Safety-door Switch D4BS Safety-door Switch’s Special Operation Key Directly Pulls Apart the Contacts from Each Other and Contributes to the Safety of the Production Site • Conforms to EN (TÜV) standards corresponding to the CE marking. • Approved by UL, CSA, BIA, and SUVA standards. • The switch contact is opened by a direct opening mechanism (NC contacts only) when the protective cover is opened. The EN-approved direct opening mechanism is indicated by on the Switch. • Degree of protection of the switch box: IP67 (EN60947-5-1). • Series includes models with gold-plated contacts for handling the micro-load range. • Metric conduit types available. Model Number Structure Model Number Legend Switch D4BS - Operation Key D4BS - K S 1 2 3 1 1. Conduit 1: PG13.5 (1 conduit) 2: G1/2 (1 conduit) 3: 1/2-14NPT (1 conduit) 4: M20 5: PG13.5 (3-conduit) 6: G1/2 (3-conduit) 7: 1/2-14NPT (3-conduit) 8: M20 (3-conduit) 2. Built-in Switch 1. Operation Key Type 5: 1NC/1NO (slow-action) 1: Horizontal mounting 6: 1NC/NO (slow-action), gold-plated contacts 2: Vertical mounting A: 2NC (slow-action) 3: Adjustable mounting (Horizontal) B: 2NC (slow-action), gold-plated contacts 3. Head Mounting Direction F: Four mounting directions possible (front-side mounting at shipping) Ordering Information List of Models Switches Type Mounting direction 1-conduit Front-side mounting 3-conduit D-104 Conduit size Pg13.5 G1/2 M20 Pg13.5 G1/2 M20 1NC/1NO (Slow-action) D4BS-15FS D4BS-25FS D4BS-45FS D4BS-55FS D4BS-65FS D4BS-85FS 2NC (Slow-action) D4BS-1AFS D4BS-2AFS D4BS-4AFS D4BS-5AFS D4BS-6AFS D4BS-8AFS Safety Sensors / Components Operation Keys (Order Separately) Type Model Horizontal mounting D4BS-K1 Vertical mounting D4BS-K2 Adjustable mounting (Horizontal) D4BS-K3 Specifications Approved Standards Agency Standards and EC Directives Standard File No. EN60947-5-1 R9351022 (Direct opening: approved) UL CSA BIA SUVA UL508 CSA C22.2 No. 14 GS-ET-15 SUVA E76675 LR45746 9303323 E6187.d D4BS TÜV Rheinland Conforms to the following EC Directives: Machinery Directive Low Voltage Directive EN50041 EN1088 Approved Standard Ratings TÜV (EN60947-5-1) Utilization category Rated operating current (Ie) Rated operating voltage (Ue) AC-15 2A 400 V Note: Use a 10-A fuse type a gI or gG that conforms to IEC269 as a short-circuit protection device. UL/CSA (UL508, CSA C22.2 No. 14) A600 Rated voltage 120 VAC 240 VAC 480 VAC 600 VAC D4BS Current Carry current 10 A Make 60 A 30 A 15 A 12 A Volt-amperes Break 6A 3A 1.5 A 1.2 A Make 7,200 VA Break 720 VA D-105 Characteristics Degree of protection (see note 2) IP67 (EN60947-5-1) Mechanical:1,000,000 operations min. Electrical:500,000 operations min. (10 A at 250 VAC, resistive load) 0.1 m/s to 0.5 m/s 30 operations/min max. 50/60 Hz 2 x 2 mm min. 19.61 N min. (EN60947-5-1) 20 mm min. (EN60947-5-1) 23 mm min. 100 MW min. (at 500 VDC) between terminals of same or different polarity, between each terminal and ground, and between each terminal and non-current-carrying metal part 25 mW max. (initial value) 600 V (EN60947-5-1) 20 A (EN60947-5-1) Impulse dielectric strength (Uimp) 4 kV (EN60947-5-1) between terminals of same or different polarity, between current-carrying metal parts and ground, and between each terminal and non-current-carrying metal part 1,500 V max. (EN60947-5-1) 100 A (EN60947-5-1) 3 (EN60947-5-1) Class I (with ground terminal) Malfunction: 10 to 500 Hz, 0.65-mm single amplitude Destruction:1,000 m/s2 min. (IEC68-2-27) Malfunction:300 m/s2 min. (IEC68-2-27) Operating:-40°C to 80°C (with no icing) Operating:95% max. Approx. 285 g (in the case of D4BS-15FS) Durability (see note 3) Operating speed Operating frequency Rated frequency Contact gap Direct opening force (see note 4) Direct opening travel (see note 4) Full stroke Insulation resistance Contact resistance Rated insulation voltage (Ui) Conventional enclosed thermal current (Ithe) Dielectric strength (Uimp) Switching overvoltage Conditional short-circuit current Pollution degree (operating environment) Insulation class Vibration resistance Shock resistance Ambient temperature Ambient humidity Weight Note: 1. The above values are initial values. 