Roller Plunger
D4CC-□002

Crossroller Plunger
D4CC-□003

Bevel Plunger
D4CC-□010

Sealed Pin Plunger
D4CC-□031

Sealed Roller Plunger

Sealed Crossroller Plunger
D4CC-□033

Panel Mount Pin Plunger
D4CC-□041

Panel Mount Roller Plunger
D4CC-□042

Panel Mount Crossroller Plunger
D4CC-□043

Note: 1. Operation is possible in any direction except parallel to the axis ↓.
2. The ideal range for operation is between the tip of the rod and 1/3 of the length of the actuator.

Center Roller Lever D4CC-□□60

Technical line drawing of a mechanical pressure sensor device (no text or symbols visible)

Plugs

XS2F-D421-☐80-A (DC)

XS2F-A421-□90-A (AC)

(Straight Type)

Technical line drawing of a mechanical connector or connector (no text or symbols)

Model	Cable length (L)
XS2F-D421-C□-A	1 m
XS2F-D421-D□-A	2 m
XS2F-D421-G□-A	5 m
XS2F-D421-J□-A	10 m

Special Mounting Plates

(Limit Switches are not attached to the Plates.)

D4C-P001 (For D4CC-□001)

Note: 1. Four hexagonal flat head bolts (M5 x 0.8, length: 10) and two Allen-head bolts (M5 x 0.8, length: 15) are included.
2. All the holes with 5.2^+0.2/_0 dia. must be used with M5 x 10 Allen-head bolts.
3. All the M5-tapped holes must be used with M5 hexagonal flat head bolts.

D4C-P002 (For D4CC-□002)

Illustration of a mechanical control device with no visible text or symbols

Note: 1. Four hexagonal flat head bolts (M5 x 0.8, length: 10) and two Allen-head bolts (M5 x 0.8, length: 15) are included.
2. All the holes with 5.2^+0.2/_0 dia. must be used with M5 x 10 Allen-head bolts.
3. All the M5-tapped holes must be used with M5 hexagonal flat head bolts.

D4C-P020 (For D4CC-□024)

Technical line drawing of a mechanical switch or lever device (no text or symbols visible)

Note: 1. Four hexagonal flat head bolts (M5 x 0.8, length: 10), two Allen-head bolts (M5 x 0.8, length: 15), and two spring pins (4 x 14) are included.
2. All the holes with 5.2^+0.2/_0 dia. must be used with M5 x 10 Allen-head bolts.
3. All the M5-tapped holes must be used with M5 hexagonal flat head bolts.

■ Correct Use

Mounting

Make sure that the plate to which the D4CC is mounted is flat. If the plate is warped or has protruding parts, the D4CC may not malfunction.

Mounting Holes

Two, 5.2-dia. or

M5 screw holes

A maximum of 6 Switches may be group-mounted. In this case, pay attention to the mounting direction so that the convex part of the group-mounting guide on one Switch fits into the concave part of the guide on the other Switch as shown in the figure below. For group mounting, the mounting panel must have a thickness (t) of 6 mm min.

Group Mounting

Tightening Torque

Be sure to tighten each screw to the proper tightening torque as shown in the table.

No.	Type	Torque
1	M5 Allen-head bolt	4.90 to 5.88 N·m
2	M3.5 head mounting screw	0.78 to 0.88 N·m
3	M5 Allen-head bolt	4.90 to 5.88 N·m

Note: By removing the two screws from the head, the head direction can be rotated 180^ . After changing the head direction, re-tighten to the torque specified above. Be careful not to allow any foreign substance to enter the Switch.

Plug Tightening

Connect the plug connector (B) to the connector threads of the D4CC. Then firmly turn the plug connector by hand so that the connector threaded portion (C) will be completely covered by the plug connector (B) so that space (A) will be almost 0. Do not use any tools, such as pliers, to tighten the plug connector, otherwise the plug connector may become damaged. Make sure, however, that the plug connector is tightened securely, otherwise the rated degree of protection of the D4CC may not be maintained. Furthermore, the plug connector may be loosened by vibration.

Properly Tightened Connector

Operation

Operation method, shapes of cam and dog, operating frequency, and overtravel have a significant effect on the service life and precision of a Limit Switch. For this reason, the dog angle must be 30^ max., the surface roughness of the dog must be 6.3S min. and hardness must be Hv400 to 500.

To allow the plunger-type actuator to travel properly, adjust the dog and cam to the proper setting positions. The proper position is where the plunger groove fits the bushing top.

To allow the roller lever-type actuator to travel properly, adjust the dog and cam so that the arrow head is positioned between the two convex markers as shown below.

Others

If failures, such as reset failures, in the plunger model are possible, use a model that has a rubber cap.

Do not expose the Switch to water exceeding 70^ C or use it in steam.

Properly adjust the stroke of the center roller lever along with the dog or cam so that the concave part (A) of the head is located between the convex parts of the head as shown below when the center roller lever is pressed by the dog or cam.

Refer to the following to adjust the stroke of the lever based on the mounting hole level.

ALL DIMENSIONS SHOWN ARE IN MILLIMETERS. To convert millimeters into inches, multiply by 0.03937. To convert grams into ounces, multiply by 0.03527.

Cat. No. C116-E1-02

In the interest of product improvement, specifications are subject to change without notice.