F502-EN2-04.book Seite 153 Dienstag, 26. Juli 2005 5:48 17 Guard Lock Safety-door Switch D4NL Lead-free, Environment-friendly Design • Contains no harmful substances, such as lead or cadmium, reducing the burden on the environment. • Models with 4-contact and 5-contact built-in switches are available. • Key holding force of 1,300 N min. • Can be used for either standard loads or microloads. • Lineup includes models with a conduit size of M20. • IP67 degree of protection. • Operation key compatible to D4DS, D4NS and D4GL. Model Number Structure Model Number Legend D4NL-@@@@-@@@ 1 2 3 4 5 6 7 1. Conduit Size 1: Pg13.5 2: G1/2 4: M20 2. Built-in Switch (with Door Open/Closed Detection Switch and Lock Monitor Switch Contacts) A: 1NC/1NO slow-action contacts plus 1NC/1NO slow-action contacts B: 1NC/1NO slow-action contacts plus 2NC slow-action contacts C: 2NC slow-action contacts plus 1NC/1NO slow-action contacts D: 2NC slow-action contacts plus 2NC slow-action contacts E: 2NC/1NO slow-action contacts plus 1NC/1NO slow-action contacts F: 2NC/1NO slow-action contacts plus 2NC slow-action contacts G: 3NC slow-action contacts plus 1NC/1NO slow-action contacts H: 3NC slow-action contacts plus 2NC slow-action contacts 3. Head Mounting Direction and Material F: Four mounting directions possible (Front-side mounting at time of delivery)/plastic D: Four mounting directions possible (Front-side mounting at time of delivery)/metal D4NL 4. Door Lock and Release A: Mechanical lock/24-VDC solenoid release B: Mechanical lock/110-VAC solenoid release C: Mechanical lock/230-VAC solenoid release G: 24-VDC solenoid lock/mechanical release H: 110-VAC solenoid lock/mechanical release J: 230-VAC solenoid lock/mechanical release 5. Indicator B: 10 to 115 VAC/VDC (orange LED indicator) E: 100 - 230V VAC (orange neon lamp indicator) 6. Release Key Type Blank:Standard 4: Special release key 7. Release Key Position Blank:Bottom S: Front Operation Key \ D4DS-K@ 1 1. Operation Key Type 1: Horizontal mounting 2: Vertical mounting 3: Adjustable mounting (horizontal) 5: Adjustable mounting (horizontal/vertical) D4NL Switch G-153 F502-EN2-04.book Seite 154 Dienstag, 26. Juli 2005 5:48 17 Ordering Information List of Models For 110V and 230V version ask your local OMRON Representative Switches (Operation Keys are sold separately.) : Models with approved direct opening contacts. Head material Plastic Release key position Release key type Solenoid voltage/ indicator Bottom Standard Solenoid: 24 VDC Orange LED: 10 to 115 VAC/VDC Prefered stock item* Lock and release types Contact configuration (door open/closed detection switch and lock monitor switch contacts) (slow-action) Approved direct opening NC contact Mechanical lock Solenoid release 1NC/1NO+1NC/1NO 1NC/1NO+2NC 2NC+1NC/1NO 2NC+2NC 2NC/1NO+1NC/1NO 2NC/1NO+2NC 3NC+1NC/1NO 3NC+2NC Solenoid lock Mechanical release 1NC/1NO+1NC/1NO 1NC/1NO+2NC 2NC+1NC/1NO 2NC+2NC 2NC/1NO+1NC/1NO 2NC/1NO+2NC 3NC+1NC/1NO 3NC+2NC G-154 Conduit opening Model Pg13.5 D4NL-1AFA-B* G1/2 D4NL-2AFA-B M20 D4NL-4AFA-B* Pg13.5 D4NL-1BFA-B G1/2 D4NL-2BFA-B M20 D4NL-4BFA-B Pg13.5 D4NL-1CFA-B* G1/2 D4NL-2CFA-B M20 D4NL-4CFA-B* Pg13.5 D4NL-1DFA-B G1/2 D4NL-2DFA-B M20 D4NL-4DFA-B Pg13.5 D4NL-1EFA-B G1/2 D4NL-2EFA-B M20 D4NL-4EFA-B* Pg13.5 D4NL-1FFA-B G1/2 D4NL-2FFA-B M20 D4NL-4FFA-B Pg13.5 D4NL-1GFA-B G1/2 D4NL-2GFA-B M20 D4NL-4GFA-B Pg13.5 D4NL-1HFA-B G1/2 D4NL-2HFA-B M20 D4NL-4HFA-B Pg13.5 D4NL-1AFG-B* G1/2 D4NL-2AFG-B M20 D4NL-4AFG-B* Pg13.5 D4NL-1BFG-B G1/2 D4NL-2BFG-B M20 D4NL-4BFG-B Pg13.5 D4NL-1CFG-B* G1/2 D4NL-2CFG-B M20 D4NL-4CFG-B* Pg13.5 D4NL-1DFG-B G1/2 D4NL-2DFG-B M20 D4NL-4DFG-B Pg13.5 D4NL-1EFG-B G1/2 D4NL-2EFG-B M20 D4NL-4EFG-B* Pg13.5 D4NL-1FFG-B G1/2 D4NL-2FFG-B M20 D4NL-4FFG-B Pg13.5 D4NL-1GFG-B G1/2 D4NL-2GFG-B M20 D4NL-4GFG-B Pg13.5 D4NL-1HFG-B G1/2 D4NL-2HFG-B M20 D4NL-4HFG-B Safety Sensors / Components F502-EN2-04.book Seite 155 Dienstag, 26. Juli 2005 5:48 17 Operation Keys Type Model Horizontal mounting D4DS-K1 Vertical mounting D4DS-K2 Adjustable mounting (Horizontal) D4DS-K3 Adjustable mounting (Horizontal/Vertical) D4DS-K5 Specifications Standards and EC Directives Approved Standard Ratings Applicable EC Directives and Standards TÜV (EN60947-5-1) • • • • • Machinery Directive Low Voltage Directive EN1088 EN60204-1 GS-ET-19 Rated operating current (Ie) AC-15 DC-13 3A 0.27 A Rated operating voltage (Ue) 240 V 250 V Note: Use a 10-A fuse type gI or gG that conforms to IEC269 as a short-circuit protection device. This fuse is not built into the Switch. Approved Standards Agency Utilization category Item Standard TÜV Product Service EN60947-5-1 (approved direct opening) UL (See note 2.) UL508, CSA C22.2 No.14 File No. (See note 1.) E76675 Note: 1. Consult your OMRON representative for details. 