Safety-door Lock Switch D4BL Protective Doors Are Locked Until Machine Completely Stops Operation Select mechanical lock/solenoid release or solenoid lock/mechanical release models Dedicated release lock ensures both easy maintenance and door-unlock at power failure Tough aluminum die-cast unit incorporating a switch box with IP67 enclosure rating (EN60529, IEC529) Equipped with horizontal and vertical conduit openings Models available with LED indicators Head can be rotated in 4 directions Approved Standards Agency Standard File No. TUV EN60947-5-1 R9451050 Rheinland (IEC947-5-1, VDE0660 Part 200, 206 UL UL508 E76675 CSA CSA C22.2, No.14 LR45746 BIA GS-ET-19 9402293 SUVA SUVA 5643 ) Ordering Information Conduit type 1/2-14NPT d it ) (2 conduits) Lock type Mechanical l k lock Solenoid lock Note: Voltage for Solenoid Without Indicator With Indicator Without Indicator 1NC /+1NO+1NC 1NC +1NC /+1NO+1NC 2NC (Slow action) (Slow action) (Slow action) With Indicator 2NC +1NC (Slow action) 24 VDC D4BL-3CRA D4BL-3CRA-A D4BL-3DRA D4BL-3DRA-A 110 VAC D4BL-3CRB D4BL-3CRB-A D4BL-3DRB D4BL-3DRB-A 230 VAC D4BL-3CRC D4BL-3CRC-A D4BL-3DRC D4BL-3DRC-A 230 VAC D4BL-3CRG D4BL-3CRG-A D4BL-3DRG D4BL-3DRG-A marking indicates the contacts which have positive opening mechanism approved by TUV Rheinland. D4BL D4BL ACCESSORIES (ORDER SEPARATELY) Operation Key Mounting type Part number Horizontal D4BL-K1 Vertical D4BL-K2 Adjustable D4BL-K3 NOMENCLATURE Lock Switch D4BL 1 2 3 4 5 1. Conduit 1: PG13.5 2: G1/2 3: 1/2-14NPT 2. Built-in Switch C: 1NC/1NO (Slow-action) + 1NC (Slow-action) D: 2NC (Slow-action) + 1NC (Slow-action) 3. Head Mounting Direction R: Right Operation Key D4BL - K 1 4. Door Lock/Release Methods (Dedicated Release Key is Incorporated by All Models) A: B: C: G: Mechanical lock/24-VDC solenoid release Mechanical lock/110-VAC solenoid release Mechanical lock/230-VAC solenoid release 24-VDC solenoid lock/mechanical release 5. Indicator Blank: Without indicator A: 1 mA at 10 to 115 VAC or VDC driving (with red and green indicator unit) 1. Operation Key Type 1: Horizontal mounting 2: Vertical mounting 3: Adjustable mounting Specifications RATINGS 1. IEC 947-5-1 and EN60947-5-1 AC-15 3A/250 V (6A/115 V for Display Models) 2. NEMA A300 (UL/CSA Pilot Duty) Rated voltage g 120 VAC 250 VAC 2 Current Switching power Continuous Make Break Make Break 10 A 60 A 6A 7,200 VA 720 VA 30 A 3A D4BL D4BL 3. General Ratings Rated voltage g Non-inductive load Resistive load NC Inductive load Lamp load NO Inductive load Motor load NC NO NC NC NO 125 VAC 10 A 3A 1.5 A 10 A NO 5A 2.5 A 250 VAC 10 A 2A 1A 10 A 3A 1.5 A 8 VDC 10 A 6A 3A 10 A 6A 14 VDC 10 A 6A 3A 10 A 6A 30 VDC 6A 4A 3A 6A 4A 125 VDC 0.8 A 0.2 A 0.2 A 0.8 A 0.2 A 250 VDC 0.4 A 0.1 A 0.1 A 0.4 A 0.1 A Note: 1. Resistive loads have a power factor (cos = ) of 1. 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, while motor loads have an inrush current of 6 times the steady-state current. 