Omron G9SR User Manual Download

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ZX-T Series

Cat. No. J12E-EN-03

G9SR

Safety Relays

OPERATION MANUAL

G9SR-BC

G9SR-AD

G9SR-EX

Summary of Contents for G9SR

Page 1: ...ZX T Series Cat No J12E EN 03 G9SR Safety Relays OPERATION MANUAL G9SR BC G9SR AD G9SR EX...

Page 2: ...ten permission of OMRON No patent liability is assumed with respect to the use of the information contained herein Moreover because OMRON is constantly striving to improve its high quality products th...

Page 3: ...Operation manual G9SR III G9SR Safety Relays G9SR BC G9SR AD G9SR EX T90 Operation Manual Revised October 2014...

Page 4: ...s 5 2 3 3 Install Power Supply 5 2 3 4 G9SR BC solid state output 6 2 4 STEP 4 CONFIGURE THE G9SR UNITS 6 2 5 STEP 5 TEST THE INSTALLATION 6 3 TEST 7 3 1 TEST THE OFF BEHAVIOUR 8 3 2 TEST THE ON BEHAV...

Page 5: ...Error 29 7 5 LED EXAMPLES G9SR AD 30 7 5 1 Normal operation LEDs G9SR AD 30 7 5 2 Error situations LEDs G9SR AD 31 7 6 TERMINAL AND SIGNAL NAMES OF THE G9SR AD UNIT 32 8 G9SR UNIT G9SR EX T90 33 8 1 I...

Page 6: ...56 11 1 4 G9SR BC for door interlocking up to PLd with F3S TGR N__C 58 11 1 5 G9SR BC with Safety Sensors in applications up to PLe F3S TGR CL 60 11 2 WIRING EXAMPLES G9SR AD UNIT 62 11 2 1 G9SR AD in...

Page 7: ...tion to provide safety during each of the following product phases mechanical design installation operation maintenance and disposal WARNING The G9SR system must be installed configured and incorporat...

Page 8: ...NTENDED USE OMRON DISCLAIMS ALL OTHER WARRANTIES EXPRESSED OR IMPLIED LIMITATIONS OF LIABILITY OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR COMMERCIA...

Page 9: ...ustive 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 electr...

Page 10: ...time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shown...

Page 11: ...ally there may be significant property damage Caution Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or in property damage Precautions for Safe...

Page 12: ...es for electrical safety acc EN 60204 1 In addition it is required to check the structure of the entire safety system EN ISO 13849 1 the diagnostic coverage and the robustness against common cause fai...

Page 13: ...nce with the construction operation or maintenance of the machinery and the hazards involved To use the G9SR system the following requirements must be met Observe the instructions in this manual regar...

Page 14: ...y Principles of Risk Assessment Safety Measures When using this safety device to build systems containing safety related components for equipment or facilities the system must be designed with the ful...

Page 15: ...inery Electrical Equipment of Machines Observing Precautions for Use When putting the selected safety device to actual use heed the specifications and precautions in this manual and those in the instr...

Page 16: ...environments where flammable or explosive gases are present Doing so may result in an explosion Do not use the auxiliary output for safety applications Do not connect the 0V line to PE Serious injury...

Page 17: ...TION Connect the AD201 and EX031 units to the same power supply Do not remove a terminal block while the unit is powered ON It may damage the unit Do not remove the 0V connection while the unit is pow...

Page 18: ...to possible exposure to radioactivity Locations close to power supplies This is a class A product designed for use in industrial environments In residential areas it may cause radio interference in w...

Page 19: ...surfaces and at least 50 mm from its top and bottom surfaces for ventilation wiring and Unit replacement Be sure to lock all locking mechanisms such as those on I O terminal blocks and connectors bef...

Page 20: ...er supply must be isolated from the primary circuit by double insulation or reinforced insulation The output characteristic requirements defined in UL 508 for class 2 circuits or control voltage curre...

Page 21: ...de in Canada and may vary from information given in the product manuals or safety precautions Surrounding air temperature 55 C The DC power supply must satisfy the requirements for an isolated power s...

Page 22: ...1 2008 Type 4 IEC 61496 1 ed 2 2004 PFHd G9SR BC 5 7 10 9 EN ISO 13849 1 2008 PFHd G9SR AD 5 7 10 9 EN ISO 13849 1 2008 PFHd G9SR EX 3 1 10 9 EN ISO 13849 1 2008 MTTFD G9SR BC 351 Year EN ISO 13849 1...