2. Approval for CSA C22.2 No. 14 is authorized by the UL mark. UL/CSA (UL508, CSA C22.2 No. 14) A300 Rated voltage 120 VAC Carry current Current Make 10 A 240 VAC Volt-amperes Break 60 A 6A 30 A 3A Make Break 7,200 VA 720 VA Solenoid Coil Characteristics Item 24 VDC 110 VAC 230 VAC Rated operating 24 VDC +10%/ 110 VAC ±10% 230 VAC ±10% voltage (100% ED) −15% Current consump- Approx. tion 200 mA Class F (130° C max.) D4NL Insulation Approx. 50 mA Approx. 30 mA Indicator Characteristics Item Rated voltage D4NL LED 10 to 115 VAC/VDC Current leakage Approx. 1 mA Color (LED) Orange G-155 F502-EN2-04.book Seite 156 Dienstag, 26. Juli 2005 5:48 17 Characteristics Degree of protection (see note 2) IP67 (EN60947-5-1) (This applies for the Switch only. The degree of protection for the key hole is IP00.) Durability (see note 3) Mechanical 1,000,000 operations min. Electrical 500,000 operations min. for a resistive load of 3 A at 250 VAC (see note 4) Operating speed 0.05 to 0.5 m/s Operating frequency 30 operations/minute max. Rated frequency 50/60 Hz Contact gap 2 x 2 mm min Direct opening force (see note 5) 60 N min. (EN60947-5-1) Direct opening travel (see note 5) 10 mm min. (EN60947-5-1) Holding force (see note 6) 1,300 N min. Insulation resistance 100 MΩ min. (at 500 VDC) Minimum applicable load (see note 7) Resistive load of 1 mA at 5 VDC (N-level reference value) Rated insulation voltage (Ui) 300 V (EN60947-5-1) Rated open thermal current (Ith) 10 A (EN60947-5-1) Impulse withstand voltage (EN60947-5-1) Between terminals of the same polarity 2.5 kV Between terminals of different polarities 4 kV Between other terminals and uncharged metallic parts 6 kV Conditional short-circuit current 100 A (EN60947-5-1) Pollution degree (operating environment) 3 (EN60947-5-1) Protection against electric shock Class II (double insulation) Contact resistance 25 mΩ max. per contact (initial value) Vibration resistance Malfunction 10 to 55 Hz, 0.75-mm single amplitude Shock resistance Destruction 1,000 m/s2 min. Malfunction 300 m/s2 min. (100 m/s2 min. for the lock monitor switch) Ambient temperature Operating:−10° C to 55° C with no icing Ambient humidity Operating:95% max. Weight Approx. 370 g (D4NL-IAFA-B) Note: 1. The above values are initial values. 2. The degree of protection is tested using the method specified by the standard (EN60947-5-1). Confirm that sealing properties are sufficient for the operating conditions and environment beforehand. Although the switch box is protected from dust or water penetration, do not use the D4NL in places where foreign material 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%. For more details, consult your OMRON representative. 4. If the ambient temperature is greater than 35° C, do not pass the 3-A, 250-VAC load through more than 2 circuits. 5. These figures are minimum requirements for safe operation. 6. This figure is based on the GS-ET-19 evaluation method. 7. This value will vary with the switching frequency, environment, and reliability level. Confirm that correct operation is possible with the actual load beforehand. G-156 Safety Sensors / Components F502-EN2-04.book Seite 157 Dienstag, 26. Juli 2005 5:48 17 Connections Indicator Internal Circuit Diagram 10 to 115 VAC/VDC R ZD LED R Constant-current diode Circuit Connection Example • Terminals 12 and 41 are connected internally and so connect terminals 11 and 42 for safety-circuit input. (GS-ET-19) • Connect terminals 21 and 22 and terminals 51 and 52 in series when using as safety-circuit input (redundancy circuit for terminals 11 and 12 and terminals 41 and 42 above). Connect the terminals individually when using as auxiliary-circuit input (e.g., terminals 21 and 22 for safety-door open/closed monitoring and terminals 51 and 52 for monitoring the lock status). • In the connection example on the right, terminals 21 and 22 and terminals 51 and 52 are used as auxiliary-circuit input. 