Technical Guide

Safety Solutions

General Information

Safety Light Curtains

Safety Switches

Emergency Stop Switches

Safety Application Controllers

Safety Relays

Safety Components

Part V: Circuit Diagram

1. List of Circuit Diagram

This part presents basic examples in which a G9SA (Safety Relay Unit), G9SX (Flexible Safety Unit), F3SX (Safety Controller) and F3SP-B1P (Safety Light Curtain Controller) are used to configure an electrical interlock device connecting inputs and outputs.
 

Index No.	Safety detection devices	Input channels	Safety category	Stop category	Models used
1	Emergency Stop Switches	2	4	0	A22E/A165E G9SA-301/G9SA-501, S82K
2	Emergency Stop Switches (Set of two)	2	4	0	A22E/A165E G9SA-301/G9SA-501, S82K
3	Safety Limit Switches (Set of two)	2	4	0	D4B-N/D4N/D4F G9SA-301/G9SA-501, S82K
4	Safety Door Switches	2	4	0	D4GS-N/D4NS/D4BS G9SA-301/G9SA-501, S82K
5	Safety Door Switches (Set of two)	2	3	0	D4GS-N/D4NS/D4BS G9SA-301/G9SA-501, S82K
6	Safety Door Switches (Set of two)	1	2	0	D4GS-N/D4NS/D4BS G9SA-301/G9SA-501, S82K
7	Guard Lock Safety-door Switches (Solenoid lock) Safety Limit Switches	2	4	0	D4GL/D4NL/D4BL/D4JL D4B-N/D4N/D4F G9SA-301, S82K
8	Guard Lock Safety-door Switches (Mechanical lock) Safety Limit Switches	2	3	0	D4NL/D4BL/D4GL/D4JL D4B-N/D4N/D4F G9SA-321-T[], G7S/G7SA, S82K
9	Guard Lock Safety-door Switches (Mechanical lock) Safety Limit Switches	2	3	1	D4NL/D4BL/D4GL/D4JL D4B-N/D4N/D4F G9SA-321-T[], S82K
10	Two-hand Control Switches	2	4	0	G9SA-TH301, S82K
11	Two-hand Control Switches	1	2	0	F3SX-N-L1D1R A22E/A165E/A22 D4GS-N/D4NS/D4BS F3SN/F3SH/F3SJ, S82K
12	Safety Light Curtains (Relay unit connection)	2	4	0	F3SN-A/F3SJ G9SA-301/G9SA-501, S82K
13	Safety Light Curtains (Relay connection)	2	4	0	F3SN-A/F3SJ G7S/G7SA, S82K
14	Safety Light Curtains (Connector connection)	2	4	0	F3SN-A/F3SJ F3SP-B1P, S82K
15	Safety Light Curtains Emergency Stop Switches	2	4	0	F3SN-A/F3SJ A22E/A165E G9SA-300-SC, S82K
16	Emergency Stop Switches	1	2	1	A22E/A165E G9SX-AD[]
17	Emergency Stop Switches	2	3	0	A22E/A165E G9SX-AD[]
18	Emergency Stop Switches (Set of two)	2	3	0	A22E/A165E G9SX-AD[]
19	Emergency Stop Switches	2	4	0	A22E/A165E/A22 F3SX-NR
20	Single-beam Safety Sensors (Set of four) Safety Limit Switches Emergency Stop Switches	2	2	0	E3FS-10B4/E3ZS-T31A F3SX-E-B1D1 D4B-N/D4N/D4F A22E/A165E/A22
21	Safety Door Switches (Set of two)	1	2	0	D4GS-N/D4NS/D4BS G9SX-AD322-T15
22	Safety Door Switches (Set of two)	2	3	0	D4GS-N/D4NS/D4BS G9SX-AD322-T15
23	Guard Lock Safety-door Switches (Mechanical lock) Safety Limit Switches	2	4	0	D4NL/D4BL/D4GL/D4JL D4B-N/D4N/D4F G9SX-AD322-T15
24	Guard Lock Safety-door Switches (Mechanical lock) Safety Limit Switches	2	4	1	D4NL/D4BL/D4GL/D4JL D4B-N/D4N/D4F G9SX-AD322-T15
25	Safety Light Curtains	2	4	0	F3SJ-A G9SX-AD322-T15
26	Emergency Stop Switches Safety Limit Switches (Set of two)	2	4	1	A22E/A165E D4B-N/D4N/D4F G9SX-BC202/G9SX-AD322-T15
27	Emergency Stop Switches Guard Lock Safety-door Switches (Set of two) (Mechanical lock) Safety Limit Switches (Set of two)	2	4	1	A22E/A165E D4NL/D4BL/D4GL D4B-N/D4N/D4F G9SX-BC202/G9SX-AD322-T15
28	Emergency Stop Switches Safety Light Curtains	2	4	0	A22E F3SJ G9SX-BC202 G9SX-GS226-T15

2. Precautions

(1) Circuit Configurations for Safety-related Applications

A variety of connection examples for electrical interlock devices are presented here, divided into safety categories. These examples, however, are only intended to show one type of configuration for securing the safety of control systems for machinery.

