Omron G9SB-2002-A Ultra slim safety relay unit Datasheet

Safety Relay Unit
G9SB
Ultra Slim Safety Relay Unit
• Models of width 17.5 mm available with 2 or 3 poles. Models of
width 22.5 mm with 3 poles also available.
• Conforms to EN standards. (TÜV approval)
• DIN track mounting possible.
Note: Be sure to read the “Safety Precautions” on page 8.
Ordering Information
Main contacts
DPST-NO
Auxiliary
contact
None
Number of input
channels
2 channels
Reset mode
Auto-reset
1 channel or 2
channels
2 channels
Manual reset
1 channel or 2
channels
3PST-NO
SPST-NC
None (direct
breaking)
Inverse
Rated voltage
24 VAC/VDC
Model
G9SB-2002-A
+ common
G9SB-200-B
Inverse
G9SB-2002-C
+ common
G9SB-200-D
---
24 VDC
2 channels
Inverse
24 VAC/VDC
1 channel or 2
channels
+ common
G9SB-301-B
Inverse
G9SB-3012-C
+ common
G9SB-301-D
2 channels
Auto-reset
Input type
Manual reset
1 channel or 2
channels
Category
4
G9SB-3010
(See note.)
3
G9SB-3012-A
4
Note: The G9SB-3010 can be applied to Safety Category 3 of the EN954-1 if double breaking is used.
Model Number Structure
■ Model Number Legend
G9SB-@@@@@-@
1 2 3 4 5
6
1. Function
None: Emergency stop
2. Contact Configuration (Safety Output)
2:
DPST-NO
3:
3PST-NO
3. Contact Configuration (OFF-delay Output)
0:
None
4. Contact Configuration (Auxiliary Output)
0:
None
1:
SPST-NC
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5. Input Configuration
None: 1-channel or 2-channel input possible
0:
None (direct breaking)
2:
2-channel input
6. Miscellaneous
A:
Auto-reset, inverse input
B:
Auto-reset, + common input
C:
Manual reset, inverse input
D:
Manual reset, + common input
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
1
G9SB
Specifications
■ Ratings
Power Input
Item
G9SB-200@-@
Power supply voltage
24 VAC/VDC: 24 VAC, 50/60 Hz, or 24VDC
24 VDC: 24 VDC
Operating voltage
range
85% to 110% of rated power supply voltage
Power consumption
1.6 VA/1.4 W max.
G9SB-3010
1.7 W max.
G9SB-301@-@
2.0 VA/1.7 W max.
Inputs
Item
G9SB-200@-@
Input current
25 mA max.
G9SB-3010
60 mA max. (See note.)
G9SB-301@-@
30 mA max.
Note: Indicates the current between terminals A1 and A2.
Contacts
Item
G9SB-200@-@
G9SB-3010
G9SB-301@-@
Resistive load
Rated load
250 VAC, 5 A
30 VDC, 5 A
Rated carry current
5A
■ Characteristics
Item
G9SB-200@-@
Contact resistance (See note 1.)
100 m:
Operating time (See note 2.)
30 ms max.
Response time (See note 3.)
10 ms max.
Insulation resistance (See note 4.)
100 M: min. (at 500 VDC)
Dielectric strength Between different
outputs
2,500 VAC, 50/60 Hz for 1 min
G9SB-3010
G9SB-301@-@
Between inputs
and outputs
Between power
inputs and outputs
Vibration resistance
Shock resistance
Durability
(See note 5.)
10 to 55 to 10 Hz, 0.375-mm single amplitude (0.75-mm double amplitude)
Destruction
300 m/s2
Malfunction
100 m/s2
Mechanical
5,000,000 operations min. (at approx. 7,200 operations/hr)
Electrical
100,000 operations min. (at approx. 1,800 operations/hr)
Failure rate (P level) (reference value)
5 VDC, 1 mA
Ambient operating temperature
25 to 55qC (with no icing or condensation)
Ambient operating humidity
35% to 85%
Terminal tightening torque
0.5 N·m
Weight
Approx. 115 g
Note: 1.
2.
3.
4.
5.
Approx. 135 g
Approx. 120 g
The contact resistance was measured with 1 A at 5 VDC using the voltage-drop method.
Not including bounce time.
The response time is the time it takes for the main contact to open after the input is turned OFF. Includes bounce time.
The insulation resistance was measured with 500 VDC at the same places that the dielectric strength was checked.
The durability is for an ambient temperature of 15 to 35qC and an ambient humidity of 25% to 75%.
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2
G9SB
Application Examples
G9SB-2002-A (24 VAC/VDC) or G9SB-3012-A (24 VAC/VDC) with 2-channel Limit Switch Input/
Auto-reset
Timing Chart
23
S2 24
Limit switches S1 and S2
11
S1
K1 and K2 (NC)
12
K1 and K2 (NO)
KM1
KM2
Open
KM1 and KM2 (NC)
Feedback loop
A1 A2 T11
T12
+ -
T31
T32
13
KM1 and KM2 (NO)
23
*
*
33
41
S1:
TH
K2
K1
K1
K2
a
SA
K1
Safety limit switch with direct
opening mechanism (NC)
(D4B-N, D4N, D4F)
S2:
Limit switch (NO)
KM1 and KM2: Magnetic Contactor
K1
Control
circuit
K2
M:
a
3-phase motor
KM1
K2
14
T22
T21
24
34
42
KM2
Note: Only the G9SB-3012-A
model has terminals 33-34
and 41-42.
* *
See note.
KM1 KM2
M
Note: 1. External connections and timing charts for G9SB-200-B/301-B models are the same as those for G9SB-2002-A/3012-A models.
2. This circuit conforms to EN954-1 Safety Category 4.
G9SB-2002-C (24 VAC/VDC) or G9SB-3012-C (24 VAC/VDC) with 2-channel Emergency Stop
Switch Input/Manual Reset
Timing Chart
S1
21
11
22
12
Emergency stop switch S1
KM1
Reset switch S2
KM2
S2
K1 and K2 (NC)
Feedback loop
K1 and K2 (NO)
KM1 and
KM2 (NC)
* *
A1 A2 T11
+ -
TH
T12
T31
T32
K2
K1
a
K1
23
33
41
KM1 and
KM2 (NO)
Note: Output turns ON with the rising edge of reset switch S2,
but will not operate if there is
a short breakdown in S2.
K1
K1
K2
SA
13
Control
circuit
K2
KM1
a
K2
S1:
KM2
T21
T22
14
24
34
42
S2:
* *
KM1 and KM2: Magnetic Contactor
See note.
KM1 KM2
Emergency stop switch with
direct opening mechanism
(A165E, A22E)
Reset switch
M:
M
3-phase motor
Note: Only the G9SB-3012-C model
has terminals 33-34 and 4142.
Note: 1. External connections and timing charts for G9SB-200-D/301-D models are the same as those for G9SB-2002-C/3012-C models.
2. This circuit conforms to EN954-1 Safety Category 4.
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3
G9SB
G9SB-200-D (24 VAC/VDC) or G9SB-301-D (24 VAC/VDC) with 2-channel Safety Sensor/Manual
Reset
Emitter
Receiver
Reset switch S1
K1 and K2 (NC)
Shield
0V (Blue)
OSSD2 (White)
OSSD1 (Green)
EDM input (Red)
Auxiliary (Yellow)
RS-485(B) (Pink)
+24 V (Brown)
Timing Chart
F3SN-A: Incident
Interrupted
+24 V (Brown)
Interlock selection
input (White)
RS-485(A) (Gray)
K1 and K2 (NO)
Open
Reset input (Yellow)
(Red)
Open
0V (Blue)
Shield
Test input (Green)
F3SN-A
KM1 and KM2 (NC)
(See note 2.)
KM1 and KM2 (NO)
Note: Output turns ON with the rising edge of
reset switch S1, but will not operate if
there is a short breakdown in S1.
Feedback loop
KM1
KM2
S1
F3SN-A:
S1:
KM1 and KM2:
M:
E1:
Safety Area Sensor
Reset switch
Magnetic Contactor
3-phase motor
24-VDC power supply (S82K)
E1
A1 A2
T21
T11
T12
T22
T31
T32
13
23
*
*
33
41
+ -
TH
K1
K2
K2
a
SA
K1
a
Control
circuit
Note: 1. Only the G9SB301-D model
has terminals
33-34 and 4142.
2. Wiring is shown
for when the
F3SN-A
auxiliary output
turns ON for
light
interruption.