51 12 11 41 42 52 21 22 34 33 Safety circuit Auxiliary circuit Auxiliary circuit Auxiliary circuit E2 (−) E1 (+) Indicator (Orange) O1 O2 • Direct opening contacts used as safety-circuit input are indicated D4NL with the mark. Terminals 11 and 12 and terminals 21 and 22 are direct opening contacts. • Connect the indicators in parallel to the auxiliary circuits or terminals E1 and E2. If an indicator is connected in parallel to a direct opening contact, when the indicator breaks, a short-circuit current will be generated, possibly resulting in an installation malfunction. • Do not switch standard loads for more than 2 circuits at the same time. Otherwise, the level of insulation may decrease. • The 24-VDC solenoid has polarity. Be sure to connect terminals with the correct polarity. D4NL G-157 F502-EN2-04.book Seite 158 Dienstag, 26. Juli 2005 5:48 17 Operation Method Operation Principles Mechanical lock models Solenoid Operation Key ON OFF OFF When the Operation Key is inserted, it is The solenoid is released only when the locked by the lock spring. The door will stay lock is turned ON. locked even if there is a power interruption. Spring Lock plate Solenoid lock models Solenoid Operation Key Plunger ON OFF OFF If the solenoid is OFF, the door will not be locked when the Operation Key is inserted. This means that the door can be opened and closed easily when replacing workpieces or parts. Spring Lock plate The door is locked only when the solenoid is turned ON. This means that the door will be unlocked if there is a power interruption and so this model cannot be used in systems that would maintain a hazardous state (e.g., systems requiring toxic gases, high temperatures, or gears that would continue to turn due to inertia). Nomenclature Structure Operation key hole Solenoid Terminal 42 The head can be mounted in 3 directions. Terminal 41 Back-mounting is also possible. Terminal E1 (+) Shorting pin (12-41) Terminal E2 (−) Terminal 01 Terminal 12 Indicator Terminal 11 Two conduits (horizontal and vertical) Terminal 02 Door open/closed detection switch Terminal 21 Lock monitor switch Conduit opening (horizontal) Terminal 22 Terminal 31/33 Terminal 32/34 Terminal 52/54 Release key Conduit opening (vertical) Special release key Standard Release Key (Bottom View) Special Release Key (Bottom View) Terminal 51/53 UNLOCK LOCK UNLOCK LOCK Note: Terminal numbers vary with the model. G-158 Safety Sensors / Components F502-EN2-04.book Seite 159 Dienstag, 26. Juli 2005 5:48 17 Contact Form Indicates conditions where the Key is inserted and the lock is applied. Terminals 12 and 41 are connected internally (as per GS-ET-19). Model D4NL-@AF@-@ Contact 1NC/1NO + 1NC/1NO Contact form Operating pattern 11 12 41 42 33 34 53 54 Remarks Lock position 11-42 33-34 53-54 ON The terminals 11-42, 3334, and 53-54 can be used as unlike poles. Stroke Extraction completion position Operation Key insertion completion position D4NL-@BF@-@ 1NC/1NO + 2NC 11 12 41 42 33 34 51 52 Lock position 11-42 33-34 51-52 Only NC contacts 1112 and 41-42 have an approved direct opening mechanism. ON Only NC contacts 1112, 41-42, and 51-52 have an approved direct opening mechanism. Stroke Operation Key insertion completion position D4NL-@CF@-@ 2NC + 1NC/1NO 11 31 12 32 41 53 Lock position 42 54 The terminals 11-42, 3334, and 51-52 can be used as unlike poles. Extraction completion position 11-42 31-32 53-54 ON Only NC contacts 1112, 31-32, and 41-42 have an approved direct opening mechanism. Stroke D4NL-@DF@-@ 2NC + 2NC 11 31 12 32 41 51 Lock position 42 52 The terminals 11-42, 3132, and 53-54 can be used as unlike poles. Extraction completion position 11-42 31-32 51-52 ON Stroke Operation Key insertion completion position D4NL-@EF@-@ 2NC/1NO + 1NC/1NO 11 12 21 22 33 34 41 53 Lock position 42 54 Extraction completion position 11-42 21-22 33-34 53-54 ON D4NL-@FF@-@ 2NC/1NO + 2NC 11 12 21 22 33 34 41 The terminals 11-42, 2122, 33-34, and 53-54 can be used as unlike poles. Extraction completion position Only NC contacts 1112, 21-22, 41-42, and 51-52 have an approved direct opening mechanism. The terminals 11-42, 2122, 33-34, and 51-52 can be used as unlike poles. 