Guard Lock Safety-door Switch D4BL Protective Doors Are Locked Until Machines Completely Stop Operating • A mechanical lock is applied automatically when the Operation Key is inserted. A high level of safety is achieved using a mechanism where the lock is only released when voltage is applied to the solenoid. • 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. Direct opening mechanism that is EN-approved is indicated by on the switch. • Auxiliary release key ensures easy maintenance and unlocks the door in the case of a power failure. • Tough aluminum die-cast body incorporating a switch box with degree of protection satisfying IP67, UL, and CSA TYPE6P, 13. • Equipped with a horizontal and vertical conduit opening. • Models incorporating easy-to-see indicators for monitoring and those using an adjustable Operation Key for a double door are available. • The mounting direction of the head can be changed to allow the Operation Key to be inserted from four directions. • Metric conduit types available Model Number Structure Model Number Legend Switch D4BL - 1 2 3 4 5 1. Conduit Size (2-conduit) 1: PG13.5 2: G1/2 3: 1/2-14NPT 4: M20 4. Door Lock and Release (Auxiliary Release Key is Incorporated by All Models) A: Mechanical lock/24-VDC solenoid release B: Mechanical lock/110-VAC solenoid release G: 24-VDC Solenoid lock/Mechanical release 2. Built-in Switch (with Safety Switch and Lock Monitor Switch Contacts) C: 1NC/1NO (slow-action) + 1NC (slow-action) D: 2NC (slow-action) + 1NC (slow-action) 5. Indicator Blank: Without indicator A: 10 to 115 VAC or VDC driving (with orange and green LED indicator unit) 3. Head Mounting Direction R: Four mounting directions possible (right-side mounting at shipping) Operation Key (Order Separately) D4BL - K 1 1. Operation Key Type 1: Horizontal mounting 2: Vertical mounting 3: Adjustable mounting (Horizontal) D-136 Safety Sensors / Components Ordering Information List of Models Switches Lock method Conduit size PG13.5 Mechanical G1/2 lock M20 Solenoid lock Pg 13.5 G1/2 M20 Voltage for solenoid 24 VDC 110 VAC 24 VDC 110 VAC 24 VDC 110 VAC 24 VDC 24 VDC 24 VDC Without indicator 1NC/1NO+ 1NC (Slow-action) D4BL-1CRA D4BL-1CRB D4BL-2CRA D4BL-2CRB D4BL-4CRA D4BL-4CRB D4BL-1CRG D4BL-2CRG With LED indicator 1NC/1NO+ 1NC (Slow-action) D4BL-1CRA-A D4BL-1CRB-A D4BL-2CRA-A D4BL-2CRB-A D4BL-4CRA-A D4BL-4CRB-A D4BL-1CRG-A D4BL-2CRG-A D4BL-4CRG-A Without indicator 2NC+ 1NC (Slow-action) D4BL-1DRA D4BL-1DRB D4BL-2DRA D4BL-2DRB D4BL-4DRA With LED indicator 2NC+ 1NC (Slow-action) D4BL-1DRA-A D4BL-1DRB-A D4BL-2DRA-A D4BL-2DRB-A D4BL-4DRA-A D4BL-1DRG D4BL-2DRG D4BL-1DRG-A D4BL-2DRG-A Operation Keys (Order Separately) Mounting type Model Horizontal mounting D4BL-K1 Vertical mounting D4BL-K2 D4BL Adjustable mounting (Horizontal) D4BL-K3 Specifications Approved Standards Agency Standards and EC Directives Standard File No. R9451050 TÜV Rheinland EN60947-5-1 BIA GS-ET-19 SUVA UL CSA SUVA UL508 CSA C22.2, No.14 D4BL (Direct opening: approved) Conforms to the following EC Directives: Machinery Directive Low Voltage Directive EN1088 Mechanical lock: 9402293 Solenoid lock: 1998 20462-01 E6186/2.d E76675 LR45746 D-137 Approved Standard Ratings TÜV (EN60947-5-1) Item Utilization category Rated operating current (Ie) Rated operating voltage (Ue) Standard model Indicator model AC-15 AC-15 3A 6A 250 V 115 V Use a 10-A fuse type gI or gG that conforms to IEC269 as a short-circuit protection device. UL/CSA (UL508, CSA C22.2 No. 14) A300 Rated voltage 120 VAC 240 VAC Current Carry current 10 A Make 60 A 30 A