4. Inrush current: NC: 30 A max.; NO: 30 A max. CHARACTERISTICS Operating speed 0.05 to 0.5 m/s Operating frequency Operating characteristics 30 operations/min max. Positive opening force 19.61 N (4.41 lbf) min. Positive opening stroke 20 mm (0.79 inch) min. All stroke 23 mm (0.91 inch) min. Locked resistive pulling force 700 N (157 lbf) min. Insulation resistance 100 M min. (at 500 VDC) Rated insulation voltage (Ui) 300 VAC Conventional enclosed thermal current (I the) (rated continuous current) 10 A Dielectric strength (Uimp) Impulse dielectric strength (Uimp) 4 kV (IEC 947-5-1) between terminals of different polarity, between each terminal and ground, and between each terminal and non-current-carrying metal part; 2.5 kV between solenoid and ground Short-circuit protective device 10 A fuse (type gl) (IEC269) Contact resistance 50 m max. (initial value) Vibration resistance Malfunction 10 to 55 Hz, 0.35-mm single amplitude with an imposed acceleration of 50 m/s2 (5G) max. (IEC68-2-6) Shock resistance Destruction 1,000 m/s2 (100G) min. (IEC68-2-27) Malfunction 300 m/s2 (30G) min. (IEC68-2-27) Mechanical 1,000,000 operations min. Electrical 500,000 operations min. (with a load rate of 0.5) Ambient temperature Operating -10 to 55C (14 to 131F) with no icing Ambient humidity Operating 95% max. Life expectancy y Operating environmental pollution level Pollution degree 3 (IEC947-5-1) Insulation class Insulation class I (IEC536) Enclosure rating g (See ( Note.)) UL 6P and 13 NEMA 6P and 13 IEC529 IP67 (60947-5-1) Note: Although the switch box does not allow the penetration of dust, oil or water, keep the operation key insertion slot free of dust, oil, and water. 3 D4BL D4BL SOLENOID COIL CHARACTERISTICS Item 24 VDC models 110 VAC models 230 VAC models Rated operating voltage 24 VDC +10%/-15% (100% ED) 110 VAC 10% (50/60 Hz) 230 VAC 10% (50/60 Hz) Current consumption Approx. 300 mA Approx. 98 mA Approx. 45 mA Insulation class Class F 130C (266F) or less INDICATOR CHARACTERISTICS Rated voltage 10 to 115 VAC/VDC Current consumption Approx. 1 mA Indicator color Orange, green LED OPERATING CHARACTERISTICS Model D4BL- Operating force (extraction) 19.61 N (4.41 lbf) min. Release force (insertion) 19.61 N (4.41 lbf) min. Pretravel 15 mm (0.59 inch) max. Construction Operation key Lock plate Lock monitor switch Rotating drum Key Operation plunger Auxiliary plunger 31 32 Rotating lever E1 E2 11 12 Safety switch Solenoid 23 Conduit opening (horizontal wiring) E1 E2 31 12 24 23 24 Connection terminal Ground terminal 4 Conduit opening (vertical wiring) D4BL D4BL Operation CONTACT FORM Model Contact D4BL-C- DPDB-1NC/1NO+ DPDB-1NC Contact form DPDB-2NC+DPDB-1NC D4BL-D- 32 31 31 11 12 23 24 11 12 32 22 21 Internal Circuit Recommended Circuit Connection Example 10 to 115 VAC/DC 1. Connect the crimp-style terminals of each indicator unit to the internal terminals (terminals 31 and 12, 23 and 24, and 21 and 22) of the D4BL. R ZD R LED 2. Each indicator unit must be connected in parallel with the contacts. When the contacts are open, the indicators will be lit. EEEEEE EEEEEE 31 E1 32 E2 11 12 23 24 E1 E2 31 12 23 24 Load Load Orange Green Power supply 5 D4BL D4BL OPERATING MODE (Example of Electromagnetic Interlock System Operating Mode of D4BL-C) Operating mode I II III IV Door The protective door is open. The protective door is closed. The protective door is closed and the machine is operating. The protective door is closed and the solenoid is operating. Door switch Operation Key: The mechanical lock is released (contacts 31 and 32 are OFF). Main Switch: The normally closed contact is forcibly opened (contacts 11 and 12 are OFF). Operation Key: Mechanically locked (contacts 31 and 32 are ON). Main Switch: The normally closed contact is closed (contacts 11 and 12 are ON). The protective door is closed and the machine