51 Extraction completion position Only NC contacts 1112, 21-22, 31-32, and 41-42 have an approved direct opening mechanism. The terminals 11-42, 2122, 31-32, and 53-54 can be used as unlike poles. Extraction completion position Only NC contacts 11-12, 21-22, 31-32, 41-42 and 51-52 have an approved direct opening mechanism. The terminals 11-42, 2122, 31-32, and 51-52 can be used as unlike poles. Lock position 42 52 11-42 21-22 33-34 51-52 ON Stroke Operation Key insertion completion position D4NL-@GF@-@ 3NC + 1NC/1NO 11 12 21 22 31 32 41 53 Lock position 42 54 11-42 21-22 31-32 53-54 ON Stroke Operation Key insertion completion position D4NL-@HF@-@ 3NC + 2NC 11 12 41 42 21 22 51 52 31 32 Lock position 11-42 21-22 31-32 51-52 ON Stroke Operation Key insertion completion position D4NL Only NC contacts 1112, 21-22, and 41-42 have an approved direct opening mechanism. Extraction completion position Stroke Operation Key insertion completion position Only NC contacts 1112, 31-32, 41-42, and 51-52 have an approved direct opening mechanism. The terminals 11-42, 3132, and 51-52 can be used as unlike poles. G-159 D4NL Operation Key insertion completion position F502-EN2-04.book Seite 160 Dienstag, 26. Juli 2005 5:48 17 Dimensions Note: All units are in millimeters unless otherwise indicated Switches D4NL-@@@@-B Operating characteristics 8 15.5 30.5 Key insertion force 15 N max. Key extraction force 30 N max. Pre-travel distance Red D4NL-@@@@-B Four, head mounting screws Operation Key Black 15.3 Three, 4.3-dia. holes 10.5 29 6.5 Pre-travel distance 9 mm max. Movement before being locked 3 mm min. 4 28.5 Dummy cap Indicator 4.4 32± 0. 2 UNLOCK (13.3) (95) (32.3) 55 ±0.2 6.5 LOCK 29 (55.8) 59 0.5 Five, cover mounting screws (3) 4 (30.7) 0.5 5 4.5 (88.5) Release key (10) UNLOCK 6.5 Cap screw (57.9) 79 ±0.2 35.5 (15.3) 29 Conduit cap LOCK Conduit opening D4NL-@@@@-B4 15.5 30.5 Operating characteristics 8 Key insertion force 15 N max. Key extraction force 30 N max. Pre-travel distance Red D4NL-@@@@-B4 Four, head mounting screws Operation Key Black 15.3 Three, 4.3-dia. holes 10.5 29 6.5 Pre-travel distance 9 mm max. Movement before being locked 3 mm min. 4 Dummy cap Indicator 28.5 4.4 32 ±0.2 UNLOCK (13.3) 6.5 LOCK 29 (55.8) 59 0.5 Five, cover mounting screws 35.5 5 (57.9) 79±0.2 4 6.5 Cap screw 4.5 (15.3) 29 (88.5) Releasing tool Release key (provided) 8 (3) (30.7) 0.5 M8 hexagonal material or equivalent (95) (32.3) 55±0.2 Conduit cap 10.5 21 (10) UNLOCK LOCK Conduit opening G-160 Safety Sensors / Components F502-EN2-04.book Seite 161 Dienstag, 26. Juli 2005 5:48 17 D4NL-@@@@-BS Operating characteristics 8 15.5 30.5 D4NL-@@@@-BS Key insertion force 15 N max. Key extraction force 30 N max. Pre-travel distance Red Black Four, head mounting screws Operation Key Three, 4.3-dia. holes 15.3 10.5 29 6.5 Pre-travel distance 9 mm max. Movement before being locked 3 mm min. Operating characteristics D4NL-@@@@-B4S 4 Release key Indicator 4.4 28.5 32 ±0.2 UNLOCK (13.3) 6.5 LOCK 29 (31.5) (55.8) 59 0.5 Five, cover mounting screws (95) (32.3) 55 ±0.2 (3) 4 (30.7) 0.5 5 6.5 Cap screw (57.9) 79±0.2 35.5 (15.3) 4.5 29 (88.5) Dummy cap Conduit cap UNLOCK LOCK Conduit opening D4NL-@@@@-B4S 8 1 Key insertion force 15 N max. Key extraction force 30 N max. Pre-travel distance Four, head mounting screws Operation Key Three, 4.3-dia. holes 10.5 Red Black 29 6.5 Pre-travel distance 9 mm max. Movement before being locked 3 mm min. 4 4.4 28.5 . Indicator 32 ±0.2 (13.3) (95) 6.5 29 55±0.2 (31.5) 59 0.5 Five, cover 4 0.5 35.5 5 Releasing tool Dummy (provided) cap M8 hexagonal material or equivalent 6.5 Cap screw (57.9) 79 9±0.2 (15.3) 4.5 (88.5) 29 Conduit cap 10.5 K 21 Conduit opening Operation Keys D4DS-K1 17.5 28 15 4 4.3 7 30 14 D4DS-K3 28 13 15 Four, 2.15R 7 30 13 13 Black 30 28 6 4.5 dia. D4DS-K5 7 13 2 4.3 20.9 28 15 15° 43 7 30 55 8 dia. 24.6 22.5 4 41 13 Four, 2.15R Black D4NL 56 9 dia. 2 10.5 D4DS-K2 40 20 6.3 9 D4NL Note: Unless otherwise specified, a tolerance of ±0.4 mm applies to all dimensions. 18° 6.5 18 (7) G-161 F502-EN2-04.book Seite 162 Dienstag, 26. Juli 2005 5:48 17 With Operation Key Inserted D4NL + D4DS-K1 D4NL + D4DS-K2 Horizontal insertion radius: R ≥ 200 Red Black 44 min 46.5 max Key insertion position Horizontal insertion radius: R ≥ 200 Red Black 40 min 42.5 max Key insertion position (30.5) (30.5) 15 Center tolerance of key hole: ± 1 15 Center tolerance of key hole: ± 1 Vertical insertion radius: R ≥ 200 44 min 46.5 max Key insertion position Vertical insertion radius: R ≥ 200 40 min 42.5 max Key insertion position (30.5) (28.5) (30.5) Center tolerance of key hole: ± 1 (6) Center tolerance of key hole: ± 1 (22.5) (28.5) D4NL + D4DS-K3 D4NL + D4DS-K5 45 min 47.5 max Key insertion position (30.5) Horizontal insertion radius: R ≥ 50 51.9 min 54.4 max Key insertion position Red (30.5) Black