In actual circuit configurations, it is necessary to use protective grounding, wiring protection, and other methods to prevent problems like open circuits and short circuits. With respect to specific measures, it is recommended that you comply with the standards in the following table, and any related standards, when designing and implementing circuit configurations, while also receiving confirmation from a third-party verification organization for the safety of the overall system.
 

Note: In some situations, it is also necessary to refer to other standards.

(2) Determining the Safety Category

The safety category, which is a performance evaluation of safety measures, is determined as a result of a risk assessment. To determine the actual safety category of safety-related parts, it is necessary to determine the safety category that is applicable to the entire machine by evaluating the machine specifications and the machine's equipment, usage, and operating environment for the duration of its service life.

(3) About 2-channel Input

The open/closed status of a protective door is confirmed by the contact signals of position detection equipment such as Safety Door Switches. It is possible to provide 2-channel input of the open/closed confirmation signal to the Controller by using two contacts inside a single position detection unit. However, when this is done, an incorrectly inserted Operation Key or a certain degree of impact may damage the head of the position detection equipment, with the result that both of the output signals lack asymmetric error characteristics and the same failure occurs to both. The method for selecting 2-channel input depends largely on the risk assessment results for the entire system, but it is recommended that two position detection units with a reciprocal mode be used to ensure correct confirmation of the open/closed status of protective doors.

(4) The Role of Safety Components

Safety-related control systems must minimize the possibility of danger occurring even when there is a failure in the interlock device. As stipulated by standards, OMRON safety components are equipped with functions such as direct opening mechanisms for switches, and forced guide contact mechanisms. These functions are designed to operate effectively within the control system in which they are contained.

(5) Using Safety Components

Refer to the precautions listed in this catalog for the use of safety components. It is particularly recommended that you use clamps, couplings, etc., to secure doors fitted with a guard lock safety-door switch. When a switch is used as a direct door lock, errors in the circuit functions can occur due to the weight of the door itself, vibration from machinery, or impacts during erroneous door opening in holding status.

(6) Detecting Entry and Presence

The basic feature of the Safety Light Curtain is to detect the entry of a person's finger, hand, or body. When it is necessary to have a presence-detecting function in a hazardous area in response to the overall system risk assessment, e.g., due to frequent entry in the hazardous area, it is recommended that the Safety Light Curtain be used together with a Safety Mat, Safety Laser Scanner, or similar device. Refer to Safety Functions for information on presence detection.

(7) Reset Methods

These connection examples use manual resetting.
In order to use an auto reset method, the dimensions from the opening to the hazardous source must be such that they will not allow a person to reach the hazardous source. For information on the connection for a system using an auto reset method, refer to the connection circuit examples in the relevant product catalog.

(8) Contactors

It is recommended that the auxiliary NC contacts used as monitors for main contact welding be equipped with a function to prevent the same failure.
 

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Use manual resetting for the emergency stop circuit. (ISO 13850)

Examples of Applicable Control Parts

S1: Reset switch
S2: Emergency stop switch
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Use manual resetting for the emergency stop circuit. (ISO 13850)

Examples of Applicable Control Parts

S1: Reset switch
S2: Emergency stop switch
S3: Emergency stop switch
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1: Reset switch
S2 and S3: Safety limit switches
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1: Reset switch
S2: Safety door switch
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1: Reset switch
S2: Safety door switch
S3: Safety door switch
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

PartsS1: Safety door switch
S2: Safety door switch
S3: Reset switch
KM1 and KM2: Magnetic contactors
M: 3-phase

Note:
A solenoid lock may cause danger to the operator if the lock is released by an unlock error operation signal during operation and the door is opened. A model with a solenoid lock can be used if a risk assessment confirms that safety can be assured, but if not, a model with a mechanical lock must be used. (EN 1088 (ISO 14119))

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1: Lock/unlock signal
S2: Guard lock safety-door switch
S3: Safety limit switch
S4: Stop signal
S5: Reset switch
KM1 and KM2: Magnetic contactors
M: 3-phase