K1
K1
KM1
K2
K2
KM2
14
24
34
*
KM1 KM2
42
*
See note.
M
Note: This circuit conforms to EN954-1 Safety Category 4.
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4
G9SB
G9SB-3010 (24 VDC) with 2-channel Limit Switch Input/Auto-reset
Timing Chart
Limit switches S1 and S2
23
K1 and K2 (NC)
S2
24
KM1
K1 and K2 (NO)
KM2
11
S1
KM1 and KM2 (NC)
12
Feedback loop
KM1 and KM2 (NO)
Open
A1
A2
+
T31
13
T32
23
33 41
-
S1:
TH
K1
K2
K1
K2
a
SA
K1
Control
circuit
Safety limit switch with direct
opening mechanism (NC)
(D4B-N, D4N, D4F)
S2:
Limit switch (NO)
KM1 and KM2: Magnetic Contactor
M:
3-phase motor
K1
K2
a
KM1
K2
14
24
34 42
KM2
KM1 KM2
M
Note: This circuit conforms to EN954-1 Safety Category 3.
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5
G9SB
Dimensions
G9SB-200@-@
G9SB-3010
Terminal Arrangement
G9SB-200@-@
G9SB-3010
83
13 23 33
41 T31 A1
PWR
K1
K2
18
2.5
2 × 5 = 10
112 max.
100 max. 68
13 23 T31
T11 T12 A1
(green)
(orange)
(orange)
PWR
K1
K2
(green)
(orange)
(orange)
T21 T22 A2
42 T32 A2
14 24 T32
14 24 34
2.6
48
18 max.
(Average: 17.5)
G9SB-301-@-@
83
Terminal Arrangement
18
G9SB-301-@-@
2.5
13 23 33 41
3 × 5 = 15
112 max.
T11 T12 T31 A1
2.6
PWR (green)
K1 (orange)
K2 (orange)
T21 T22 T32 A2
100 max. 68
48
14 24 34 42
23 max.
(Average: 22.5)
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6
G9SB
Connections
■ Internal Connections
G9SB-2002-A/C (24 VAC/VDC)
G9SB-3012-A/C (24 VAC/VDC)
A1 A2 T11
+ -
TH
T12
T31
T32
K2
K1
33
41
14
24
34
42
K1
a
K1
23
K1
K2
SA
* *
13
Control
circuit
K2
a
K2
T22
T21
* *
G9SB-200-B/D (24 VAC/VDC)
G9SB-301-B/D (24 VAC/VDC)
A1 A2
T21
T11
T12
T22
T31
T32
13
23
14
24
* *
33
41
34
42
+ -
TH
K1
K2
K1
K1
K2
a
SA
K1
a
Control
circuit
K2
K2
* *
G9SB-3010 (24 VDC)
A1
A2
+
T31
T32
13
23
33 41
14
24
34 42
TH
K1
K2
K2
a
SA
K1
Control
circuit
K1
K1
K2
a
K2
Note: 1. For 1-channel input with G9SB-@@@-B/D models, short
terminals T12 and T22. It is not possible to wire G9SB@@@2-A/C models for 1-channel input.
2. Always provide a protective ground externally, e.g., on the
power supply.
* Only G9SB-301@-@ models have terminals 33-34 and 41-42.
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7
G9SB
Safety Precautions
Refer to the “Precautions for All Relays” and “Precautions for All Relays with Forcibly Guided Contacts”.
!CAUTION
Turn OFF the G9SB before wiring the G9SB. Do not touch
the terminals of the G9SB while the power is turned ON,
because the terminals are charged and may cause an
electric shock.
■ Precautions for Correct Use
Installation
• The G9SB can be installed in any direction.
Wiring
• Use the following to wire the G9SB.
Stranded wire: 0.2 to 2.5 mm2
Solid wire:
0.2 to 2.5 mm2
• Tighten each screw to a torque of 0.5 to 0.6 N·m, or the G9SB may
malfunction or generate heat.
• External inputs connected to T11 and T12 or T21 and T22 of the
G9SB must be no-voltage contact inputs.
Mounting Multiple Units
• When mounting multiple Units close to each other, the rated current
will be 3 A. Do not apply a current higher than 3 A.
Connecting Inputs
• If using multiple G9SB models, inputs cannot be made using the
same switch. This is also true for other input terminals.
T11 T12
T11 T12
G9SB
G9SB
Ground Shorts
• A positive thermistor (TH) is built into the G9SB internal circuit to
detect ground shorts and shorts between channels 1 and 2. When
such faults are detected, the safety outputs are interrupted. (Only
G9SB-2002-@/3012-@ is able to detect shorts between channels 1
and 2.)
If the short breakdown is repaired, the G9SB automatically
recovers.
Note: In order to detect earth short breakdowns, connect the minus
side of the power supply to ground.
Resetting Inputs
• When only channel 1 of the 2-channel input turns OFF, the safety
output is interrupted. In order to restart when this happens, it is
necessary to turn OFF and ON both input channels. It is not
possible to restart by resetting only channel 1.
■ Applicable Safety Category
(EN954-1)
G9SB-200@-@/301@-@ meet the requirements of Safety Category 4
of the EN954-1 standards when they are used as shown in the
examples provided by OMRON. Relays may not meet the standards
in some operating conditions. The G9SB-3010 can be applied to
Safety Category 3 of the EN954-1 using double breaking.
The applicable safety category is determined from the whole safety
control system. Make sure that the whole safety control system
meets EN954-1 requirements.
■ Certified Standards
The G9SB-200@-@/3010/301@-@ conforms to the following
standards.
• EN standards, certified by TÜV Rheinland:
EN954-1
EN60204-1
• Conformance to EMC (Electromagnetic Compatibility), certified by
TÜV Rheinland
EMI (Emission): EN55011 Group 1 Class A
EMS (Immunity): EN61000-6-2
• UL standards: UL508 (Industrial Control Equipment)
• CSA standards: CSA C22.2 No. 14 (Industrial Control Equipment)
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. J130-E1-05
In the interest of product improvement, specifications are subject to change without notice.
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8
Precautions for All Relays with Forcibly Guided Contacts
Note: Refer to the Safety Precautions section for each Switch for specific precautions applicable to each Switch.
■ Precautions for Safe Use
CE Marking
Mounting
(Source: Guidelines on the Application of Council Directive 73/23/
EEC)
The Relays with Forcibly Guided Contacts can be mounted in any
direction.
Relays with Forcibly Guided Contacts
While the Relay with Forcibly Guided Contacts has the previously
described forcibly guided contact structure, it is basically the same as
an ordinary relay in other respects. Rather than serving to prevent
malfunctions, the forcibly guided contact structure enables another
circuit to detect the condition following a contact weld or other
malfunction. Accordingly, when a contact weld occurs in a Relay with
Forcibly Guided Contacts, depending on the circuit configuration, the
power may not be interrupted, leaving the Relay in a potentially
dangerous condition (as shown in Fig. 1.)
To configure the power control circuit to interrupt the power when a
contact weld or other malfunction occurs, and to prevent restarting
until the problem has been eliminated, add another Relay with
Forcibly Guided Contacts or similar Relay in combination to provide
redundancy and a self-monitoring function to the circuit (as shown in
Fig. 2). Refer to the Technical Guide section.
The G9S/G9SA/G9SB Safety Relay Unit, which combines Relays
such as the Relay with Forcibly Guided Contacts in order to provide
the above-described functions, is available for this purpose. By
connecting a contactor with appropriate input and output to the
Safety Relay Unit, the circuit can be equipped with redundancy and a
self-monitoring function.
Fig 1
The G7SA, G7S and G7S-@-E have been recognized by the VDE for
meeting the Low Voltage Directive according to EN requirements for
relays and relays with forcibly guided contacts. The Low Voltage
Directive, however, contains no clauses that specify handling
methods for components, and interpretations vary among test sites
and manufacturers. To solve this problem, the European Commission
has created guidelines for the application of the Low Voltage
Directive in EU. These guidelines present concepts for applying the
Low Voltage Directive to components. The G7SA, G7S and G7S-@E, however, do not display the CE Marking according to the concepts
in the guidelines.
VDE recognition, however, has been obtained, so there should be no
problems in obtaining the CE Marking for machines that use the
G7SA, G7S or G7S-@-E. Use the manufacturer’s compliance
declaration to prove standard conformance.
Contents of the Guidelines
The Guidelines on the Application of Council Directive 73/23/EEC
apply to components. Relays with PWB terminals are not covered by
the Low Voltage Directive.