Red Black 40±0.15 Center tolerance of key hole: ± 1 41 20.9 Horizontal insertion radius: R ≥ 50 Vertical insertion radius: R ≥ 200 45 min 47.5 max Key insertion position (30.5) Vertical insertion radius: R ≥ 50 51.9 min 54.4 max Key insertion position Center (28.5) tolerance of key hole: ± 1 Center 43±0.1 55 tolerance of (41±0.1) key hole: ± 1 (30.5) Center tolerance of key hole: ± 1 (28.5) G-162 Safety Sensors / Components F502-EN2-04.book Seite 163 Dienstag, 26. Juli 2005 5:48 17 Application Examples G9SA-321-T@ (24 VAC/VDC) + D4NL-@@@A-@, @@@B-@, @@@C-@ (Mechanical Lock Type) + D4D-@520N Circuit Diagram Lock release signal KM1 KM2 S2 S4 42 S1: Safety Limit Switch with direct opening mechanism (D4N) S2: Guard Lock Safety-door Switch S3: Reset switch S4: Lock release switch KM1 and KM2: Magnetic Contactor M: 3-phase motor 41 12 11 Feedback loop OPEN Stop signal TH SA Off delay timer Control circuit Guard opens Timing Chart Limit switch S1 Guard Lock Safety-door Switch S2 Lock release signal Operation instruction Lock release switch S4 Motor controller Guard can be opened Stop signal Reset switch S3 K1 and K2 (NC) K1 and K2 (NO) D4NL K3 and K4 (NC) K3 and K4 (NO) KM1 and KM2 (NC) KM1 and KM2 (NO) Operation instruction Motor rotation OFF-delay time D4NL G-163 F502-EN2-04.book Seite 164 Dienstag, 26. Juli 2005 5:48 17 G9SA-301 (24 VAC/VDC) + D4NL-@@@G-@, @@@H-@, @@@J-@ (Solenoid Lock Type) + D4D-@520N Circuit Diagram Lock signal S2 32 31 12 Note: Lock release is possible at any time. Therefore, do not use the solenoid lock type in applications where the operator may be exposed to danger when the guard opens. Use the mechanical lock type instead. 11 S1 Feedback loop OPEN Operation signal TH SA Control circuit Operation instruction Motor controller KM1 Timing Chart Guard opens KM2 Limit switch S1 Guard Lock Safety-door Switch S2 Operation signal Lock signal K1 and K2 (NC) M S1: Safety Limit Switch with direct opening mechanism (D4N) S2: Guard Lock Safety-door Switch KM1 and KM2: Magnetic Contactor M: 3-phase motor K1 and K2 (NO) KM1 and KM2 (NC) KM1 and KM2 (NO) G-164 Safety Sensors / Components F502-EN2-04.book Seite 165 Dienstag, 26. Juli 2005 5:48 17 Precautions Release Key Do not insert the Operation Key with the door open. The machine may operate and damage may result. UNLOCK !Caution Do not use metal connectors or conduits with this switch. Damage to the broken conduit hole may cause electric shock. !Caution Change the head direction after changing the release key to the UNLOCK position. Do not change the head direction with the cover removed. Failure to observe these points may result in Switch malfunction or damage. Holding Force • Do not apply a force exceeding the specified holding force. Doing so may break the Switch and the machine may continue to operate. • Either install another locking component (e.g., a stop) in addition to the Switch, or use a warning sticker or an indicator showing the lock status so that a force exceeding the specified holding force is not applied. Safety Precautions • The Switch contacts can be used for either standard loads or microloads. Once a contact has been used to switch a standard load, however, it cannot be used for a load of a smaller capacity. Doing so may result in roughening of the contact surface and contact reliability may be lost. • Turn OFF the power before disassembling the Switch or touching any internal parts. Not doing so may result in electric shock. • Mount the Operation Key in a location where it will not come in contact with users when the door is opened or closed. Otherwise, injury may result. • Do not impose excessive force on the Operation Key when it is inserted into the Switch or drop the Switch with the Operation Key inserted. Otherwise, the Operation Key may be deformed or the Switch may be broken. • Observe the specified insertion radius for the Operation Key and insert it in a direction perpendicular to the key hole. • Do not use the Switch in starting circuits. (Use for safety confirmation signals.) • When using the Switch in emergency-stop circuits or other safety circuits that have a direct impact on human lives, operate the NC contacts that have a direct opening mechanism in direct opening mode. For safety purposes, prevent easy removal by, for example, mounting the Switch and Operation Key with one-way screws or attaching a protective cover and warning label. • In order to prevent