Page 23: ...vices or the equipment OMRON cannot confirm compliance in the customer s actual application however because the customer may use a variety of components and equipment and EMC performance depends on th...

Page 24: ...sure appropriate overvoltage protection to a maximum of 30V DC G9SR series products that comply with the EC Directives also comply with the Generic Emission Standard EN 61000 6 4 for EMI The radiated...

Page 25: ...G9SR BC A Basic unit BC of the G9SR series G9SR AD An Advanced unit AD of the G9SR series G9SR EX T90 An Extension unit EX of the G9SR series Input Signal going into the unit Input signals can come f...

Page 26: ...vel as defined in ISO 13849 1 RESTART A sequence of the total system to come from a non powered situation to an operational situation In an operational situation OSSDs can be activated ON when a valid...

Page 27: ...SR EX units have an ON delay timer and an OFF delay timer for additional control of your outputs 1 2 Family Overview The product family G9SR consists of a G9SR BC BC Basic a G9SR AD AD Advanced and a...

Page 28: ...ne or in a system with up to two additional G9SR BC as input expansion up to three G9SR EX as additional safety relay outputs See also Chapter 7 G9SR unit G9SR AD on page 26 1 2 3 G9SR EX The G9SR EX...

Page 29: ...114 5 mm 114 5 mm 114 5 mm Thickness 17 6 mm 22 5 mm 22 5 mm Width without terminal blocks 99 0 mm 99 0 mm 99 0 mm Width with spring type terminal blocks 117 0 mm 117 0 mm 117 0 mm Width with screw t...

Page 30: ...unting on page 18 2 2 Step 2 Mechanical installation The installation should be carried out by qualified personnel only Mount each G9SR unit on a DIN rail in a vertical position as shown in the figure...

Page 31: ...ter 11 Appendix A Wiring examples on page 52 10 1 Input loop on page 49 10 2 Output loop on page 50 10 3 Input loop and Output loop on page 51 2 3 1 Install fuses for G9SR units G9SR units require ext...

Page 32: ...ches on the units are used to set the function of the safety control system Set the switches to achieve the desired behaviour of your system See also 6 3 Dip switches and functions of G9SR BC on page...

Page 33: ...he local requirements local standards and or safety rules WARNING Incorrect testing can cause potentially hazardous situations which if not avoided could result in death or serious injury Additionally...

Page 34: ...Operation manual G9SR Page 8 of 79 3 1 Test the OFF behaviour...

Page 35: ...Operation manual G9SR Page 9 of 79 3 2 Test the ON behaviour...

Page 36: ...EC 68 2 6 Shock to IEC 68 2 27 0 375mm 10 to 70 Hz 30G 18ms Operating voltage 24V DC 20 Current consumption excluding auxiliary output 0 15A Minimum EDM and RESTART input current 6mA Minimum EDM and R...

Page 37: ...G9SR EX G9SR AD 3 G9SR EX 1 BC AD 1 EX 2 BC AD 1 EX 1 BC AD 2 EX 2 BC AD 2 EX 1 BC AD 3 EX 2 BC AD 3 EX 54ms 52ms 214ms for system 294ms for system 58ms 61ms 64ms 218ms 298ms 222ms 302ms 225ms 306ms R...

Page 38: ...luenced by Load Current A and the distance 25 mm between units Use the derating curve to determine the maximum allowed relay contact current for the actual operating temperature of the unit This appli...

Page 39: ...a OSSD1 test pulse1 with a duration of 250 micro second Tb OSSD1 test pulse2 with a duration of 350 micro second Tres Cycle time of the complete G9SR unit 4 3 Test pattern for Dynamic Input testing Te...

Page 40: ...e wiring of the G9SR Restart input is depending on the DIP switch setting 1 DIP switch 2 ON The G9SR monitors to detect unexpected signals between all terminals and or power supply for full diagnosis...

Page 41: ...Minimum Restart input pulse 300ms WARNING Make sure that the source of the restart signal is complementing the requirements for the safety control system Improper use of the restart input may lead to...

Page 42: ...the dynamic test pulses Applicable up to Ple acc EN ISO 13849 1 Output connections and EDM not shown in this schematic 24V 0V Fuse 5A F 5 2 2 Manual Restart without dynamic input testing Power supply...

Page 43: ...n ON delay time set on the G9SR EX tOff OFF delay time set on the G9SR EX Automatic Restart Diagram Not used ON OFF WARNING The Automatic Restart option shall only be used when it is guaranteed that a...