is operating. Operation Key: The mechanical lock is released (contacts 31 and 32 are OFF). EE Operation key (door) 31 E1 Contact 32 E2 EEEEEE EEEEEE EEEEEE Operation key (door) 11 12 23 24 31 E1 32 E2 11 12 23 24 Operation key (door) Operation key (door) 31 32 E1 E2 11 12 23 24 31 E1 32 E2 11 12 23 24 E1 E2 31 12 23 24 E1 E2 31 12 23 24 E1 E2 31 12 23 24 E1 E2 31 12 23 24 Orange Orange Orange Orange Green Green Green Green 31 and 12 23 and 24 31 and 12 23 and 24 31 and 12 23 and 24 31 and 12 23 and 24 OFF ON ON OFF ON OFF OFF OFF Control device (1) Confirmation of door opening (2) Safety work indication (3) Confirmation of door closing (4) Start signal (5) Machine interrupt signal (6) Confirmation of machine interruption (Processing) Machine (Start) (See note) (Completion) (Interruption) Indicator Orange: ON Green: OFF Orange: OFF Green: ON (Interruption) Orange: OFF Green: ON Note: Be sure to use the dedicated push button to start or stop the machine or release the door lock. 6 (8) Release confirmation signal (7) Lock release signal Orange: ON Green: ON D4BL D4BL Application Examples CONNECTION EXAMPLE WITH OMRON'S G9S SAFETY RELAY UNIT G9S-301 (24 VDC)+D4BL-CRG- (Solenoid lock type)+D4D-520 N Circuit Diagram Product Configuration PC output Motor control system PC 31 Operation instruction D4BL PC output G9S-301 Contactor Contactor D4DN 24 12 Closed Emergency stop S2 24 23 32 11 12 Reset switch S1 M 23 11 Open Feed back loop PC output (Stop signal) ESW R1 KM1 KM2 (Operation instruction) Emergency stop or standby IN Motor control system PC OUT G9S S1: D4DN or D4BN Safety-door Lock Switch S2: D4BL Safety-door Lock Switch with solenoid lock S3: Reset switch c 1 2 C 1 2 T11 T12 T22 T21 KM1, KM2: J7K Magnet Contactor M: 3-phase motor E-SW: Emergency stop switch 7 D4BL D4BL CONNECTION EXAMPLE WITH OMRON G9S SAFETY RELAY UNIT G9S-321-T (24 VDC)+D4BL-CRA-/-CRB- (Mechanical lock type)+D4D-520N Circuit Diagram Product Configuration PC output KM1 Motor control system PC KM2 S3 Operation instruction Emergency stop 31 D4BL S2 24 23 32 11 12 PC output A22E Closed PC out put G9S Contactor (off delay) Contactor (off delay) D4DN 24 12 PBS (Reset signal) M 23 11 S1 Open Feed back loop PC output (Stop signal) ESW Off delay timer (Operation instruction) Emergency stop or standby IN Motor control system PC OUT G9S S1: Safety Switch (D4D-j520N) S2: D4BL Safety-door Lock Switch with mechanical lock KM1, KM2: Magnet Contactor (LC1-D) 8 M: 3-phase motor ESSW: Emergency-stop switch (A22E) c 1 2 C 1 T11 T12 T22 T21 2 D4BL solenoid D4BL D4BL Dimensions Unit: mm (inch) Note: Unless otherwise specified, a tolerance of 0.4 mm applies to all dimensions. SAFETY DOOR SWITCH D4BL-- Four, M3.5 head clamping screws 31 (1.22) 116.5 (4.59) 10 (0.39) 17 (0.67) 7 (0.27) 37.5 (1.48) 34.2 (1.35) Lock protection cap Four, 5.3 (0.21) dia. mounting holes 123.5 (4.86) 74 (2.91) 86 (3.39) Four, M4 cover clamping screws Cover 5.5 (0.22) 100 (3.94) 16 (0.63) 6.8 (0.27) 39.6 (1.56) 112 (4.41) 46.3 (1.82) Indicators Conduit opening Conduit opening OPERATION KEYS D4BL-K1 D4BL-K2 53.7 (2.11) 40.7 (1.60) 15.6 (0.61) 5.3 x 7.3 mounting long hole 13 (0.51) 78.7 (3.10) 15.6 (0.61) 7.3 (0.29) 52.4 (2.06) 15 (0.59) 26 (1.02) 36 (1.42) Two, R2.65 5.3 5.3 (0.21) (0.21) 2.5 (0.10) 7.5 (0.30) 20 (0.79) 11.4 (0.45) 40 (1.57) 26 (1.02) 36 (1.42) 12 (0.47) 7.5 (0.30) 20 (0.79) 11.4 (0.45) 5 (0.20) 5.4 (0.21) 4 (0.16) dia. 4 (0.16) dia. 2.5 (0.10) 5.3 (0.21) 9 D4BL D4BL 40 (1.57) D4BL-K3 12 (0.47) 20 (0.79) 26 (1.02) 2.5 (0.10) 40 (1.57) 80.7 (3.18) 30 (1.18) 36 (1.42) 11.6 (0.47) 30 (1.18) 19.5 (0.77) 5.4 (0.21) 37.8 (1.49) 5.3 (0.21) dia. 17.5 (0.69) 4 (0.16) dia. 34.6 (1.36) WITH OPERATION KEY INSERTED D4BL + D4BL-K3 81.5 min 85 max (3.21 min 3.35 max) 41 (1.61) R 250 (side view) 40 (1.57) 30 (1.18) INDICATOR UNIT Four terminal plates 7 (0.28) Two, 7 (0.28) dia. Two indicators 16 (0.61) 57.2 26.8 (1.06) 53.2 (2.25) (2.10) 16 (0.61) 35 26.2 (1.38) (1.03) 61.2 (2.41) 10 0.3 2 (0.01) (0.08) 10.6 (0.42) 5.6 (0.22) 12.6 (0.50) M4 bolt with hexagonal hole D4BL D4BL Installation PROCEDURE FOR CONNECTING CABLE The following procedure is recommended so that the D4BL can be wired or connected to the Indicator Units with ease. Recommended connecting cable: AWB20 to AWG18 with seven conductors A UL2464-style cable is recommended. Apply sealing tape to the cable and conduit opening so that the D4BL can conform to IP67. Tighten the connector to a torque of 1.8 to 2.2 Nm (15.93 to 19.47 in lbs). Connect the Indicator Units to the D4BL after connecting the 7-conductor cable to the D4BL. Cable Connecting Example 1. As shown in the following illustration, the wires must be connected in sequence beginning with the terminal nearest to the conduit opening. A E1 E2 31 12 23 24 a Lv B Lp The wire leads must be wrapped around the screws clockwise. Tighten each screw to a torque of 0.5 to 0.7 Nm (4.43 to 6.20 in lbs). a Terminal no. Lp mm (inch) Lv mm (inch) a mm (inch) E1 302 (1.180.08) 802 (3.150.08) 81 (0.310.08) E2 352 (1.380.08) 752 (2.950.08) 31 452 (1.770.08) 602 (2.360.08) 12 552 (2.170.08) 502 (1.970.08) 23 (21) 652 (2.560.08) 452 (1.770.08) 24 (22) 702 (2.760.08) 352 (1.380.08) Ground 902 (3.540.08) 502 (1.90.087) 2. The external insulation sheath of the 7-conductor cable must contact with side A or B as shown in the above D4BL illustration. Edge of insulation sheath 11 D4BL D4BL Precautions MOUNTING Be sure to install a stopper as shown in the following illustration when mounting the Safety-door Lock Switch. The range of space "a" must be determined according to the available set zone 4 mm (0.16 inch) max. of the Operation Key. Switch Mounting Holes Four, M5 Stopper 74 (2.91) a 100 (3.94) Set zone mark Operation key Switch Operation Key Mounting Holes D4BL-K1 Two, M5 20 (0.79) D4BL-K2 Two, M5 40 (1.57) Refer to Dimensions for the mounting dimensions of the Operation Key to mount the Operation Key correctly. The Operation Key will quickly become damaged or worn away if it is not mounted correctly. D4BL-K3 Two, M5 30 (1.18) Proper Mounting Screw Tightening Torque Two, M5 operation key clamping screws 2.4 to 2.8 Nm (21.24 to 24.78 in lbs) Four, M3.5 head clamping screws 0.8 to 1.0 Nm (7.08 to 8.85 in lbs) Four, M4 cover clamping screws 1.2 to 1.4 Nm (10.62 to 12.39 in lbs) Conduit 1.8 to 2.2 Nm (15.93 to 19.47 in lbs) 12 Four, M5 Conduit opening cap Unit mounting screws 1.3 to 1.7 Nm (11.51 4.9 to 5.9 Nm (43.37 to 11.51 in lbs) to 52.22 in lbs) D4BL D4BL HEAD DIRECTIONS DEDICATED RELEASE KEY The head can be mounted in four directions. To remove the head, turn the head by 45 as shown in figures A and B below. To change the direction of the head, make sure that the protruding part of the rotating lever engages with the groove of the plunger. Then turn the head clockwise or