short-circuit damage to the Switch, connect a fuse to the Switch in series. Use a fuse with a breaking current of 1.5 to 2 times the rated current. To conform to EN ratings, use a IEC269-compliant 10-A fuse type gI or gG. • Turn the power OFF when wiring. After wiring is completed, be sure to mount the cover before use. • In order to prevent burning due to overvoltage, insert a protective fuse in the solenoid circuits. • Do not use the Switch where explosive gas, flammable gas, or any other dangerous gas may be present. • Ensure that the load current does not exceed the rated current. • Be sure to wire the terminals correctly. • Be sure to evaluate the Switch under actual operating conditions after installation. • Do not drop the package or the product. Do not disassemble internal parts. D4NL LOCK • The release key is used to unlock the Switch in case of emergency or if the power supply to the Switch stops. • If the release key setting is changed from LOCK to UNLOCK using an appropriate tool, the lock will be released and the safety door can be opened (mechanical lock models only). • After setting the release key to UNLOCK in order to, for example, change the head direction or perform maintenance, be sure to return it to LOCK setting before resuming operation. • When the Switch is used for the door of a machine room to ensure the safety of people performing adjustment work inside, if the 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. • Do not use the release key to start or stop machines. • The auxiliary lock must only be released by authorized personnel. • Do not impose a force exceeding 1 N·m on the release key screws. The release key may be damaged and may not operated properly. • To prevent the release key from being used by unauthorized personnel, set it to LOCK and seal it with seal wax. Mounting Door Stopper Switch Operation Key Set zone (0.5 to 3 mm) • Do not use the Switch as a stopper. To prevent the door from coming into contact with the flange of the Operation Key, be sure to mount the Switch with a stopper as shown above. • When the Switch is used for a hinged door at a location near to the hinged side, where the Operation Key’s insertion radius is comparatively small, if an attempt is made to open the door beyond the lock position, the force imposed will be much larger than for locations far from the hinged side, and the lock may be damaged. Solenoid Lock Models The solenoid lock locks the door only when power is supplied to the solenoid. Therefore, the door will be unlocked if the power supply to the solenoid stops. Therefore, do not use solenoid lock models for machines that may be operating and dangerous even after the machine stops operating. D4NL !Caution G-165 F502-EN2-04.book Seite 166 Dienstag, 26. Juli 2005 5:48 17 Correct Use Switch and Operation Key Mounting Operating Environment • Mount the Switch and Operation Key securely to the applicable tightening torque with M4 screws. • This Switch is for indoor use only. Do not use it outdoors. Otherwise, it may malfunction. • Do not use the Switch in the following locations: •Locations subject to severe temperature changes •Locations subject to high humidity levels or condensation •Locations subject to severe shocks or vibrations •Locations where the Switch may come in contact with metal dust, oil, or chemicals •Locations subject to thinner, detergent, or other solvents. • Although the Switch itself is protected from dust or water penetration, ensure that foreign material does not penetrate through the key hole on the head, otherwise Switch damage or malfunctioning may occur. • Do not use the Switch submerged in oil or water, or in locations continuously subject to splashes of oil or water. Doing so may result in oil or water entering the Switch interior. (The IP67 degree of protection specification for the Switch pertains to the amount of water penetration after the Switch is submerged in water for a certain period of time.) ] Mounting Hole Dimensions for Switch Mounting Hole Dimensions for Operation Key D4DS-K1/-K2 (horizontal/vertical mounting) Three, M4 Two, M4 32±0.1 15 ±0.1 55±0.1 D4DS-K3 (adjustable mounting: horizontal) Two, M4 79±0.1 40 ±0.1 D4DS-K5 (adjustable mounting: vertical) Two, M4 Life Expectancy 41±0.1 or, 43±0.1 The life expectancy of the Switch will vary with the switching conditions. Before applying the Switch, test it under actual operating conditions and be sure to use