Page 44: ...the dynamic test pulses Applicable up to Ple acc EN ISO 13849 1 Output connections and EDM not shown in this schematic 24V 0V Fuse 5A F 5 4 2 Automatic Restart without dynamic input testing Power supp...

Page 45: ...with a maximum of 2A switching current each This unit can be used stand alone or as an additional Input unit for the G9SR AD See also 10 1 Input loop on page 49 6 2 Internal connections of G9SR BC Pow...

Page 46: ...DIP SWITCH 3 BANK1 OFF and DIP SWITCH 3 BANK2 ON ERROR Caution Do not change the setting of the DIP switches during operation of the G9SR BC In this case the G9SR BC will change the outputs to OFF and...

Page 47: ...ves a valid input signal OFF when no valid input signal is received at T12 6 4 2 IN2 LED Input 2 Color Yellow ON when T22 receives a valid input signal OFF when no valid input signal is received at T2...

Page 48: ...FLASH fast 3 per second when input loop chain is OK OFF when the outputs are de activated OFF 6 4 6 OFF ERR LED OFF Error Color Red ON when OSSDs are OFF FLASH when an error occurs EDM and Restart led...

Page 49: ...Waiting for restart EDM disabled Output not active 3 T12 OFF T22 OFF EDM enabled Output not active 4 T12 ON T22 ON EDM disabled Input loop function activated module running OK 1 5 T12 OFF T22 OFF EDM...

Page 50: ...or on EDM input 2 Error during cyclic test Error because other module is connected when G9SR BC is configured with input loop 3 DIP switch settings incorrect 4 Error on solid state safety outputs over...

Page 51: ...ry Status A1 Power Supply T31 Restart Input T11 Test Signal 1 A2 Power Supply GND T32 EDM Input or Input Loop IN depending on dip switches T21 Test Signal 2 14 Output 1 OSSD1 or Input Loop OUT dependi...

Page 52: ...This unit can be expanded with up to 3 G9SR EX units to increase the output signal capabilities See also 10 1 Input loop on page 49 up to 2 G9SR BC units to increase the input signal capabilities See...

Page 53: ...ANK2 ON ERROR Caution Do not change the setting of the DIP switches during operation of the G9SR AD In this case the G9SR AD will change the outputs to OFF and will enter a lockout state Use the switc...

Page 54: ...hown as 7 4 1 POWER LED Power Color Green ON when power supply is correctly applied to the unit OFF when no power is supplied 7 4 2 IN1 LED Input 1 Color Yellow ON when T12 receives a valid input sign...

Page 55: ...DM function is enabled FLASH when any error on External Device Monitoring occurs OFF EDM function is disabled 7 4 6 ON LED Outputs Color Green ON when the outputs are ON OFF when the outputs are OFF 7...

Page 56: ...signal Pattern Description ID OFF ERR ON EDM RESTART IN2 IN1 POWER 1 T12 ON T22 ON EDM disabled Output active 2 T12 ON T22 ON EDM enabled Output active 3 T12 ON T22 ON EDM disabled Waiting for restar...

Page 57: ...Pattern Description ID OFF ERR ON EDM RESTART IN2 IN1 POWER 1 Error on EDM input 2 Error during cyclic test 3 DIP switch settings incorrect 4 ERR and RES fast blinking 3 per sec communication error of...

Page 58: ...ut Channel 1 44 Output Auxiliary Status A1 Power Supply T31 Restart Input T11 Test Signal 1 T43 Input loop IN T44 Input loop OUT A2 Power Supply GND T32 EDM input T21 Test Signal 2 T41 Output loop OUT...

Page 59: ...AC15 Max 4A DC1 Max 5A DC13 See also 4 2 Derating curve The output signals of the G9SR EX T90 unit can be switched with 16 timing pre sets for an ON delay and 16 timing pre sets for an OFF delay See a...

Page 60: ...switches in the G9SR EX to configure the ON and OFF delay time setting Switch 1 and 3 define the ON delay time setting Switch 2 and 4 define the OFF delay time setting The rotary switch settings repre...

Page 61: ...ied 8 4 2 COM LED Input Color Yellow ON when the communication line sends or receives a valid signal FLASH when an ONdelay or OFFdelay is in progress Fast blinking ERR fast blinking Communication erro...

Page 62: ...ERR LED Error Color Red ON when OSSDs are OFF System startup internal testing failed FLASH when an error occurs Fast blinking RES or COM fast blinking Communication error of another unit Slow blinkin...