2. Although the switch box is protected from dust, oil, or water penetration, do not use the D4BS in places where dust, oil, water, or chemicals may penetrate through the key hole on the head, otherwise Switch damage or malfunctioning may occur. 3. The durability is for an ambient temperature of 5° C to 35° C and an ambient humidity of 40% to 70%. Contact your OMRON sales representative for more detailed information on other operating environments. 4. These figures are minimum requirements for safe operation. Contact Form (Diagrams Show State with Key Inserted) Model Contact form Diagram Zb D4BS-#5#S 1NC/1NO 11 12 23 24 Zb D4BS-#A#S 2NC 11 12 21 22 11 - 12 23 - 24 Stroke Operation Key insertion completion position ON Extraction completion position 11 - 12 21 - 22 Stroke Operation Key insertion completion position Remarks Terminals 11-12 and 23-24 can be used as unlike poles. ON Extraction completion position Only NC contact 11-12 has an approved direct opening mechanism. NC contacts 11-12 and 21-22 have an approved direct opening mechanism. Terminals 11-12 and 21-22 can be used as unlike poles. Note: The terminal numbers are in accordance with EN50013, and the contact symbols are in accordance with IEC947-5-1. D-106 Safety Sensors / Components Nomenclature Head The switch head is coated with easy-to-see red paint. The mounting direction of the switch head can be varied to any of the four directions. Operation Key D4BS's exclusive-use Operation Key is provided to assure accurate switching operation. Set Zone Mark A triangular Set Zone Mark makes it easy to adjust the operating position when inserting the Operation Key. Seal Ring (NBR) Oil Seal (NBR) The operation plunger employs an oil seal, with which the switch box meets the requirements of IP67 (the sealing capability of the Operation Key's insertion mouth is IP00). Built-in Switch A shearing force contact separating mechanism (NC contact) is employed, which positively pulls apart the contacts from each other by using shearing force if any abnormality such as contact welding should occur in the contact area. Seal Packing (NBR) Conduit Opening Available in four different types of conduit threads: Pg 13.5, G1/2, or 1/2-14NPT, M20. There is a difference in level between the NC and NO terminal, which assures easy wiring. D4BS Ground Terminal Screw A ground terminal is provided to improve safety. (Built into the Unit.) D4BS D-107 Dimensions Note: 1. All units are in millimeters unless otherwise indicated. 2. Unless otherwise specified, a tolerance of ±0.4 mm applies to all dimensions. 3. The conduit thread varies with the model as follows:. Conduit thread Pg 13.5 G1/2 M20 Model D4BS-1##S, D4BS-5##S D4BS-2##S, D4BS-6##S D4BS-4##S, D4BS-8##S Switches 1-conduit D4BS-1##S D4BS-2##S D4BS-4##S 31.4 17 41 Red 16 Four, M3.5 head clamping screws 7 34.5 35 (111.5) Two, 5.3 dia. mounting holes Two, M4 cover clamping screws 60±0.2 31.4 17 41 10±5 mm Direct opening force Direct opening stroke 19.61 N min. 20 mm min. Operating characteristics D4BS-5##S D4BS-6##S D4BS-8##S Key insertion force Key extraction force 19.61 N max. 19.61 N max. Four, M3.5 head clamping screws 16 7 Red 19.61 N max. 19.61 N max. D4BS-1##S: Pg13.5 D4BS-2##S: G1/2 D4BS-4##S: 1/2-14NPT 15 31.5 43 40+1 0 3-conduit D4BS-5##S D4BS-6##S D4BS-8##S Key insertion force Key extraction force Pretravel (PT) 5.3 30±0.1 8 D4BS-1##S D4BS-2##S D4BS-4##S 77 Cover 7.3 Operating characteristics 34.5 5.3 (110) Six, 5.3 dia. mounting holes Four, M3.5 x 10 cover clamping screws Two caps Cover 30±0.2 50.9 66.4 Pretravel (PT) 71.4 75.4 17.2 51 28.5 57 63 D4BS-5##S: 