it at a switching frequency that will not lower its performance. Operation Key Applying weight • If the Switch is back-mounted, the release key can only be operated from the bottom and the indicator cannot be used. • Use the designated OMRON Operation Key with the Switch. Using another Operation Key may result in Switch damage. • Ensure that the alignment offset between the Operation Key and the key hole does not exceed ±1 mm. Head Direction By removing the four screws of the head, the mounting direction of the head can be changed. The head can be mounted in four directions. Ensure that no foreign matter penetrates the interior of the Switch. Dropping Securing the Door • Use the designated OMRON Operation Key with the Switch. Using another Operation Key may result in Switch damage. • Do not impose excessive force on the Operation Key when it is inserted into the Switch or drop the Switch with the Operation Key inserted. Otherwise, the Operation Key may be deformed or the Switch may be broken. Set zone (0.5 to 3 mm) Mounting Tightening Torque Be sure to tighten each screw of the Switch properly. Loose screws may result in malfunction. Type Terminal screw Operation Key Tightening torque 0.59 to 0.78 N·m Cover mounting screw 0.49 to 0.69 N·m Head mounting screw 0.49 to 0.59 N·m Operation Key mounting screw 2.35 to 2.75 N·m Switch mounting screw 0.49 to 0.69 N·m Connector 1.77 to 2.16 N·m Cap screw 1.27 to 1.67 N·m G-166 When the door is closed (with the Operation Key inserted), it may be pulled beyond the set zone because of, for example, the door’s weight, or the door cushion rubber. Also, if a load is applied to the Operation Key, the door may fail to unlock properly. Use hooks to ensure that the door stays within the set zone (0.5 to 3 mm). Safety Sensors / Components F502-EN2-04.book Seite 167 Dienstag, 26. Juli 2005 5:48 17 Wiring Recommended Connectors Wiring Precautions Use a connector with a screw section not exceeding 11 mm, otherwise the screws will protrude into the case interior. The connectors given in the following table have connectors with screw sections not exceeding 11 mm. Use the following connectors to ensure conformance to IP67. 11 12 21 22 33 34 Size • When connecting to the terminals via insulating tube and M3.5 crimp terminals, cross the crimp terminals as shown above so that they do not rise up onto the case or the cover. Applicable lead wire size: AWG20 to AWG18 (0.5 to 0.75mm2). • When connecting lead wires directly to terminals, perform wiring securely so that there are no loose wire strands. • Do not push crimp terminals into gaps in the case interior. Doing so may cause damage or deformation of the case. • Use lead wires of an appropriate length. Not doing so may cause the cover to rise. • Use crimp terminals not more than 0.5 mm in thickness. Otherwise, they will interfere with other components inside the case. The crimp terminals shown below are not more than 0.5 mm thick. Manufacturer Model J.S.T. 0.5 mm 3.7 mm 2.9 mm 6.6 mm 19 mm 7.7 mm 8.0 mm LAPP Ohm Denki Model ST-PF1/2 5380-1002 Applicable cable diameter 6.0 to 12.0 mm OA-W1609 7.0 to 9.0 mm OA-W1611 9.0 to 11.0 mm Pg13.5 LAPP S-13.5 5301-5030 5.0 to 12.0 mm M20 LAPP ST-M20 *1.5 5311-1020 7.0 to 13.0 mm Use LAPP connectors together with seal packing (JPK-16, GP-13.5, or GPM20), and tighten with the applicable torque. Seal packing is sold separately. Maintenance and Repairs FV0.5-3.7 t: dz dia.: D dia.: B: L: F: I: G 1 /2 Manufacturer The user must not perform repairs or maintenance. Contact the machine manufacturer if repairs or maintenance are required. L l F Storage B D Do not store the Switch in locations where harmful gases (e.g., H2S, SO2, NH3, HNO3, or Cl2) or dust are present, or in locations subject to high humidity levels. dz Terminal screw Crimp terminal Miscellaneous • Do not touch the solenoid. The temperature of the solenoid increases when current is passed. • In conditions requiring greater rigidity, sealing performance, and oil resistance, use OMRON’s D4BL. • Perform regular inspections. Conduit Opening D4NL • Connect a recommended connector to the opening of the conduit and tighten the connector to the proper torque. The case may be damaged if an excessive tightening torque is applied. • In order to ensure IP67 degree of protection, wrap sealing tape around the conduit end of the connector. • Be sure that the outer diameter of the cable connected to the connector is correct. • Attach and tighten a conduit cap to the unused conduit opening when wiring. The conduit cap is provided with the Switch. D4NL G-167 F502-EN2-04.book Seite 168 Dienstag, 26. Juli 2005 5:48 17 Production Termination Following the release of the D4NL, production of the D4DL will be terminated. Dimensions Date of Production Termination Discontinued Model (D4DL) Production of the D4DL Series will be terminated in November 2003. 