Volt-amperes Break 6A 3A Make 7,200 VA Break 720 VA Note: The UL/CSA approved rating for products with indicators (-A) is 6 A/115 VAC. Characteristics Degree of protection Durability (See note 3.) Operating speed Operating frequency Rated frequency Operating characteristics IP67 (See note 2.) Mechanical:1,000,000 operations min. Electrical:500,000 operations min. (10-A resistive load at 250 VAC) 0.05 to 0.5 m/s 30 operations/min max. 50/60 Hz Direct opening force:19.61 N min. (EN60947-5-1) Direct opening travel:20 mm min. (EN60947-5-1) All stroke:23 mm min. 700 N min. (GS-ET-19) 100 MW min. (at 500 VDC) 300 V (EN60947-5-1) Holding force Insulation resistance Rated insulation voltage (Ui) Conventional enclosed thermal current 10 A (EN60947-5-1) (Ithe) Impulse dielectric strength (Uimp) 4 kV (EN60947-5-1) between terminals of different polarity, between each terminal and ground, and between each terminal and non-current-carrying metal Dielectric strength (Uimp) part; 2.5 kV between solenoid and ground (EN60947-5-1) Conditional short-circuit current 100 V (EN60947-5-1) Pollution degree 3 (EN60947-5-1) (operating environment) Protection against electric shock Class I (with ground terminal) Switching overvoltage 1,500 V max. (EN60947-5-1) Contact resistance 50 mW max. (initial value) Vibration resistance Malfunction: 10 to 55 Hz, 0.35-mm single amplitude Destruction:1,000 m/s2 min. (IEC68-2-27) Shock resistance Malfunction:300 m/s2 min. (IEC68-2-27) Ambient temperature Operating:–10°C to 55°C (with no icing) Ambient humidity Operating:95% max. Weight Approx. 800 g 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 D4BL 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%. D-138 Safety Sensors / Components Solenoid Coil Characteristics Item Rated operating voltage Current consumption Insulation 24-VDC mechanical lock models 110-VAC mechanical lock models 24-VAC solenoid lock models 24 VDC +10%/–15% (100% ED) 110 VAC ±10% (50/60 Hz) 24 VDC +10%/–15% (100% ED) Approx. 300 mA Approx. 98 mA Approx. 300 mA Class F (130°C or less) Indicator Characteristics Item LED Rated voltage 10 to 115 VAC/VDC Current leakage Approx. 1 mA Color (LED) Orange, green Contact Form (Diagrams Show State with Key Inserted and Lock Engaged) Contact 31 32 Diagram 11 23 D4BL-#C##-# Lock position 12 24 ON o 1NC/ 1NO+1NC Stroke Operation Key insertion completion position 31 32 11 21 D4BL-#D##-# 12 2NC+1NC Lock position ON Stroke Operation Key insertion completion position Extraction completion position Only NC contacts 11-12 and 31-32 have an approved direct opening mechanism. The terminals 11-12 and 23-24 can be used as unlike poles. Extraction completion position 22 Note: The EN-approved direct opening mechanism is indicated by D4BL Remarks NC contacts 11-12, 21-22, and 31-32 have an approved direct opening mechanism. The terminals 11-12 and 21-22 can be used as unlike poles. on the switch. D-139 D4BL Model Connections Indicator Unit Internal Circuit Dimensions 10 to 115 VAC/DC R Four terminal plates Two, 7 dia. Two LED indicators (7) ZD (16) LED R 26.8 53.2 57.2 (16) 0.3 5.6 2 Constant-current diode 10.6 (12.6) (35) 26.2 (61.2) Circuit Connection Example • Do not connect the indicators to the safety contact terminals (1112-31-32) or the safety circuit side. • When using indicators, connect them to the auxiliary circuit side (monitor circuit) or the solenoid input terminals as shown below. • The indicators can be used to confirm the open/closed status of the door, the ON/OFF status of the power supply, and the ON/OFF status of the solenoid. • Do not connect the indicators in parallel with the direct opening contact. If the indicators are broken, a short-circuit current may flow, causing equipment to malfunction. • The 24-VDC solenoid terminals have polarity. Confirm the polarity before wiring. • Be sure to use a special pushbutton switch to stop and start machinery and release locks. 