Fig 2
S1
S1
21
11
22
12
S2
K1
S2
K1
K1
A1 A2 T11 T12
+ −
B1
Y1 X1
D
Power source
F1
K3 K1
K1
PE T21
K3 K2
K2
T22
K3
13
K1
K1
K2
K2
K3
14
Power source
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C-1
Precautions for All Relays
Refer to the Safety Precautions section for each Relay for specific precautions applicable to that Relay.
■ Precautions for Safe Use
These precautions are required to ensure safe operation.
• Do not touch the charged Relay terminal area or the charged
socket terminal area while the power is turned ON. Doing so may
result in electric shock.
• Do not use a Relay for a load that exceeds the Relay's switching
capacity or other contact ratings. Doing so will reduce the specified
performance, causing insulation failure, contact welding, and
contact failure, and the Relay itself may be damaged or burnt.
• Do not drop or disassemble Relays. Doing so may reduce Relay
characteristics and may result in damage, electric shock, or
burning.
• Relay durability depends greatly on the switching conditions.
Confirm operation under the actual conditions in which the Relay
will be used. Make sure the number of switching operations is
within the permissible range. If a Relay is used after performance
has deteriorated, it may result in insulation failure between circuits
and burning of the Relay itself.
• Do not apply overvoltages or incorrect voltages to coils, or
incorrectly wire the terminals. Doing so may prevent the Relay from
functioning properly, may affect external circuits connected to the
Relay, and may cause the Relay itself to be damaged or burnt.
• Do not use Relays where flammable gases or explosive gases may
be present. Doing so may cause combustion or explosion due to
Relay heating or arcing during switching.
• Perform wiring and soldering operations correctly and according to
the instructions contained in Precautions for Correct Use given
below. If a Relay is used with faulty wiring or soldering, it may
cause burning due to abnormal heating when the power is turned
ON.
■ Precautions for Correct Use
Contents
No.
Area
No. Classification No.
A
Using Relays
B
Selecting
Relays
C
Circuit
Design
Item
Page
C-3
C-4
A
Mounting
Structure and
Type of
Protection
1
2
3
Type of Protection
Combining Relays and Sockets
Using Relays in Atmospheres Subject to Dust
B
Drive Circuits
1
2
Providing Power Continuously for Long Periods
Operation Checks for Inspection and Maintenance
C-4
C
Loads
1
2
Contact Ratings
Using Relays with a Microload
C-4
A
Load Circuits
1
C-5
2
3
4
5
6
7
8
9
10
11
Load Switching
A Resistive Loads and Inductive Loads
B Switching Voltage
C Switching Current
Electrical Durability
Failure Rates
Contact Protection Circuits
Countermeasures for Surge from External Circuits
Connecting Loads for Multi-pole Relays
Motor Forward/Reverse Switching
Power Supply Double Break with Multi-pole Relays
Short-circuiting Due to Arcing between NO and NC Contacts in SPDT Relays
Using SPST-NO/SPST-NC Contact Relays as an SPDT Relay
Connecting Loads of Differing Capacities
B
Input Circuits
1
2
3
4
5
6
7
8
9
10
11
12
13
Maximum Allowable Voltage
Voltage Applied to Coils
Changes in Must-operate Voltage Due to Coil Temperature
Applied Voltage Waveform for Input Voltage
Preventing Surges when the Coil Is Turned OFF
Leakage Current to Relay Coils
Using with Infrequent Switching
Configuring Sequence Circuits
Connecting Relay Grounds
Individual Specifications for Must-operate/release Voltages and Operate/Release Times
Using DC-operated Relays, (1) Input Power Supply Ripple
Using DC-operated Relays, (2) Coil Polarity
Using DC-operated Relays, (3) Coil Voltage Insufficiency
C-7
C
Mounting
Design
1
2
3
4
Lead Wire Diameters
When Sockets are Used
Mounting Direction
When Devices Such as Microcomputers are in Proximity
C-9
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C-2
No.
Area
No. Classification No.
D
Operating and Storage
Environments
E
Relay
Mounting
Operations
1
2
3
4
5
6
7
8
Item
Page
Operating, Storage, and Transport
C-9
Operating Atmosphere
Using Relays in an Atmosphere Containing Corrosive Gas (Silicon, Sulfuric, or Organic Gas)
Adhesion of Water, Chemicals, Solvent, and Oil
Vibration and Shock
External Magnetic Fields
External Loads
Adhesion of Magnetic Dust
A
Plug-in Relays 1
2
3
Panel-mounting Sockets
Relay Removal Direction
Terminal Soldering
B
Printed Circuit 1
Board Relays
Ultrasonic Cleaning
C
Common Items 1
2
3
4
Removing the Case and Cutting Terminals
Deformed Terminals
Replacing Relays and Performing Wiring Operations
Coating and Packing
F
Handling Relays
1
2
Vibration and Shock
Dropped Products
C-11
G
Relays for Printed Circuit Boards
(PCBs)
1
2
3
4
Selecting PCBs, (1) PCB Materials
Selecting PCBs, (2) PCB Thickness
Selecting PCBs, (3) Terminal Hole and Land Diameters
Mounting Space
A Ambient Temperature
B Mutual Magnetic Interference
Pattern Design for Noise Countermeasures
A Noise from Coils
B Noise from Contacts
C High-frequency Patterns
Shape of Lands
Pattern Conductor Width and Thickness
Conductor Pitch
Securing the PCB
Automatic Mounting of PCB Relays
C-11
5
6
7
8
9
10
H
C-10
C-15
Troubleshooting
A Using Relays
• When actually using Relays, unanticipated failures may occur. It is
therefore essential to test the operation is as wide of range as
possible.
• Unless otherwise specified in this catalog for a particular rating or
performance value, all values are based on JIS C5442 standard
test conditions (temperature: 15 to 35°C, relative humidity: 25% to
75%, air pressure: 86 to 106 kPa). When checking operation in the
actual application, do not merely test the Relay under the load
conditions, but test it under the same conditions as in the actual
operating environment and using the actual operating conditions.
• The reference data provided in this catalog represent actual
measured values taken from samples of the production line and
shown in diagrams. They are reference values only.
• Ratings and performance values given in this catalog are for
individual tests and do not indicate ratings or performance values
under composite conditions.
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C-3
B Selecting Relays
A Mounting Structure and Type of Protection
B-A-1 Type of Protection
If a Relay is selected that does not have the appropriate type of
protection for the atmosphere and the mounting conditions, it may
cause problems, such as contact failure.
Refer to the type of protection classifications shown in the following
table and select a Relay suitable to the atmosphere in which it is to
be used.
Classification by Type of Protection
Item Features
Representative model
Mounting
structure
Type of
protection
PCB-mounted
Relay
Flux protection
G7SA
Structure that
helps prevent
flux from
entering Relays
during soldering
Unsealed
G7S
Structure that
protects against
contact with
foreign material
by means of
enclosure in a
case (designed
for manual
soldering)
Atmosphere conditions
Dust and dirt
Corrosive
gases
Some protection No protection
(No large dust or
dirt particles
inside Relay.)
B-A-2 Combining Relays and Sockets
B Drive Circuits
Use OMRON Relays in combination with specified OMRON Sockets.
If the Relays are used with sockets from other manufacturers, it may
cause problems, such as abnormal heating at the mating point due to
differences in power capacity and mating properties.
B-B-1 Providing Power Continuously for Long Periods
B-A-3 Using Relays in Atmospheres Subject to Dust
If a Relay is used in an atmosphere subject to dust, dust will enter
the Relay, become lodged between contacts, and cause the circuit to
fail to close. Moreover, if conductive material such as wire clippings
enter the Relay, it will cause contact failure and short-circuiting.
Implement measures to protect against dust as required by the
application.
If power is continuously provided to the coil for a long period,
deterioration of coil insulation will be accelerated due to heating of
the coil. Also see 3-2-7 Using with Infrequent Switching.
B-B-2 Operation Checks for Inspection and
Maintenance
If a socket with an operation indicator is used, Relay status during
operation can be shown by means of the indicator, thereby facilitating
inspection and maintenance.
Type
Built-in indicator
Description
LED
Examples of
applicable models
G7S
G7SA
Note: The built-in indicator shows that power is being provided to the
coil. The indicator is not based on contact operation.
C Loads
B-C-1 Contact Ratings
Contact ratings are generally shown for resistance loads and
inductive loads.
B-C-2 Using Relays with a Microload
Check the failure rate in the performance tables for individual
products.