8 15.5 30.5 Cap head 10.5 Operation Key Three, 4.3-dia. holes 4 28.5 4.4 32±0.2 15.3 Date of Substitute Product Release 10 Sale of the D4NL Series commenced in October 2002. Indicator (21) (32.3) 10 Product Replacement 4 (59) 79±0.2 (88.5) 5 Cap screw 4.5 (15.3) Conduit cap Release key D4NL-@ Switch color Very similar Dimensions Very similar Wiring/connection Significantly different Mounting method Very similar Ratings/performance Very similar Operating method 10 (25.1) 35 Comparison of the D4DL and Substitute Products Operating characteristics (28.8) (3) The D4DL and D4NL have basically the same structure, and use the same mounting method and Operation Keys. There are differences, however, in the external appearance and the mounting sections. Model (95) 55±0.2 59 (37) Replacement products (D4NL Series) 15.5 30.5 8 Cap head Operation Key 15.3 Three, 4.3-dia. holes 10.5 29 6.5 4 Very similar Dummy cap Indicator 28.5 4.4 Completely compatible A 32±0.2 UNLOCK (13.3) 6.5 LOCK 29 59 (55.8) (95) (32.3) 55±0.2 0.5 (3) 4 0.5 (30.7) 35.5 5 (57.9) 79±0.2 6.5 Cap screw 4.5 (15.3) 29 (88.5) Release key (10) Conduit cap UNLOCK LOCK The above diagram is for Switches with the release key on the bottom. For Switches with the release key on the front, interchange the positions of the release key and dummy cap (A). Differences:The depth of the M4 mounting screw holes is 29 mm for the D4NL, as opposed to 10 mm for the D4DL. Therefore, when replacing the D4DL with the D4NL, use M4 screws that are 19 mm longer than the ones used before. G-168 Safety Sensors / Components F502-EN2-04.book Seite 169 Dienstag, 26. Juli 2005 5:48 17 List of Recommended Substitute Products Switch D4DL product Recommended substitute product D4DL-1CFA-B D4NL-1AFA-B, D4NL-1BFA-B D4DL-2CFA-B D4NL-2AFA-B, D4NL-2BFA-B D4DL-1DFA-B D4NL-1CFA-B, D4NL-1DFA-B D4DL-2DFA-B D4NL-2CFA-B, D4NL-2DFA-B D4DL-1CFG-B D4NL-1AFG-B, D4NL-1BFG-B D4DL-2CFG-B D4NL-2AFG-B, D4NL-2BFG-B D4DL-1DFG-B D4NL-1CFG-B, D4NL-1DFG-B D4DL-2DFG-B D4NL-2CFG-B, D4NL-2DFG-B D4DL-1CFB-B D4NL-1AFB-B, D4NL-1BFB-B D4DL-2CFB-B D4NL-2AFB-B, D4NL-2BFB-B D4DL-1DFB-B D4NL-1CFB-B, D4NL-1DFB-B D4DL-2DFB-B D4NL-2CFB-B, D4NL-2DFB-B D4DL-1CFH-B D4NL-1AFH-B, D4NL-1BFH-B D4DL-2CFH-B D4NL-2AFH-B, D4NL-2BFH-B D4DL-1DFH-B D4NL-1CFH-B, D4NL-1DFH-B D4DL-2DFH-B D4NL-2CFH-B, D4NL-2DFH-B D4DL-1CFC-EW D4NL-1AFC-E, D4NL-1BFC-E D4DL-2CFC-EW D4NL-2AFC-E, D4NL-2BFC-E D4DL-1DFC-EW D4NL-1CFC-E, D4NL-1DFC-E D4DL-2DFC-EW D4NL-2CFC-E, D4NL-2DFC-E D4DL-1CFJ-EW D4NL-1AFJ-E, D4NL-1BFJ-E D4DL-2CFJ-EW D4NL-2AFJ-E, D4NL-2BFJ-E D4DL-1DFJ-EW D4NL-1CFJ-E, D4NL-1DFJ-E D4DL-2DFJ-EW D4NL-2CFJ-E, D4NL-2DFJ-E D4DL-1CFA-B-HT D4NL-1AFA-B4, D4NL-1BFA-B4 D4DL-2CFA-B-HT D4NL-2AFA-B4, D4NL-2BFA-B4 D4DL-1DFA-B-HT D4NL-1CFA-B4, D4NL-1DFA-B4 D4DL-2DFA-B-HT D4NL-2CFA-B4, D4NL-2DFA-B4 D4DL-1CFG-B-HT D4NL-1AFG-B4, D4NL-1BFG-B4 D4DL-2CFG-B-HT D4NL-2AFG-B4, D4NL-2BFG-B4 D4DL-1DFG-B-HT D4NL-1CFG-B4, D4NL-1DFG-B4 D4DL-2DFG-B-HT D4NL-2CFG-B4, D4NL-2DFG-B4 Substitute with M20 conduit D4NL-4AFA-B, D4NL-4BFA-B D4NL-4CFA-B, D4NL-4DFA-B D4NL-4AFG-B, D4NL-4BFG-B D4NL-4CFG-B, D4NL-4DFG-B D4NL-4AFB-B, D4NL-4BFB-B D4NL-4CFB-B, D4NL-4DFB-B D4NL-4AFH-B, D4NL-4BFH-B D4NL-4CFH-B, D4NL-4DFH-B D4NL-4AFC-E, D4NL-4BFC-E D4NL-4CFC-E, D4NL-4DFC-E D4NL-4AFJ-E, D4NL-4BFJ-E D4NL-4CFJ-E, D4NL-4DFJ-E D4NL-4AFA-B4, D4NL-4BFA-B4 D4NL-4CFA-B4, D4NL-4DFA-B4 D4NL-4AFG-B4, D4NL-4BFG-B4 D4NL-4CFG-B4, D4NL-4DFG-B4 Note: With standard products, terminals 12 and 41 are connected with a shorting pin. In cases where D4DL terminals 11 and 12 and terminals 41 and 42 are currently being used independently, remove the shorting pin. Note: Operation Key D4DS-K1 D4DS-K2 D4DS-K3 D4DS-K5 D4NL • • • • All of the above Operation Keys can be used with the D4NL. D4NL G-169 F502-EN2-04.book Seite 170 Dienstag, 26. Juli 2005 5:48 17 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. C126-E2-01-X G-170 In the interest of product improvement, specifications are subject to change without notice. Safety Sensors / Components