Note:
A solenoid lock may cause danger to the operator if the lock is released by an unlock error operation signal during operation and the door is opened. A model with a solenoid lock can be used if a risk assessment confirms that safety can be assured, but if not, a model with a mechanical lock must be used. (EN 1088 (ISO 14119))

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1: Lock release signal
S2: Guard lock safety-door switchS3: Safety limit switch
S4: Stop signal
S5: Reset switch
RY1 and RY2: Safety relays
KM1 and KM2: Magnetic contactors
M: 3-phase

Note:
A solenoid lock may cause danger to the operator if the lock is released by an unlock error operation signal during operation and the door is opened. A model with a solenoid lock can be used if a risk assessment confirms that safety can be assured, but if not, a model with a mechanical lock must be used. (EN 1088 (ISO 14119))

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1: Lock release signal
S2: Guard lock safety-door switch
S3: Safety limit switch
S4: Stop signal
S5: Reset switch
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S11 and S12: Two-hand control switch (momentary operation)
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note:

1. Refer to the precautions on page 75 when actually configuring the circuit.
2. Example of a Safety Light Curtain (PNP type) circuit.

Examples of Applicable Control Parts

S1: Emergency stop switch with direct opening mechanism)
S2: Reset switch
S31, S32: Two-hand control switch
S4, S5: Safety limit switch with direct opening mechanism
KM1, KM2: Magnetic contactors
M: 3-phase motor
E1: 24-VDC power supply
External indicator: Filament-type indicator (When an external indicator is not necessary, connect resistance of 1/4 W, 4.7 kΩ.)
S6: External test switch
AS1: Auxiliary control output (synchronized with K1, K2 NO contacts)
AS2: Information trigger
AS3: Standby output
SSC: Start command input (Not connected in the above circuit diagram. When this input is not necessary, connect it to terminal A1.)

Note:

1. In this connection example, the auxiliary output is set to the standard setting (Dark-ON operation). To operate using non-standard settings, refer to the catalog or operation manuals for the F3SN/F3SH.
2. Make sure the wiring arrangement satisfies EN574.
3. Use switches that can be used with microloads.

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Note that the safety category depends on the type of Safety Light Curtain being connected.
3. The F3SN-A uses auto reset.

4. Example of a Safety Light Curtain (PNP type) circuit.

Examples of Applicable Control Parts

S1: External test switch
S2: Lockout reset switch (momentary operation)
S3: Reset switch
KM1 and KM2: Magnetic contactors
M: 3-phase motor

Note: Use switches that can be used with microloads.

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Interlock Function; Manual reset; Setting: Start/restart interlock
3. Note that the safety category depends on the type of Safety Light Curtain being connected.

Examples of Applicable Control Parts

S1: External test switch
S2: Lockout reset switch (momentary operation)
KM1 and KM2: Magnetic contactors
K3: PLC (for monitoring)
M: 3-phase motor

Note: Use switches that can be used with microloads.

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Interlock Function
Manual reset
Setting: Start/restart interlock
3. Note that the safety category depends on the type of Safety Light Curtain being connected.

4. Example of a Safety Light Curtain (PNP type) circuit.

Examples of Applicable Control Parts

S1: External test switch
S2: Lockout reset switch (momentary operation)
KM1 and KM2: Magnetic contactors
K3: PLC (for monitoring)
M: 3-phase motor

Note: Use switches that can be used with microloads.

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Interlock Function; Manual reset; Setting: Start/restart interlock
3. Note that the safety category depends on the type of Safety Light Curtain being connected.

4. Example of a Safety Light Curtain (PNP type) circuit.

Examples of Applicable Control Parts

S1: Reset switch (momentary operation)
S2: Emergency stop switch
S3: External test switch (momentary operation)
KM1 and KM2: Magnetic contactors
M: 3-phase motor

Note: Use switches that can be used with microloads.

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Use manual resetting for the emergency stop circuit.

Examples of Applicable Control Parts

S1: Emergency stop switch
S2: Reset switch
KM1 to KM4: Magnetic contactors
M1 and M2: 3-phase motors

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Use manual resetting for the emergency stop circuit.

Examples of Applicable Control Parts

S1: Emergency stop switch
S2: Reset switch
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Use manual resetting for the emergency stop circuit.

Examples of Applicable Control Parts

S1 and S2: Emergency stop switches
S3: Reset switch
KM1 and KM2: Magnetic contactors
M: 3-phase

● Timing Chart

Note:
1. Refer to the precautions when actually configuring the circuit.
2. Use manual resetting for the emergency stop circuit.