counterclockwise to the desired direction. At that time, make sure that the groove of the plunger is located under the rotating lever. If the direction of the head is not set when the plunger is rotated by 45, the groove of the plunger presses the rotating lever. The head, plunger, or the built-in switch may be damaged as a result. The dedicated release key, which is provided with the D4BL, is used to unlock the protective door in case of emergency or power failure. To open the protective door, insert the dedicated release key and set the key lock to UNLOCK. If the key lock is set to UNLOCK, when the protective door is closed and people are doing preparation work on the machine inside, the protective door will not be locked and the machine will not start operating. Use the release key to set the key lock to LOCK. Do not use the release key to start or stop the machine. This key lock must be normally set to LOCK and sealed with a rubber cap in order to conform to IP67 requirements. The dedicated release key should be kept only by the person in charge. If necessary, to prevent easy access to the dedicated release key, seal the key lock using a suitable sealing wax. Be careful not to damage the key lock when breaking the seal between the rubber cap and the key lock. A cover can be attached to the D4BL. Before attaching the cover, make sure that the key lock is set to LOCK. HEAD DIRECTION CHANGES Left Front (45) (45) (A) (B) Back Right Head Bottom View Operation plunger and groove mechanism Switch Top View Rotation lever and protruding part LOCK UNLOCK Release key OPERATION KEY The D4BL is provided with a shock absorptive damper when shipped attached to the D4BL in order to prevent the D4BL from being damaged if it is dropped accidentally. Be sure to remove the shock absorptive damper after the D4BL is mounted. Do not impose excessive force to the Operation Key in the switch or drop the Operation Key, or the Operation Key may be deformed or damaged. Normal Positions of Rotating Lever and Plunger Switch body Rotating lever (with protruding part) Plunger (with groove) Dropping Do not operate the Safety-door Lock Switch with a tool other than OMRON's special Operation Key for the Safety-door Lock Switch, otherwise the Safety-door Lock Switch may be damaged or the safety of the system will not be assured. Built-in switch Be sure to check the mechanical lock and solenoid release functions when mounting the D4BL. If the head direction is changed, recheck the tightening torque of each of screw. Make sure that no foreign materials will penetrate through the key hole on the head. 13 D4BL D4BL OTHERS When connecting lead wires with crimp-style terminals to the built-in switch terminals, do not impose excessive force on the crimp-style terminals. Each crimp-style terminal must be connected in the direction as shown in the following illustrations and the crimp-style terminal must not be on the case or cover. Terminal screw Crimp-style terminal Terminal screw Terminal screw Crimp-style terminal Cover Cover Case Case Crimp-style terminal NOTE: DIMENSIONS SHOWN ARE IN MILLIMETERS. To convert millimeters to inches divide by 25.4. OMRON ELECTRONICS, INC. OMRON CANADA, INC. One East Commerce Drive Schaumburg, IL 60173 885 Milner Avenue Scarborough, Ontario M1B 5V8 1-800-55-OMRON 416-286-6465 Cat. No. CEDSAX3 10/99 Specifications subject to change without notice. Printed in U.S.A.