1. Orange: Lights when the solenoid turns ON. Green: Lights when the door opens. 2. Orange: Lights when the solenoid turns ON. Green: Lights when power turns ON. (Power supply side) (Power supply side) E1 (+) 11 12 31 32 E1 (+) 11 12 31 32 Solenoid 23 24 LED (orange) Solenoid E2 (−) 23 24 LED (orange) LED (green) Auxiliary circuit (monitor circuit) Safety circuit LED (green) Auxiliary circuit (monitor circuit) (Ground side) 3. Orange: Lights when the solenoid turns ON. Green: Lights when door closes. Safety circuit (Ground side) 4. Orange: Lights when the solenoid turns ON. Green: Lights when power turns ON. (Power supply side) (Power supply side) E1 (+) E1 (+) 11 12 31 11 32 12 31 32 Solenoid 21 22 LED (orange) Solenoid E2 (−) 21 22 LED (orange) LED (green) Auxiliary circuit (monitor circuit) D-140 Safety circuit (Ground side) E2 (−) E2 (−) LED (green) Auxiliary circuit (monitor circuit) Safety circuit (Ground side) Safety Sensors / Components Nomenclature D4BL-#C##-# D4BL-#D##-# Operation Key Lock plate Operation Key Lock plate Auxiliary release key Lock monitor switch Solenoid Auxiliary release key Rotating drum Rotating drum Lock monitor switch Solenoid Operation plunger Operation plunger Seal ring (NBR) Auxiliary plunger Seal packing (NBR) Rotating lever Seal ring (NBR) Auxiliary plunger Seal packing (NBR) Rotating lever Safety switch Safety switch Seal packing (NBR) Seal packing (NBR) Conduit opening Connection (Pull out terminal M3.5 horizontally) Ground terminal M3.5 Conduit opening Conduit opening (Pull out (Pull out horizontally) vertically) Connection terminal M3.5 Conduit opening (Pull out vertically) Ground terminal M3.5 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. Switches D4BL-####-# Four, M3.5 head clamping screws (116.5) 15 34.2 37.5 Four, 5.3 dia. mounting holes Four, M4 cover clamping screws Cover (123.5) 74±0.1 6.8 Conduit opening 7 Lock protection cap 100±0.1 112+1 0 Indicators 5.5 D4BL 31.5 17 10 Red 86+10 16 39.6 46.3 Conduit opening Operating Characteristics D4BL-#### Key insertion force 19.61 N max. Key extraction force 19.61 N max. Movement before being locked 15 mm max. D4BL D-141 Operation Keys Horizontal Mounting Vertical Mounting D4BL-K1 D4BL-K2 Red Red 53.7 78.7 40.7 12 20±0.15 Long mounting hole 13 5.3 x 7.3 long mounting hole 7.3 15 25.8 15.6 25.8 15.6 40±0.15 52.4 Two, 2.65R 36 5.3 5.3 2.6 7.5 36 5.3 11.9 7.5 20 11.8 20 11.8 5.6 5.6 4 dia. 4 dia. 2.6 Adjustable Mounting (Horizontal) D4BL-K3 40 Red 12 20 26 (80.7) 40 Red 36 30±0.15 2.6 11.8 30 19.5±0.1 (37.8) 5.6 5.3 dia. 17.5 4 dia. D-142 34.6 M4 Allen-head bolt Safety Sensors / Components With Operation Key Inserted Horizontal Mounting D4BL + D4BL-K1 Red Horizontal direction Operation Key insertion radius R ≥ 1200 53.5 min. 57 max. (41) (20±0.15) (12) Vertical direction Operation Key insertion radius R ≥ 1000 53.5 min. 57 max. (20±0.15) (41) (35) Vertical direction Operation Key insertion radius R ≥ 1000 Vertical Mounting D4BL + D4BL-K2 Horizontal direction Operation Key insertion radius R ≥ 1200 Red 54.5 min. 58 max. (41) 54.5 min. 58 max. (13) (41) (40±0.15) D4BL (35) Adjustable Mounting (Horizontal) D4BL + D4BL-K3 Vertical direction Operation Key insertion radius R ≥ 1000 Red Horizontal direction Operation Key insertion radius R ≥ 250 81.5 min. 85 max. 81.5 min. 85 max. (41) (41) (40) (30±0.15) (35) Note: 1. Unless otherwise specified, a tolerance of ±0.4 mm applies to all dimensions. 