3-Pg13.5 D4BS-6##S: 3-G1/2 D4BS-8##S: 3-1/2-14NPT 10±5 mm Direct opening force Direct opening stroke 19.61 N min. 20 mm min. Two, 5+0.15 dia. holes (6 mm deep) -0 35.7 38.3 Operation Keys 53.7 D4BS-K1 D4BS-K2 78.7 20±0.15 40.7 12 Black 26 5.3 5.3 26 40±0.15 52.4 15 Two, 2.65R 7.5 2.5 36 20 11.4 5.3 12 7.5 20 11.4 5 5 4 dia. 4 dia. 40 12 20 2.5 15 D4BS-K3 Black 26 40 30±0.15 (80.7) 36 2.5 11.4 Red 30 5.3 dia. mounting hole D-108 5.3 ¥ 7.3 mounting long hole Black 7.3 15 15 36 13 19.5±0.15 5 (37.8) 4 dia. 17.5 34.6 M4 Allen-head bolt Safety Sensors / Components With Operation Key Inserted Horizontal Mounting D4BS-1##S +D4BS-K1 D4BS-2##S +D4BS-K1 D4BS-4##S +D4BS-K1 Red 53.5 min. 58 max. Vertical Mounting D4BS-1##S +D4BS-K2 D4BS-2##S +D4BS-K2 D4BS-4##S +D4BS-K2 54.5 min. 59 max. Operation Key insertion radius in horizontal direction: R ≥ 1000 Operation Key insertion radius in horizontal direction: R ≥ 1200 53.5 min. 58 max. Operation Key insertion radius in horizontal direction: R ≥ 1000 Operation Key insertion radius in horizontal direction: R ≥ 1200 54.5 min. 59 max. D4BS Red Adjustable Mounting (Horizontal) D4BS-1##S +D4BS-K3 D4BS-2##S +D4BS-K3 81.5 min. D4BS-4##S +D4BS-K3 86 max. Operation Key insertion radius in horizontal direction: R ≥ 150 81.5 min. 86 max. Operation Key insertion radius in horizontal direction: R ≥ 1000 Red Note: "R" is the Operation Key insertion radius. Note: Unless otherwise specified, a tolerance of ±0.4 mm applies to all dimensions. D4BS D-109 Precautions Securing the Door Caution Do not dismount the Operation Key from the door intentionally and insert it to the Switch with the door open. Machine may start operating and injury or death may be caused. Mount the Operation Key at a location where it will not come in contact with users when the door is opened or closed. If the Operation Key on the closed door is pulled outside the set zone by a force caused by vibration, the door’s weight, or the door cushion rubber, the switch contact may be opened (causing the machinery to stop) or the D4BS may be damaged. Secure the door with hooks so that it will remain within the set zone. When operating the D4BS as a part of a safety category circuit to prevent injury, operate the NC contacts that have a direct opening mechanism in direct opening mode. For safety purposes, tighten the switch body and Operation Key with one-way screws or equivalents or install a switch protection cover and warning label for safety purposes to prevent easy removal of the D4BS. Extra space Connect the fuse to the D4BS in series to prevent it from short-circuit damage. The value of the breaking current of the fuse must be calculated by multiplying rated current by 150% to 200%. When using the D4BS with EN ratings, use 10-A fuse Type gI or gG that complies with IEC60269. Set zone Correct Use Operating Environment Mounting Make sure in advance that the environment is suitable, with no oil, water, or chemicals, as these may cause the seal to deteriorate, resulting in faulty contact, faulty isolation, current leakage, or burning. Do not use the Switch as a stopper. Be sure to install a stopper as shown in the following illustration when mounting the Switch. The range of space “a” must be determined according to the available set zone of the Operation Key. Do not use the D4BS in the following locations: • • • • Locations subject to severe temperature changes Locations subject to high temperatures or condensation Locations subject to severe vibration Locations where the product may come into direct contact with processing waste or dust Stopper a Switch Operation Key Be sure to use a special Operation Key only. Do not operate the D4BS with anything other than the special Operation Key, otherwise the D4BS may break or the safety of the system may not be maintained. Do not impose excessive force on the Operation Key inserted into the D4BS or drop the