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(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-4
C Circuit Design
A Load Circuits
AC Loads and Inrush Current
In actual Relay operation, the switching capacity, electrical durability,
and applicable load will vary greatly with the type of load, the
ambient conditions, and the switching conditions. Confirm operation
under the actual conditions in which the Relay will be used.
A Resistive Loads and Inductive Loads
The switching power for an inductive load will be lower than the
switching power for a resistive load due to the influence of the
electromagnetic energy stored in the inductive load.
B Switching Voltage (Contact Voltage)
The switching power will be lower with DC loads than it will with AC
loads. Applying voltage or current between the contacts exceeding
the maximum values will result in the following:
1. The carbon generated by load switching will accumulate around
the contacts and cause deterioration of insulation.
2. Contact deposits and locking will cause contacts to malfunction.
Solenoid
Approx.
10
Incandescent bulb
Approx.
10 to 15
Motor
Approx.
5 to 10
Relay
Approx.
2 to 3
Capacitor
Approx.
20 to 50
Resistive
load
1
C Switching Current (Contact Current)
Current applied to contacts when they are open or closed will have a
large effect on the contacts. For example, when the load is a motor or
a lamp, the larger the inrush current, the greater the amount of
contact exhaustion and contact transfer will be, leading to deposits,
locking, and other factors causing the contacts to malfunction.
(Typical examples illustrating the relationship between load and
inrush current are given below.) If a current greater than the rated
current is applied and the load is from a DC power supply, the
connection and shorting of arcing contacts will result in the loss of
switching capability.
Current
DC Loads and Inrush Current
Incandescent bulb
(approx. 6 to 11 times
steady-state current)
Motor
(approx. 5 to
10 times steadystate current)
Waveform
Type of load Ratio of
inrush
current
to
steadystate
current
Inrush current
C-A-1 Load Switching
Steadystate
current
C-A-2 Electrical Durability
Electrical durability will greatly depend on factors such as the coil
drive circuit, type of load, switching frequency, switching phase, and
ambient atmosphere. Therefore be sure to check operation in the
actual application.
Coil drive circuit
Rated voltage applied to coil using
instantaneous ON/OFF
Type of load
Rated load
Switching frequency
According to individual ratings
Switching phase
(for AC load)
Random ON, OFF
Ambient atmosphere
According to JIS C5442 standard test
conditions
Resistive load
C-A-3 Failure Rates
Relay,
solenoid
Time (t)
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The failure rates provided in this catalog are determined through
tests performed under specified conditions. The values are reference
values only. The values will depend on the operating frequency, the
ambient atmosphere, and the expected level of reliability of the
Relay. Be sure to check relay suitability under actual load conditions.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-5
C-A-4 Contact Protection Circuits
1. Depending on factors such as the nature of the load and the
Relay characteristics, the effects may not occur at all or adverse
effects may result. Therefore be sure to check operation under
the actual load conditions.
2. When a contact protection circuit is used, it may cause the
release time (breaking time) to be increased. Therefore be sure to
check operation under the actual load conditions.
Using a contact protection circuit is effective in increasing contact
durability and minimizing the production of carbides and nitric acid.
The following table shows typical examples of contact protection
circuits. Use them as guidelines for circuit design.
Typical Examples of Contact Protection Circuits
Circuit example
Applicable
current
AC
CR
(See
remarks.)
(Yes)
C
R
Element selection
*Load impedance must be much smaller than
the CR circuit impedance when using the Relay
for an AC voltage.
When the contacts are open, current flows to the
inductive load via CR.
Use the following as guides for C and R values:
C: 0.5 to 1 μF per 1 A of contact current (A)
R: 0.5 to 1 Ω per 1 V of contact voltage (V)
These values depend on various factors,
including the load characteristics and variations
in characteristics. Confirm optimum values
experimentally.
Capacitor C suppresses the discharge when the
contacts are opened, while the resistor R limits
the current applied when the contacts are closed
the next time.
Generally, use a capacitor with a dielectric
strength of 200 to 300 V. For applications in an
AC circuit, use an AC capacitor (with no polarity).
If there is any question about the ability to cut off
arcing of the contacts in applications with high
DC voltages, it may be more effective to connect
the capacitor and resistor across the contacts,
rather than across the load. Perform testing with
the actual equipment to determine this.
DC
*See
Yes
remarks.
Power
supply
Features and remarks
Inductive
load
Yes
Yes
The release time of the contacts will be
increased if the load is a Relay or solenoid.
No
Yes
The electromagnetic energy stored in the
inductive load reaches the inductive load as
current via the diode connected in parallel, and
is dissipated as Joule heat by the resistance of
the inductive load. This type of circuit increases
the release time more than the CR type.
No
Yes
This circuit effectively shortens the release time The breakdown voltage of the Zener diode
in applications where the release time of a diode should be about the same as the supply voltage.
circuit is too slow.
Yes
Yes
This circuit prevents a high voltage from being
applied across the contacts by using the
constant-voltage characteristic of a varistor. This
circuit also somewhat increases the release
time. Connecting the varistor across the load is
effective when the supply voltage is 24 to 48 V,
and across the contacts when the supply voltage
is 100 to 240 V.
(See
C
remarks.)
Power
supply
R
Inductive
load
Diode
Power
supply
Inductive
load
Diode + Zener
diode
Power
supply
Inductive
load
Varistor
Power
supply
Use a diode having a reverse breakdown voltage
of more than 10 times the circuit voltage, and a
forward current rating greater than the load
current. A diode having a reverse breakdown
voltage two or three times that of the supply
voltage can be used in an electronic circuit
where the circuit voltage is not particularly high.
Inductive
load
The cutoff voltage Vc must satisfy the following
conditions. For AC, it must be multiplied by 2 .
Vc > (Supply voltage × 1.5)
If Vc is set too high, its effectiveness will be
reduced because it will fail to cut off high
voltages.
Do not use the following types of contact protection circuit.
C
Power
supply
Load
This circuit arrangement is very effective for diminishing
arcing at the contacts when breaking the circuit. However,
since electrical energy is stored in C (capacitor) when the
contacts are open, the current from C flows into the
contacts when they close. This may lead to contact
welding.
Power C
supply
Load
This circuit arrangement is very useful for diminishing
arcing at the contacts when breaking the circuit. However,
since the charging current to C flows into the contacts
when they are closed, contact welding may occur.
Note: Although it is thought that switching a DC inductive load is more difficult than a resistive load, an appropriate contact protection circuit can achieve almost the
same characteristics.
C-A-5 Countermeasures for Surge from External
Circuits
Install contact protection circuits, such as surge absorbers, at
locations where there is a possibility of surges exceeding the Relay
withstand voltage due to factors such as lightning. If a voltage
exceeding the Relay withstand voltage value is applied, it will cause
line and insulation deterioration between coils and contacts and
between contacts of the same polarity.
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C-6
C-A-6 Connecting Loads for Multi-pole Relays
Arc short-circuiting occurs.
Connect multi-pole Relay loads according to diagram "a" below to
avoid creating differences in electric potential in the circuits. If a
multi-pole Relay is used with an electric potential difference in the
circuit, it will cause short-circuiting due to arcing between contacts,
damaging the Relays and peripheral devices.
Load
Incorrect
Example of incorrect circuit
Load
X1
Power
supply
Load Load Load
Load
X2
Load
Power
supply
ON
X1
Load
Load
ON
Load
X2
Example of correct circuit
a. Correct Connection
b. Incorrect Connection
C-A-7 Motor Forward/Reverse Switching
Switching a motor between forward and reverse operation creates an
electric potential difference in the circuit, so a time lag (OFF time)
must be set up using multiple Relays.
Correct
C-A-10 Using SPST-NO/SPST-NC Contact Relays as an
SPDT Relay
Do not construct a circuit so that overcurrent and burning occur if the
NO, NC and SPDT contacts are short-circuited. Also, with SPST-NO/
SPST-NC Relays, a short-circuit current may flow for forward/reverse
motor operation.
(Short-circuit current)
Power supply
Arc short-circuiting occurs.
M
Incorrect
ON
ON
X1
X1
ON
X2
X2
M
L
C-A-11 Connecting Loads of Differing Capacities
B
Example of Incorrect Circuit
X2
OFF time
B Input Circuits
B
Reverse
operation
Motor
X1
Example of Correct Circuit
Correct
Forward
operation
OFF
time
Do not have a single Relay simultaneously switching a large load and
a microload. The purity of the contacts used for microload switching
will be lost as a result of the contact spattering that occurs during
large load switching, and this may give rise to contact failure during
microload switching.