2. In the above diagrams, the Operation Key is inserted from the front. D4BL D-143 Precautions Stopper Caution Do not insert the Operation Key to the Switch with the door open. Before using the machine, be sure to remove the shock-absorbing damper, which is provided before shipping. Otherwise the machine may start operating and injury may be caused. Stopper Mount the Operation Key at a location where it will not come in contact with users when the door is opened or closed. When operating the D4BL as a part of a safety circuit or an emergency stop 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 D4BL. Switch Do not use the Switch as a stopper. When mounting the Switch, be sure to locate a stopper as shown in the following illustration to prevent the top of the Operation Key from hitting the switch head. Connect the fuse to the D4BL 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 D4BL with EN ratings, use 10-A fuse Type gI or gG that complies with IEC60269. In order to prevent the D4BL from burning due to overvoltage, insert a protection fuse into the solenoid circuit. If the D4BL is imposed with force exceeding the lock strength, the D4BL may break and the equipment may continue to operate. Correct Use Auxiliary Release Key Due to the wear and tear of the sealing of the D4BL, water and some types of oil and chemical sprayed onto the D4BL may cause contact or insulation failures, current leakages, or fires. The auxiliary release key is used to unlock the D4BL in case of emergency or in case the power supply to the D4BL fails. Use an appropriate tool to set the auxiliary release key to UNLOCK so that the lock will be released and the door can be opened. LOCK Operating Environment Do not use the D4BL 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 in contact with metal dust, oil, or chemicals UNLOCK Auxiliary release key The auxiliary release key applied to the door of a machine room ensures the safety of people adjusting the equipment in the machine room. If the auxiliary release key is set to UNLOCK, the door will not be locked when the door is closed and no power will be supplied to the equipment. To lock the door, set the auxiliary release key to LOCK. Operation Key The D4BL is provided with a shock-absorbing damper to protect the D4BL from damage that may result from dropping the D4BL during transportation. Be sure to remove the damper after mounting the D4BL. The mounting tolerance of the Operation Key is ±0.3 mm vertically or horizontally. Be sure to mount the D4BL correctly without leaning, otherwise the D4BL may soon break or wear out. Do not use the auxiliary release key to start or stop machines. To prevent the auxiliary release key from being handled carelessly by unauthorized people, seal the auxiliary release key with sealing wax and the provided seal cap to ensure IP67. ±0.3 min. Make sure that the auxiliary release key is kept with the person in charge. Before attaching the cover to the D4BL, make sure that the auxiliary release key position is set to LOCK. ±0.3 min. Do not drop the D4BL with the Operation Key inserted, otherwise the Operation Key may deform or break. D-144 Safety Sensors / Components Two, M5 Operation Key mounting screw Four, M3.5 head-mounting screw Four, M4 cover-mounting screw Drop The head is constructed so that it cannot be operated with