D4BS with the Operation Key inserted, otherwise the Operation Key may deform or break. Refer to Dimensions for the mounting dimension of the Operation Key and mount the Operation Key correctly. The Operation Key will soon become damaged or worn out if it is not mounted correctly. Make sure that the Operation Key can be inserted properly with a tolerance of ±0.5 mm in the upward, downward, left, or right direction, otherwise the D4BS may soon become damaged. Excessive force ±0.5 min. Drop Secure the Operation Key with a one-way screw, or an equivalent, so that the Operation Key cannot be easily removed. D-110 ±0.5 min. Safety Sensors / Components Other Mounting Dimensions (M5) Make sure that the D4BS is located outside the safety door and that no metal dust, oil, or chemical will be sprayed onto the D4BS. Otherwise, the D4BS may soon fail to operate due to the penetration of metal dust, oil, or chemical. Standard Model Three-conduit Model 30 40 42 Tightening Torque Be sure to tighten each screw of the D4BS properly, otherwise the D4BS may malfunction. 59.3±0.1 60 Protruding portions 27±0.1 30 5 -0.05 -0.15 dia. holes, max. height 5 Mounting hole Mounting side Insertion hole for protrusions -0.05 dia. holes, max. height 5 5-0.15 1 2 3 4 5 6 7 Type M3.5 terminal screw (including ground terminal screw) Cover mounting screw (see note 1) Head mounting screw M5 body mounting screw (see note 2) Operation Key mounting screw Connector Cap screw Torque 0.59 to 0.78 N·m Operating Key Mounting Dimensions Horizontal Mounting 1.18 to 1.37 N·m Two, M5 D4BS No. The D4BS can be mounted more securely by adding two protruding portions, each of which is 5 mm maximum in height and 5 –0.05/–0.15 mm in diameter as shown below. 0.78 to 0.98 N·m 20±0.1 4.90 to 5.88 N·m 2.35 to 2.75 N·m 1.77 to 2.16 N·m 1.27 to 1.67 N·m Note: 1. Apply a torque of 0.78 o 0.88 N·m if the D4BS is a three-conduit model. 2. Apply a torque of 4.90 to 5.88 N·m in the case of an Allenhead bolt. If it is a pan head screw, apply a torque of 2.35 to 2.75 N·m. Vertical Mounting Two, M5 40±0.1 Adjustable Mounting (Horizontal) Two, M5 30±0.1 Changes in Head Mounting Direction By removing the screws on the four corners of the head, the head can be reset in any of four directions. The head direction can be changed with or without the Operation Key inserted in the head. Make sure that no foreign materials penetrate through the head and that the head is tightened securely within the proper torque range. D4BS D-111 Wiring Connector Do not connect the lead wires directly to the terminals. Connect the lead wires through insulation tubes and M3.5 crimp terminals. Tighten each terminal screw within the proper torque range. Tighten the connector to a suitable torque. Excessive tightening torque may damage the casing. The proper lead wire is AWG20 to AWG14 (0.5 to 2.5 mm2) in size. dz dia.: D dia.: B: L: F: I: 3.7 4.5 7.0 20.2 7.7 9.0 (mm) When using a 1/2-14NPT conduit, apply sealing tape between connector and conduit opening so that the enclosure will confirm to IP67. If using a Pg13.5 conduit, use an ABS-08 Pg13.5 connector or an ABS-12 Pg13.5 connector (manufactured by Nippon Flex). Use a connector (SC Series, sold separately) suitable for the outer diameter of the cable. When wiring a 3-conduit model, securely tighten the cap screw provided for unused conduit openings. D dia. dz dia. Make sure that all crimp terminals are correctly connected and located within the casing or cover as shown below. Incorrect Correct Maintenance and Repairs The user must not maintain or repair equipment incorporating any D4BS model. Contact the manufacturer of the equipment for any maintenance or repairs required. Terminal screw Crimp terminal Incorrect Correct Crimp terminal Terminal screw Terminal screw Cover Cover Casing Crimp terminal Casing Crimp terminal Crimp terminal D-112 Safety Sensors / Components