Forward
operation
OFF
time
C-A-8 Power Supply Double Break with Multi-pole
Relays
If a double break circuit for the power supply is constructed using
multi-pole Relays, take factors into account when selecting models:
Relay structure, creepage distance, clearance between unlike poles,
and the existence of arc barriers. Also, after making the selection,
check operation in the actual application. If an inappropriate model is
selected, short-circuiting will occur between unlike poles even when
the load is within the rated values, particularly due to arcing when
power is turned OFF. This can cause burning and damage to
peripheral devices.
C-A-9 Short-circuiting Due to Arcing between NO and
NC Contacts in SPDT Relays
With Relays that have NO and NC contacts, short-circuiting between
contacts will result due to arcing if the space between the NO and
NC contacts is too small or if a large current is switched.
Do not construct a circuit in such a way that overcurrent and burning
occur if the NO, NC, and SPDT contacts are short-circuited.
C-B-1 Maximum Allowable Voltage
The coil's maximum allowable voltage is determined by the coil
temperature increase and the heat withstand temperature of the
insulation material. (If the heat withstand temperature is exceeded, it
will cause coil burning and layer shorting.) There are also important
restrictions imposed to prevent problems such as thermal changes
and deterioration of the insulation, damage to other control devices,
injury to humans, and fires, so be careful not to exceed the specified
values provided in this catalog.
C-B-2 Voltage Applied to Coils
Apply only the rated voltage to coils. The Relays will operate at the
must-operate voltage or greater, but the rated voltage must be
applied to the coils in order to obtain the specified performance.
C-B-3 Changes in Must-operate Voltage Due to Coil
Temperature
It may not be possible to satisfy this catalog values for must-operate
voltages during a hot start or when the ambient temperature exceeds
23°C, so be sure to check operation under the actual application
conditions.
Coil resistance is increased by a rise in temperature causing the
must-operate voltage to increase. The resistance thermal coefficient
of a copper wire is approximately 0.4% per 1°C, and the coil
resistance also increases at this percentage.
This catalog values for the must-operate voltage and must-release
voltage are given for a coil temperature of 23°C.
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C-7
C-B-4 Applied Voltage Waveform for Input Voltage
C-B-8 Configuring Sequence Circuits
As a rule, power supply waveforms are based on the rectangular
(square) waveforms, and do not operate in such a way that the
voltage applied to the coil slowly rises and falls. Also, do not use
them to detect voltage or current limit values (i.e., using them for
turning ON or OFF at the moment a voltage or current limit is
reached).
When configuring a sequence circuit, care must be taken to ensure
that abnormal operation does not occur due to faults such as sneak
current.
This kind of circuit causes faulty sequence operations. For example,
the simultaneous operability of contacts may not be dependable (for
multi-pole Relays, time variations must occur in contact operations),
and the must-operate voltage varies with each operation. In addition,
the operation and release times are lengthened, causing durability to
drop and contact welding. Be sure to use an instantaneous ON/OFF.
The following diagram shows an example of sneak current. After
contacts A, B, and C are closed causing Relays X1, X2, and X 3 to
operate, and then contacts B and C are opened, a series circuit is
created from A to X1 to X2 to X3. This causes the Relay to hum or to
not release.
A
B
X1
X2
X3
C-B-5 Preventing Surges when the Coil Is Turned OFF
Counter electromotive force generated from a coil when the coil is
turned OFF causes damage to semiconductor elements and faulty
operation.
As a countermeasure, install surge absorbing circuits at both ends of
the coil. When surge absorbing circuits have been installed, the
Relay release time will be lengthened, so be sure to check operation
using the actual circuits.
C
The following diagram shows an example of a circuit that corrects the
above problem. Also, in a DC circuit, the sneak current can be
prevented by means of a diode.
C
External surges must be taken into account for the repetitive peak
reverse voltage and the DC reverse voltage, and a diode with
sufficient capacity used. Also, ensure that the diode has an average
rectified current that is greater than the coil current.
Do not use under conditions in which a surge is included in the power
supply, such as when an inductive load is connected in parallel to the
coil. Doing so will cause damage to the installed (or built-in) coil
surge absorbing diode.
C-B-6 Leakage Current to Relay Coils
Do not allow leakage current to flow to Relay coils. Construct a
corrective circuit as shown in examples 1 and 2 below.
Example: Circuit with Leakage Current Occurring
TE
IO
Incorrect
Incorrect
D
B
A
X1
X2
X3
Correct
C-B-9 Connecting Relay Grounds
Do not connect a ground when using a Relay at high temperatures or
high humidity. Depending on the grounding method, electrolytic
corrosion may occur, causing the wire to the coil to sever. If the Relay
must be grounded, use the method shown in the following diagrams.
(1) Ground the positive side of the power supply. (Fig. 1 and Fig. 2)
(2) If grounding the positive side of the power supply is not possible
and the negative side must be grounded, connect a switch at the
positive side so that the coil is connected to the negative side.
(Fig. 3)
(3) Do not ground the negative side and connect a switch to the
negative side. This will cause electrolytic corrosion to occur. (Fig.
4)
Core
Core
Corrective Example 1
Correct
Fig. 1
Correct
Fig. 2
Difference in electric potential
Core
Corrective Example 2:
When an Output Value Is Required in the Same Phase as the
Input Value
Core
Correct
Correct
Fig. 3
Incorrect
Fig. 4
C-B-10 Individual Specifications for Must-operate/
release Voltages and Operate/Release Times
Correct
C-B-7 Using with Infrequent Switching
If it is necessary to know the individual specifications of
characteristics, such as must-operate voltages, must-release
voltages, operate times, and release times, please contact your
OMRON representative.
For operations using a microload and infrequent switching,
periodically perform continuity tests on the contacts. When switching
is not executed for contacts for long periods of time, it causes contact
instability due to factors such as the formation of film on contact
surfaces. The frequency with which the inspections are needed will
depend on factors such as the operating environment and the type of
load.
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C-8
C-B-11 Using DC-operated Relays
(1) Input Power Supply Ripple
C-C-3 Mounting Direction
For a DC-operated Relay power supply, use a power supply with a
maximum ripple percentage of 5%. An increase in the ripple
percentage will cause humming.
Smoothing
capacitor
Relay
Ripple component
Emin Emax
Ripple percentage %=
Emean
DC component
E max.= Maximum value of ripple component
Emax−Emin
× 100% E min.= Minimum value of ripple component
Emean
E mean= Mean value of DC component
C-B-12 Using DC-operated Relays
(2) Coil Polarity
To make the correct connections, first check the individual terminal
numbers and applied power supply polarities provided in this catalog.
If the polarity is connected in reverse for the coil power supply when
Relays with surge suppressor diodes or Relays with operation
indicators are used, it can cause problems such as Relay
malfunctioning, damage to diodes, or failure of indicators. Also, for
Relays with diodes, it can cause damage to devices in the circuit due
to short-circuiting.
Polarized Relays that use a permanent magnet in a magnetic circuit
will not operate if the power supply to the coil is connected in reverse.
C-B-13 Using DC-operated Relays
(3) Coil Voltage Insufficiency
If insufficient voltage is applied to the coil, either the Relay will not
operate or operation will be unstable. This will cause problems such
as a drop in the electrical durability of the contacts and contact
welding.
In particular, when a load with a large surge current, such as a large
motor, is used, the voltage applied to the coil may drop when a large
inrush current occurs to operate the load as the power is turned ON.
Also, if a Relay is operated while the voltage is insufficient, it will
cause the Relay to malfunction even at vibration and shock values
below the specifications specified in the specification sheets and this
catalog. Therefore, be sure to apply the rated voltage to the coil.
Depending on the model, a particular mounting direction may be
specified. Check this catalog and then mount the device in the
correct direction.
C-C-4 When Devices Such as Microcomputers are in
Proximity
If a device that is susceptible to external noise, such as a
microcomputer, is located nearby, take noise countermeasures into
consideration when designing the pattern and circuits. If Relays are
driven using a device such as a microcomputer, and a large current
is switched by Relay contacts, noise generated by arcing can cause
the microcomputer to malfunction.
D Operating and Storage
Environments
D-1 Operating, Storage, and Transport
During operation, storage, and transport, avoid direct sunlight and
maintain room temperature, humidity, and pressure.
• If Relays are used or stored for a long period of time in an
atmosphere of high temperature and humidity, oxidation and
sulphurization films will form on contact surfaces, causing problems
such as contact failure.