tools such as screwdrivers. Always use OMRON’s Operation Key to operate the head in order to ensure the safety of the machine and protect the D4BL from damage. Four, M5 switch-mounting screw Conduit Conduit cap The Operation Key provided for the D4BL is not compatible with that of the D4BS. Switch and Operation Key Mounting Mount the Operation Key and secure it with one-way screws or equivalents to prevent easy removal of the D4BL. Mount the D4BL and Operation Key with four M5 screws with washers and tighten each screw to the specified torque. Securing the Door Mounting Dimensions 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 D4BL may be damaged. Secure the door with hooks so that it will remain within the set zone. Switch Mounting Dimensions Four, M5 Space D4BL 74±0.1 100±0.1 Set zone Operation Key Mounting Holes • Horizontal Mounting D4BL-K1 Two, M5 Tightening Torque Be sure to tighten each screw of the D4BL properly, otherwise the D4BL may malfunction. 1 2 3 4 5 6 7 Type M3.5 terminal screw (including terminal screw) Cover mounting screw Head mounting screw M5 body mounting screw Operation Key mounting screw Connector Cap screw 20±0.1 • Vertical Mounting D4BL-K2 Torque Two, M5 0.59 to 0.78 N·m 1.18 to 1.37 N·m 0.78 to 0.98 N·m 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 40±0.1 • Adjustable Mounting (Horizontal) D4BL-K3 Two, M5 30±0.1 D4BL D-145 Head Directions 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. 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 Normal Positions of Rotating Lever and Plunger Switch body Rotating lever (with protruding part) Plunger (with groove) 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. Mounting the Cover When tightening the cover, first check the specified torque, and then tighten each screw to the that torque. Also, make sure that no foreign matter has entered the switch. When mounting the cover, make sure that the cover and switch box are properly aligned. D-146 Safety Sensors / Components Processing and Connecting Cable/Conduit The following procedures are recommended for mounting and wiring the indicator unit securely. In order to ensure IP67, use OMRON’s SC-#M and Nippon Flex’s ABS-08Pg13.5 and ABS-12 Pg13.5 Connectors. Cable Connection Example 1. Connect the wires to the terminals in the order shown below for wiring efficiency. Recommended cable: UL2464-type cable that is 20 to 18 AWG (0.5 to 1.0 mm2) in size and has seven conductors If the 1/2-14NPT is used, cover the cable and conduit end with sealing tape in order to ensure IP67. Tighten the connector to a torque of 1.77 to 2.16 N·m. Connect the indicator unit after connecting the seven-conductor cable. Tighten each wired terminal clockwise to a torque of 0.59 to 0.78 N·m. Twist the wire two or three times and make sure that no bare wire exists outside the terminal when tightening the terminal. Lp (mm) 30±2 35±2 45±2 55±2 65±2 70±2 Lv (mm) 80±2 75±2 60±2 50±2 45±2 35±2 90±2 50±2 a (mm) 2. The insulation sheath of the seven-conductor cable must come into contact with the wall of the conduit mouth, side A or side B. 8±1 Properly attach and securely tighten the provided conduit cap to the unused conduit opening when wiring the D4BL. D4BL Terminal no. E1 E2 31 12 23 (21) 24 (22) Insulation sheath edge Maintenance and Repairs Contact your OMRON representative for any repair or maintenance work on the D4BL. The D4BL must not be maintained or repaired by any unauthorized party. Others Do not touch the solenoid because the solenoid radiates heat while power is being supplied. D4BL D-147