Page 63: ...ring 4 Outputs not active Output loop active 8 5 2 Error situations LEDs G9SR EX T90 LED signal Pattern Description ID OFF ERR ON EDM COM POWER 1 Error on EDM input 2 Error during cyclic test Error du...

Page 64: ...the G9SR EX T90 13 Relay Output 1 1 NO 23 Relay Output 2 1 NO 33 Relay Output 3 1 NO 44 Output Auxiliary Status A1 Power Supply A2 Power Supply GND T32 EDM Input T41 Output Loop OUT 14 Relay Output 1...

Page 65: ...the table below G9SR BC G9SR AD G9SR EX E Stop function Yes Yes No Door monitoring safety limit switches Yes Yes No Door monitoring key operated switches Yes Yes No Door monitoring non contact switch...

Page 66: ...d to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks Wiring is using the dynamic test pulses Applicable up to PLe acc EN ISO 138...

Page 67: ...ed to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks Applicable up to PLd acc EN ISO 13849 1 Motor circuit contacts of KM1 and...

Page 68: ...ted to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Remarks Wiring is using the dynamic test pulses Applicable up to PLd acc EN ISO 13849 1 Motor circuit contacts of KM...

Page 69: ...top pushbutton connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Remarks Applicable up to PLd acc EN ISO 13849 1 Motor circuit contacts of KM1 and KM2 not shown...

Page 70: ...d to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks Wiring is using the dynamic test pulses Applicable up to PLe acc EN ISO 13849 1 Motor circuit contacts of KM1 and KM2 n...

Page 71: ...n connected to T31 KM1 and KM2 Motor Contactors Remarks Wiring is using the dynamic test pulses Applicable up to PLd acc EN ISO 13849 1 Motor circuit contacts of KM1 and KM2 not shown Power supply cir...

Page 72: ...connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks Applicable up to PLd acc EN ISO 13849 1 Motor circuit contacts of KM1 and KM2 not shown Power supply circuit S...

Page 73: ...T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Remarks Applicable up to PLd acc EN ISO 13849 1 Motor circuit contacts of KM1 and KM2 not shown Power supply circuit Safety Input 1...

Page 74: ...with up to two G9SR BC plus up to three G9SR EX This creates an input loop and an output loop See also 10 3 Input loop and Output loop on page 51 Caution Use a single power supply for AD and EX units...

Page 75: ...ollowing wiring schematic Caution Maximum cable length for each wire of the Input loop is 20 meters Caution Maximum cable impedance for the safety input circuit must be less than 250 ohm Caution When...

Page 76: ...afety outputs available G9SR AD units use terminals T41 and T42 for the Output loop G9SR EX units use terminals T41 and T42 for the Output loop Connect 1 2 or 3 G9SR EX T90 units according to followin...

Page 77: ...afety outputs Figure 13 Maximum configuration This configuration shows three safety inputs two on the G9SR BCs one on the G9SR AD one safety output with two NO contacts on the G9SR AD three safety out...

Page 78: ...OFF OFF Description E Stop pushbutton connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used w...

Page 79: ...ol Auxiliary Output Control T32 T31 T22 T21 T12 A1 A2 14 24 44 KM1 KM2 T11 KM1 KM2 24V 0V Fuse 5A F Figure 14 G9SR BC in E stop application up to PLe Note Ensure the dip switch settings of your G9SR B...

Page 80: ...escription E Stop pushbutton connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used with safet...

Page 81: ...ol Auxiliary Output Control T32 T31 T22 T21 T12 A1 A2 14 24 44 KM1 KM2 T11 KM1 KM2 24V 0V Fuse 5A F Figure 15 G9SR BC in E Stop application up to PLd Note Ensure the dip switch settings of your G9SR B...

Page 82: ...on contact switch connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used with safety limit swi...

Page 83: ...22 T21 T12 A1 A2 14 24 44 KM1 KM2 T11 KM1 KM2 24V 0V Fuse 5A F blue white green black yellow red Actuator F3S TGR N__C Figure 16 G9SR BC for door interlocking up to PLe with F3S TGR N__C Note Ensure t...

Page 84: ...OFF OFF Description Non contact switch connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used...

Page 85: ...22 T21 T12 A1 A2 14 24 44 KM1 KM2 T11 KM1 KM2 24V 0V Fuse 5A F blue white green black yellow red Actuator F3S TGR N__C Figure 17 G9SR BC for door interlocking up to PLd with F3S TGR N__C Note Ensure t...