• If the ambient temperature is suddenly changed in an atmosphere
of high temperature and humidity, condensation will develop inside
of the Relay. This condensation may cause insulation failure and
deterioration of insulation due to tracking (an electric phenomenon)
on the surface of the insulation material.
Also, in an atmosphere of high humidity, with load switching
accompanied by a comparatively large arc discharge, a dark green
corrosive product may be generated inside of the Relay. To prevent
this, it is recommended that Relays be used in at low humidity.
• If Relays are to be used after having been stored for a long period,
first inspect the power transmission before use. Even if Relays are
stored without being used at all, contact instability and obstruction
may occur due to factors such as chemical changes to contact
surfaces, and terminal soldering characteristics may be degraded.
D-2 Operating Atmosphere
• Do not use Relays in an atmosphere containing flammable or
explosive gas. Arcs and heating resulting from Relay switching may
cause fire or explosion.
• Do not use Relays in an atmosphere containing dust. The dust will
get inside the Relays and cause contact failure.
C Mounting Design
D-3 Using Relays in an Atmosphere Containing
Corrosive Gas (Silicon, Sulfuric, or Organic Gas)
C-C-1 Lead Wire Diameters
Do not use Relays in a location where silicon gas, sulfuric gas (SO2
or H2S), or organic gas is present.
Lead wire diameters are determined by the size of the load current.
As a standard, use lead wires at least the size of the cross-sectional
areas shown in the following table. If the lead wire is too thin, it may
cause burning due to abnormal heating of the wire.
If Relays are stored or used for a long period of time in an
atmosphere of sulfuric gas or organic gas, contact surfaces may
become corroded and cause contact instability and obstruction, and
terminal soldering characteristics may be degraded.
Cross-sectional area (mm2)
Permissible current (A)
6
0.75
10
1.25
15
2
20
3.5
Also, if Relays are stored or used for a long period of time in an
atmosphere of silicon gas, a silicon film will form on contact surfaces,
causing contact failure.
The effects of corrosive gas can be reduced by the processing
shown in the following table.
Item
C-C-2 When Sockets are Used
Check Relay and socket ratings, and use devices at the lower end of
the ratings. Relay and socket rated values may vary, and using
devices at the high end of the ratings can result in abnormal heating
and burning at connections.
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Processing
Outer case, housing
Seal structure using packing.
PCB, copper plating
Apply coating.
Connectors
Apply gold plating or rhodium
plating.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-9
D-4 Adhesion of Water, Chemicals, Solvent, and Oil
E-A-2 Relay Removal Direction
Do not use or store Relays in an atmosphere exposed to water,
chemicals, solvent, or oil. If Relays are exposed to water or
chemicals, it can cause rusting, corrosion, resin deterioration, and
burning due to tracking. Also, if they are exposed to solvents such as
thinner or gasoline, it can erase markings and cause components to
deteriorate.
Insert and remove Relays from the socket perpendicular to the
socket surface.
If oil adheres to the transparent case (polycarbonate), it can cause
the case to cloud up or crack.
D-5 Vibration and Shock
Do not allow Relays to be subjected to vibration or shock that
exceeds the rated values.
If abnormal vibration or shock is received, it will not only cause
malfunctioning but faulty operation due to deformation of
components in Relays, damage, etc. Mount Relays in locations and
using methods that will not let them be affected by devices (such as
motors) that generate vibration so that Relays are not subjected to
abnormal vibration.
D-6 External Magnetic Fields
Do not use Relays in a location where an external magnetic field of
800 A/m or greater is present. If they are used in a location with a
strong magnetic field, it will cause malfunctioning.
Also, strong magnetic field may cause the arc discharge between
contacts during switching to be bent or may cause tracking or
insulation failure.
Magnetic
field
Relay or
transformer
Relay
D-7 External Loads
Do not use or store Relays in such a way that they are subjected to
external loads. The original performance capabilities of the Relays
cannot be maintained if they are subjected to an external load.
D-8 Adhesion of Magnetic Dust
Correct
Incorrect
If they are inserted or removed at an angle, Relay terminals may be
bent and may not make proper contact with the socket.
E-A-3 Terminal Soldering
Solder General-purpose Relays manually following the precautions
described below.
1. Smooth the tip of the solder gun and then begin the soldering.
• Solder: JIS Z3282, H60A or H63A (containing rosin-based flux)
• Soldering iron: Rated at 30 to 60 W
• Tip temperature: 280 to 300°C
• Soldering time: Approx. 3 s max.
Solder
Flux
Note: For lead-free solder, perform
the soldering under conditions that conform to the applicable
specifications.
2. Use a non-corrosive rosin-based flux suitable for the Relay's
structural materials.
For flux solvent, use an alcohol-based solvent, which tends to be
less chemically reactive.
3. As shown in the above illustration, solder is available with a cut
section to prevent flux from splattering.
When soldering Relay terminals, be careful not to allow materials
such as solder, flux, and solvent to adhere to areas outside of the
terminals. If this occurs, solder, flux, or solvent can penetrate inside
of the Relays and cause degrading of the insulation and contact
failure.
Do not use Relays in an atmosphere containing a large amount of
magnetic dust. Relay performance cannot be maintained if magnetic
dust adheres to the case.
B Printed Circuit Board Relays
E Relay Mounting Operations
Do not use ultrasonic cleaning for Relays that are not designed for it.
Resonance from the ultrasonic waves used in ultrasonic cleaning can
cause damage to a Relay's internal components, including sticking of
contacts and disconnection of coils.
A Plug-in Relays
E-B-1 Ultrasonic Cleaning
E-A-1 Panel-mounting Sockets
C Common Items
1. Socket Mounting Screws
When mounting a panel-mounting socket to the mounting holes,
make sure that the screws are tightened securely. If there is any
looseness in the socket mounting screws, vibration and shock can
cause the socket, Relays, and lead wire to detach.
Panel-mounting sockets that can be snapped on to a 35-mm DIN
Track are also available.
2. Lead Wire Screw Connections
Tighten lead wire screws to a torque of 0.98 N·m (P7SA and
P7S).
If the screws connecting a panel-mounting socket are not
sufficiently tightened, the lead wire can become detached and
abnormal heating or fire can be caused by the contact failure.
Conversely, excessive tightening can strip the threads.
E-C-1 Removing the Case and Cutting Terminals
Absolutely do not remove the case and cut terminals. Doing so will
cause the Relay's original performance capabilities to be lost.
E-C-2 Deformed Terminals
Do not attempt to repair and use a terminal that has been deformed.
Doing so will cause excessive force to be applied to the Relay, and
the Relay's original performance capabilities will be lost.
E-C-3 Replacing Relays and Performing Wiring
Operations
Before replacing a Relay or performing a wiring operation, first turn
OFF the power to the coil and the load and check to make sure that
the operation will be safe.
E-C-4 Coating and Packing
G7S and G7SA Relays are not fully sealed, so do not use a coating
or packing resin.
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C-10
F Handling Relays
F-1 Vibration and Shock
F-2 Dropped Products
Relays are precision components. Regardless of whether or not they
are mounted, do not exceed the rated values for vibration and shock.
The vibration and shock values are determined individually for each
Relay, so check the individual Relay specifications in this catalog.
Do not use a product that has been dropped, or that has been taken
apart. Not only may its characteristics not be satisfied, but it may be
susceptible to damage or burning.
If a Relay is subjected to abnormal vibration or shock, its original
performance capabilities will be lost.
G Relays for Printed Circuit Boards
(PCBs)
G-1 Selecting PCBs
(1) PCB Materials
PCBs are classified into those made of epoxy and those made of
phenol. The following table lists the characteristics of these PCBs.
Select one, taking into account the application and cost. Epoxy PCBs
are recommended for mounting Relays to prevent the solder from
cracking.
Material
Item
Epoxy
Phenol
Glass epoxy (GE) Paper epoxy (PE) Paper phenol (PP)
Characteristics
Electrical
• High insulation
between glass
characteristics
resistance.
epoxy and phenol
• Insulation
resistance hardly
affected by
moisture
absorption.
New PCBs are
highly insulationresistive but easily
affected by
moisture
absorption.
Mechanical
• The dimensions Characteristics
between glass
characteristics
are not easily
epoxy and phenol
affected by
temperature or
humidity.
• Suitable for
through-hole or
multi-layer PCBs.
• The dimensions
are easily
affected by
temperature or
humidity.
• Not suitable for
through-hole
PCBs.
Relative cost
High
Moderate
Low
Applications
Applications that
require high
reliability.
Characteristics
between glass
epoxy and phenol
Applications in
comparatively good
environments with
low-density wiring.