Examples of Applicable Control Parts

S1: Emergency stop switch
S2: Reset switch
KM1 and KM2: Magnetic contactors
M: 3-phase motor
E1: 24 VDC power supply
External indicator: Filament-type indicator (When an external indicator is not necessary, connect resistance of 1/4 W, 4.7 kΩ.)
PLC: Programmable controller (The PLC is not part of the safety system.)
AS1: Instant-breaking auxiliary output (synchronized with K1 and K2 NO contacts)
AS2: Information trigger
AS3: Standby output
SSC: Start command input

● Timing Chart

Note:

1. Refer to the precautions when actually configuring the circuit.
2. The next reset input is ON only when the time difference between inputs is 500 ms max.
3. This chart does not consider the response delay time for each I/O device.

Examples of Applicable Control Parts

S1: Emergency stop switch (direct opening mechanism)
S2: Reset switch
S3 to S6: Safety limit switches (direct opening mechanism)
KM1 and KM2: Magnetic contactors
RY1 and RY2: Safety relays with forcibly guided contacts
M: 3-phase motor
E1: 24 VDC power supply
AS1: Safety output monitor (synchronized with SS1 and SS2)
AS2: Ready output
AS3: Standby output
SSC: Start command input (SSC is not used in the above circuit example. When it is not used, connect it to terminal A1.)

Note:
1.The black wire is used when the Cable with Connector (Socket) on One End (XS2F-D42[]-[]80-[]) is connected to an E3FS-10B4-M1-M Connector.
2.The white wire is used when the Cable with Connector (Socket) on One End (XS2F-D42[]-[]80-[]) is connected to an E3FS-10B4-M1-M Connector.

● Timing Chart

Note: Off-delay time is 0 s.
Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1 and S2: Safety door switches
S3 : Reset switch
KM1 to KM4: Magnetic contactors
M1 and M2 : 3-phase motors

● Timing Chart

Note: Off-delay time is 0 s.
Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1 and S2: Safety door switches
S3 : Reset switch
KM1 to KM4: Magnetic contactors
M1 and M2 : 3-phase motors

● Timing Chart

Note: Off-delay time is 0 s.
Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1 : Safety limit switch
S3 : Guard lock safety switch
S3 : Reset switch
S4 : Lock release signal
KM1 and KM2: Magnetic contactors
M : 3-phase motor

● Timing Chart

Note: Off-delay time is 0.2 to 15 s.
Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1 : Safety limit switch
S3 : Guard lock safety switch
S3 : Reset switch
S4 : Lock release signal
KM1 and KM2: Magnetic contactors
M : 3-phase motor

● Timing Chart

Note: Off-delay time is 0 s.

Note:

1. Refer to the precautions when actually configuring the circuit.
2.Example of a Safety Light Curtain (PNP type) circuit.

Examples of Applicable Control Parts

S1 : External test switch
S2 : Lockout reset switch
S3 : Reset switch
F3SJ-A : Safety light curtain
KM1 to KM4: Magnetic contactors
M1 and M2 : 3-phase motors

● Timing Chart

Note: Off-delay time is 0.2 to 15 s.
Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1 : Emergency stop switch
S2 : Reset switch
S3 : Safety limit switch
S4 : Limit switch
KM1 to KM6: Magnetic contactors
M1 to M3 : 3-phase motors

● Timing Chart

Note: Off-delay time is 0.2 to 15 s.

Note: Refer to the precautions when actually configuring the circuit.

Examples of Applicable Control Parts

S1 : Emergency stop switch
S3 and S7 : Guard lock safety door switches
S2 : Reset switch
S6 and S10 : Lock release switches
S4 and S8 : Safety limit switches
(Direct opening contacts)
KM1 to KM4: Magnetic contactors
M1 and M2 : 3-phase motors

<Application Example>

Note: Diagnostic checks of the external indicators connected to external indicator outputs UA and UB can be switched with Y3 and Y4, respectively.

● Timing Chart

(1) Prior to operation start
(2) Operator inserts workpiece
(3) Robot processes workpiece
(4) Both operator and robot enter the coordinated area: Only the G9SX-GS stops.
(5) The G9SX-GS restarts.
(6) Emergency stop switch pressed: All units stop.

Note:

1. Refer to the precautions when actually configuring the circuit.
2. Example of a Safety Light Curtain (PNP type) circuit.

Examples of Applicable Control Parts

S1 : Emergency stop switch
S2 : Reset switch
KM1 to KM4: Magnetic contactors
M1 and M2 : 3-phase motors

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