Page 86: ...switch settings 1 2 3 4 5 6 7 8 OFF OFF ON OFF OFF OFF OFF OFF Description Safety Sensor connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM co...

Page 87: ...14 24 44 KM1 KM2 T11 KM1 KM2 24V 0V Fuse 5A F blue gray pink brown F3S TGR CL transmitter F3S TGR CL receiver white blue brown Figure 18 G9SR BC with Safety Sensors in applications up to PL e F3S TGR...

Page 88: ...E Stop pushbutton connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used with safety limit sw...

Page 89: ...T Loop K1 K2 K1 K2 A1 T11 T12 T21 T22 T31 T32 13 23 T44 T41 T43 T42 A2 44 14 24 KM1 KM2 24V KM1 KM2 0V Fuse 1A F Fuse 5A F Fuse 5A F Figure 19 G9SR AD in E Stop application up to PLe Note Ensure the d...

Page 90: ...on connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used with safety limit switches and key o...

Page 91: ...T Loop K1 K2 K1 K2 A1 T11 T12 T21 T22 T31 T32 13 23 T44 T41 T43 T42 A2 44 14 24 KM1 KM2 24V KM1 KM2 0V Fuse 1A F Fuse 5A F Fuse 5A F Figure 20 G9SR AD in E Stop application up to PLd Note Ensure the d...

Page 92: ...tact switch connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used with safety limit switches...

Page 93: ...T31 T32 13 23 T44 T41 T43 T42 A2 44 14 24 KM1 KM2 24V KM1 KM2 0V Fuse 1A F Fuse 5A F Fuse 5A F blue white green black yellow red Actuator F3S TGR N__C Figure 21 G9SR AD with door interlocking up to P...

Page 94: ...F Description Non contact switch connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T32 Remarks This setup can also be used with s...

Page 95: ...T31 T32 13 23 T44 T41 T43 T42 A2 44 14 24 KM1 KM2 24V KM1 KM2 0V Fuse 1A F Fuse 5A F Fuse 5A F blue white green black yellow red Actuator F3S TGR N__C Figure 22 G9SR AD with door interlocking up to P...

Page 96: ...ings 1 2 3 4 5 6 7 8 OFF OFF ON OFF OFF OFF OFF OFF Description Safety Sensor connected to T12 and T22 Restart pushbutton connected to T31 KM1 and KM2 Motor Contactors Feedback loop EDM connected to T...

Page 97: ...13 23 T44 T41 T43 T42 A2 44 14 24 KM1 KM2 24V KM1 KM2 0V Fuse 1A F Fuse 5A F Fuse 5A F blue gray pink brown F3S TGR CL transmitter F3S TGR CL receiver white blue brown Figure 23 G9SR AD with Safety S...

Page 98: ...unctions in this application 1 When the E Stop is pushed the winder stops immediately and the door is locked for another 30s 2 When the Light Curtain detects a person the winder stops immediately and...

Page 99: ...nput Monitoring of Safety Light Curtain Output Winder Motor Contactors Input Output loop func tion Output Solenoid Door locking switch 14 3 4 Function settings and DIP switch settings G9SR BC1 Dynamic...

Page 100: ...G9SR AD OFF OFF ON ON ON OFF ON OFF SW1 SW2 SW3 SW4 G9SR EX 0 B 0 B Note Ensure the dip switch settings of all G9SR units are according to the requirements of your application See also 6 3 Dip switche...

Page 101: ...2 Restart EDM Safety Output Control Auxiliary Output Control T32 T31 T22 T21 T12 A1 A2 14 24 44 T11 24V Fuse 5A F Power supply circuit Safety Input 1 Safety Input 2 Restart EDM Safety Output Control...

Page 102: ...Operation manual G9SR Page 76 of 79 My notes...

Page 103: ...7 of 79 12 Appendix B Logging of test results MONTH SYSTEM Date Performed with good results OFF Test ON Test Both Technicians Signature Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 104: ...Page 78 of 79 Logging of test results MONTH SYSTEM Date Performed with good results OFF Test ON Test Both Technicians Signature Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24...

Page 105: ...Operation manual G9SR Page 79 of 79 My notes...

Page 106: ...0 73 6481811 Fax 31 0 73 6444100 GENERAL AGENCY OMRON EUROPE B V Wegalaan 67 69 NL 2132 JD Hoofddorp THE NETHERLANDS Tel 31 0 23 5681300 Fax 31 0 23 5681388 www industrial omron eu Cat No J12E EN 03 N...

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