G-2 Selecting PCBs
(2) PCB Thickness
The PCB may warp due to the size, mounting method, or ambient
operating temperature of the PCB or the weight of components
mounted to the PCB. Should warping occur, the internal mechanism
of the Relay on the PCB will be deformed and the Relay may not
provide its full capability. Determine the thickness of the PCB by
taking the material of the PCB into consideration.
In general, PCB thickness should be 0.8, 1.2, 1.6, or 2.0 mm. Taking
Relay terminal length into consideration, the optimum thickness is
1.6 mm.
Terminal length
G-3 Selecting PCBs
(3) Terminal Hole and Land Diameters
Refer to the following table to select the terminal hole and land
diameters based on the Relay mounting dimensions. The land
diameter may be smaller if the land is processed with through-hole
plating.
Terminal hole diameter (mm)
Nominal value
0.6
Minimum land diameter (mm)
Tolerance
±0.1
1.5
0.8
1.8
1.0
2.0
1.2
2.5
1.3
2.5
1.5
3.0
1.6
3.0
2.0
3.0
G-4 Mounting Space
A Ambient Temperature
When mounting a Relay, check this catalog for the specified amount
of mounting space for that Relay, and be sure to allow at least that
much space.
When two or more Relays are mounted, their interaction may
generate excessive heat. In addition, if multiple PCBs with Relays
are mounted to a rack, the temperature may rise excessively. When
mounting Relays, leave enough space so that heat will not build up,
and so that the Relays' ambient temperature remains within the
specified operating temperature range.
B Mutual Magnetic Interference
When two or more Relays are mounted, Relay characteristics may
be changed by interference from the magnetic fields generated by
the individual Relays. Be sure to conduct tests using the actual
devices.
G-5 Pattern Design for Noise Countermeasures
A Noise from Coils
When the coil is turned OFF, reverse power is generated to both
ends of the coil and a noise spike occurs. As a countermeasure,
connect a surge absorbing diode. The diagram below shows an
example of a circuit for reducing noise propagation.
Noise is superimposed
on the power supply line,
so a separate pattern is
connected from a
smoothing capacitor to
supply coil power.
The pattern will
form an antenna
circuit, so make
it as short as
possible.
Power supply line
Smoothing
capacitor
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Relay drive transistor
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C-11
B Noise from Contacts
G-8 Conductor Pitch
Noise may be transmitted to the electronic circuit when switching a
load, such as a motor or transistor, that generates a surge at the
contacts. When designing patterns, take the following three points
into consideration.
The conductor pitch on a PCB is determined by the insulation
characteristics between conductors and the environmental
conditions under which the PCB is to be used. Refer to the following
graph. If the PCB must conform to safety organization standards
(such as UL, CSA, or IEC), however, priority must be given to
fulfilling their requirements. Also, multi-layer PCBs can be used as a
means of increasing the conductor pitch.
As the manipulated frequency is increased, pattern mutual
interference also increases. Therefore, take noise countermeasures
into consideration when designing high-frequency pattern and land
shapes.
G-6 Shape of Lands
1. The land section should be on the center line of the copper-foil
pattern, so that the soldered fillets become uniform.
Correct Examples
Voltage between Conductors vs. Conductor Pitch
(According to IEC Pub326-3)
Rated Voltage between Conductors (Vdc)
1. Do not place a signal transmission pattern near the contact
pattern.
2. Shorten the length of patterns that may be sources of noise.
3. Block noise from electronic circuits by means such as
constructing ground patterns.
C High-frequency Patterns
3,000
C
2,000
1,000
700
500
A
D
300
B
200
100
70
50
30
20
Incorrect
Examples
0.1
0.2 0.3 0.5 0.7 1.0
2
3
5
10
Conductor pitch (mm)
2. A break in the circular land area will prevent molten solder from
filling holes reserved for components which must be soldered
manually after the automatic soldering of the PCB is complete.
A = Without coating at altitude of 3,000 m max.
B = Without coating at altitude of 3,000 m or higher but lower than 15,000 m
C = With coating at altitude of 3,000 m max.
D = With coating at altitude of 3,000 m or higher
G-9 Securing the PCB
Break in land
0.2 to 0.5 mm
G-7 Pattern Conductor Width and Thickness
The following thicknesses of copper foil are standard: 35 μm and
70 μm. The conductor width is determined by the current flow and
allowable temperature rise. Refer to the chart below as a simple
guideline.
50
100˚C
75˚C
50˚C
40˚C
30˚C
20˚C
10˚C
30
20
Temperature rise
Permissible current (A)
Conductor Width and Permissible Current
(According to IEC Pub326-3)
Although the PCB itself is not normally a source of vibration or shock,
it may prolong vibration or shock by resonating with external vibration
or shock. Securely fix the PCB, paying attention to the following
points.
Mounting method
Process
Rack mounting
No gap between rack's guide and PCB
Screw mounting
• Securely tighten screw.
Place heavy components such as Relays on
part of PCB near where screws are to be
used.
• Attach rubber washers to screws when
mounting components that are affected by
shock (such as audio devices.)
10
7
5
3
2
305 /m2
35 μm
Conductor width (mm)
0.03 0.05 0.07 0.1
7
0.3
0.5 0.7 1
Cross-sectional area (mm2)
5
3
610 /m2
70 μm
2
1
0.5
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C-12
G-10 Automatic Mounting of PCB Relays
A Through-hole PCBs
When mounting a Relay to a PCB, take the following points into consideration for each
process. There are also certain mounting precautions for individual Relays, so refer to the
individual Relay precautions as well.
Process 1
1. Do not bend any terminals of the Relay to use it as a self-clinching Relay.
The initial performance characteristics of the Relay will be lost.
2. Execute PCB processing correctly according to the PCB process diagrams.
Placement
Process 2
Flux Application
Flux
Process 3
Preheating
1. The G7S has no protection against flux
penetration, so absolutely do not use the method
shown in the diagram on the right, in which a
sponge is soaked with flux and the PCB pressed
down on the sponge. If this method is used for the
G7S, it will cause the flux to penetrate into the
Relay. Be careful even with the flux-resistant
G7SA, because flux can penetrate into the Relay
if it is pressed too deeply into the sponge.
2. The flux must be a non-corrosive rosin-based flux
suitable for the Relay's structural materials.
For the flux solvent, use an alcohol-based solvent,
which tends to be less chemically reactive.
Apply the flux sparingly and evenly to prevent
penetration into the Relay.
When dipping the Relay terminals into liquid flux,
be sure to adjust the flux level, so that the upper
surface of the PCB is not flooded with flux.
3. Make sure that flux does not adhere anywhere
outside of the Relay terminals. If flux adheres to
an area such as the bottom surface of the Relay, it
will cause the insulation to deteriorate.
1. Preheating is required to create the optimum
conditions for soldering.
2. The following conditions apply for preheating.
Pressing deeply
PCB
Relay
Sponge soaked with
flux
Example of incorrect method
Applicability of Dipping Method
G7S
G7SA
NO
YES
(Must be checked when
spray flexor is used.)
Temperature
100°C max.
3. Do not use a Relay if it has been left at a high
temperature for a long period of time due to a
circumstance such as equipment failure. These
conditions will cause the Relay's initial
characteristics to change.
Time
1 min max.
Applicability of Preheating
G7S
Heater
NO
G7SA
YES
Process 4
Automatic soldering
Manual soldering
Soldering
1. Flow soldering is recommended to assure a uniform
solder joint.
• Solder: JIS Z3282 or H63A
• Solder temperature and soldering time: Approx. 250°C
(DWS: Approx. 260°C)
• Solder time: 5 s max. (DWS: Approx. 2 s for first time
and approx. 3 s for second time)
• Adjust the level of the molten solder so that the PCB is
not flooded with solder.
1. Smooth the solder with the tip of the iron, and then
perform the soldering under the following conditions.
• Solder: JIS Z3282, H60A, or H63A
(containing rosin-based flux)
• Soldering iron: Rated at 30 to 60 W
Solder
• Tip temperature: 280 to 300°C
Flux
• Soldering time: Approx. 3 s max.
2. As shown in the above illustration, solder is available
with a cut section to prevent flux from splattering.
Applicability of Automatic Soldering
Applicability of Manual Soldering
G7S
NO
Continued next
page.
G7SA
YES
G7S
YES
G7SA
YES
Note: For lead-free solder, perform the soldering under conditions that conform to the applicable specifications.
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C-13
Process 5
Cooling
Process 6
Cleaning
1. Upon completion of automatic soldering, use a
fan or other device to forcibly cool the PCB. This
helps prevent the Relay and other components
from deteriorating from the residual heat of
soldering.
2. Fully sealed Relays are washable. Do not,
however, put fully sealed Relays in a cold cleaning
solvent immediately after soldering or the seals
may be damaged.
Cooling
G7SA
Required
Refer to the following table to select the cleaning
method and solvent.
Cleaning Method
G7S
G7SA
Neither boiling cleaning nor immersion cleaning is
possible.
Clean only the back of the PCB with a brush.
Process 7
Coating
1. With the G7S or G7SA, coating will penetrate
inside Relays and damage the contacts.
Therefore either do not apply coating at all or
apply the coating first, before mounting the
Relays.
2. Be very careful in selecting the coating material.
Depending on the type of coating selected, it may
damage the Relay case and chemically dissolve
the seals, causing them to lose their sealing
capability.
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3. Do not secure the entire Relay in resin, or the
Relay's characteristics will be changed.
Do not exceed the maximum value for the
coating's ambient operating temperature.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-14
H Troubleshooting
The following table can be used for troubleshooting when Relay
operation is not normal. Refer to this table when checking the circuit
and other items. If checking the circuit reveals no abnormality, and it
appears that the fault is caused by a Relay, contact your OMRON
representative. (Do not disassemble the Relay. Doing so will make it
impossible to identify the cause of the problem.)
These problems, however, mostly occur as a result of external factors
such as methods and conditions of operation, and can generally be
prevented by means of careful consideration before operation and by
selecting the correct Relays.
The following table shows the main faults that may occur, their
probable causes, and suggested countermeasures to correct them.
A Relay is composed of various mechanical parts, including a coil,
contacts, and iron core. Among these, problems occur most often
with the contacts, and next often with the coil.
Fault
Probable cause
Countermeasures
(1) Operation fault
1.
2.
3.
4.
5.
Incorrect coil rated voltage selected
Faulty wiring
Input signal not received
Power supply voltage drop
Circuit voltage drop (Be careful in particular of highcurrent devices operated nearby or wired at a
distance.)
6. Rise in operating voltage along with rise in ambient
operating temperature (especially for DC)
7. Coil disconnection
1.
2.
3.
4.
5.
6.
7.
Select the correct rated voltage.
Check the voltage between coil terminals.
Check the voltage between coil terminals.
Check the power supply voltage.
Check the circuit voltage.
Test individual Relay operation.
• For coil burning, see fault (3).
• For disconnection due to electrical corrosion,
check the polarity being applied to the coil voltage.
(2) Release fault
1. Input signal OFF fault
2. Voltage is applied to the coil by a sneak current
3. Residual voltage by a combination circuit such as a
semiconductor circuit
4. Release delay due to parallel connection of coil and
capacitor
5. Contact welding
1.
2.
3.
4.
5.
Check the voltage between coil terminals.
Check the voltage between coil terminals.
Check the voltage between coil terminals.
Check the voltage between coil terminals.
For contact welding, see fault (4).
(3) Coil burning
1. Unsuitable voltage applied to coil
2. Incorrect rated voltage selected
3. Short-circuit between coil layers
1. Check the voltage between coil terminals.
2. Select the correct rated voltage.
3. Recheck the operating atmosphere.
(4) Contact welding
1. Excessive device load connected (insufficient
contact capacity)
2. Excessive switching frequency
3. Short-circuiting of load circuit
4. Abnormal contact switching due to humming
5. Expected service life of contacts reached
1.
2.
3.
4.
5.
(5) Contact failure
1. Oxidation of contact surfaces
2. Contact abrasion and aging
3. Terminal and contact displacement due to faulty
handling
1. • Recheck the operating atmosphere.
• Select the correct Relay.
2. The expected service life of the contacts has been
reached.
3. Be careful of vibration, shock, and soldering
operations.
(6) Abnormal contact
consumption
1. Unsuitable Relay selection
2. Insufficient consideration of device load (especially
motor, solenoid, and lamp loads)
3. No contact protection circuit
4. Insufficient withstand voltage between adjacent
contacts
1.
2.
3.
4.
Select the correct Relay.
Select the correct devices.
Add a circuit such as a spark quenching circuit.
Select the correct Relay.
(7) Humming
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
Check the voltage between coil terminals.
Check the ripple percentage.
Select the correct rated voltage.
Make supplemental changes to circuit.
The expected service life has been reached.
Remove the foreign material.
Insufficient voltage applied to coil
Excessive power supply ripple (DC)
Incorrect coil rated voltage selected
Slow rise in input voltage
Abrasion in iron core
Foreign material between moveable iron piece and
iron core
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Check the load capacity.
Check the number of switches.
Check the load circuits.
For humming, see fault (7).
Check the contact ratings.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-15
WARNING
This catalog is a guide to help customers select the proper safety products. Observe the following items when choosing
products, select the right products for your devices or equipment, and develop a safety-related system to fully utilize product
functions.
Setting Up a Risk Assessment System
The items listed in this catalog must be used properly in terms of product location as well as product performance and
functionality. Part of the process of selecting and using these products should include the introduction and development of a
risk assessment system early in the design development stage to help identify potential dangers in your equipment that will
optimize safety product selection. A badly designed risk assessment system often results in poor choices when it comes to
safety products.
• Related International Standards:
ISO 14121 Principles of Risk Assessment
Safety Policy
When developing a safety system for the devices and equipment that use safety products, make every effort to understand
and conform to the entire series of international and industrial standards available, such as the examples given below.
• Related International Standards:
ISO 12100 Basic Concepts, General Principles for Design
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
Role of Safety Products
Safety products have functions and mechanisms that ensure safety as defined by standards. These functions and
mechanisms are designed to attain their full potential within safety-related systems. Make sure you fully understand all
functions and mechanisms, and use that understanding to develop systems that will ensure optimal usage.
• Related International Standards:
ISO 14119 Interlocking Devices Associated with Guards-Principles for Design and Selection
Installing Safety Products
Make sure that properly educated and trained engineers are selected to develop your safety-related system and to install
safety products in devices and equipment.
• Related International Standards:
ISO 12100 Basic Concepts, General Principles for Design
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
Observing Laws and Regulations
Safety products should conform to pertinent laws, regulations, and standards, but make sure that they are used in
accordance with the laws, regulations, and standards of the country where the devices and equipment incorporating these
products are distributed.
• Related International Standards:
IEC 60204 Electrical Equipment of Machines
Observing Usage Precautions
Carefully read the specifications and precautions listed in this catalog for your product as well as all items in the Operating
Manual packed with the product to learn usage procedures that will optimize your choice. Any deviation from precautions
will lead to unexpected device or equipment failure not anticipated by safety-related systems or fire originating from
equipment failure.
Transferring Devices and Equipment
When transferring devices and equipment, be sure to keep one copy of the Operating Manual and pack another copy with
the device or equipment so the person receiving it will have no problem operating it.
• Related International Standards:
ISO 12100 Basic Concepts, General Principles for Design
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
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Read and Understand This Catalog
Please read and understand this catalog before purchasing the products. Please consult your OMRON representative if you have any questions or
comments.
Warranty and Limitations of Liability
WARRANTY
OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if
specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR
FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS
DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS, OR COMMERCIAL
LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR
STRICT LIABILITY.
In no event shall responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS
OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT
SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
Application Considerations
SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's
application or use of the product.
At the customer's request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the
products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product,
machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible
uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this catalog.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety
equipment, and installations subject to separate industry or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE
SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND
INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
Disclaimers
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other reasons.
It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made.
However, some specifications of the product may be changed without any notice. When in doubt, special model numbers may be assigned to fix
or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual
specifications of purchased product.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.
ERRORS AND OMISSIONS
The information in this catalog has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical,
typographical, or proofreading errors, or omissions.
PERFORMANCE DATA
Performance data given in this catalog is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent
the result of OMRON’s test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON
Warranty and Limitations of Liability.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user's programming of a programmable product, or any consequence thereof.
COPYRIGHT AND COPY PERMISSION
This catalog shall not be copied for sales or promotions without permission.
This catalog is protected by copyright and is intended solely for use in conjunction with the product. Please notify us before copying or reproducing this
catalog in any manner, for any other purpose. If copying or transmitting this catalog to another, please copy or transmit it in its entirety.
Cat. No. J130-E1-05
OMRON Corporation
2007. 3
In the interest of product improvement, specifications are subject to change without notice.
Industrial Automation Company
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