OMRON D41G High-Coded Guard Lock Safety-Door Switch Instruction Manual

: June 6, 2024
: Omron

OMRON D41G High-Coded Guard Lock Safety-Door Switch

OMRON-D41G-High-Coded-Guard-Lock-Safety-Door-Switch

Thank you for purchasing Omron products. This product is a high-coded safety door switch. Please read and understand this document before using the products. Keep this document ready to use whenever needed. Only qualified person trained in professional electrical technique should handle the product. Please consult your Omron representative if you have any questions or comments. Make sure that information written in this document are delivered to the final user of the product.
© OMRON Corporation 2021 All Rights Reserved.
D41G is designed for safety circuits and is used to monitor the position of movable guards.

EU Declaration of Conformity

OMRON declares that the D41G is in conformity with the requirements of the following EU Directives:
Machinery Directive 2006/42/EC RE Directive 2014/53/EU

Standards

D41G is designed and manufactured in accordance with the following standards:

EN ISO 13849-1: 2015 PL e, Category 4
EN 60947-5-3
EN 300 330
EN 61508
EN 62061
EN ISO 14119

Dispose in accordance with applicable regulations.

Safety Precautions

WARNING: Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage.
WARNING:

Use only appropriate components or devices complying with relevant safety standards corresponding to the required performance level and safety category. Failure to do so may result in serious injury or death. Conformity to requirements of the performance level and safety category must be determined as an entire system. It is recommended to consult a certification body regarding assessment of conformity to the required safety level
Do not apply DC voltages exceeding the rated voltages, nor any AC voltages to the product. Failure to do so may result in serious injury or death.
Install the switch and actuator in a position where the opening of the guard door can be detected within a safe distance. Failure to do so may result in serious injury or death.
Install the switch and actuator in a position where the opening of the guard door can be detected within a safe distance. Failure to do so may result in serious injury or death.
Do not apply force exceeding the specified holding force (Fzh). Either install another locking component (e.g., a hook) in addition to the product, or use a warning measures or an indicator showing the controlled system is locked to avid overloading the holding force in lock mode. Failure to do so may result in serious injury or death.
When complying with safety standards, install the product in an appropriate manner in accordance with ISO 14119, with due consideration of the risk of defeat by the operator. Failure to do so may result in serious injury or death.
Make sure that the DC power supply meets the following items. Failure to do so may result in serious injury or death.
- Satisfies the requirements of PELV power supply defined in IEC 60204-1.
- Satisfies the requirements of class 2 circuits defined in UL508.

Precautions for Safe Use

Disconnect the product from power supply when wiring the product. Failure to do so may cause unexpected operation of devices connected to the product.
Wire the input and output terminals correctly and verify the correct operation of the product before using the system in which the product is incorporated. Incorrect wiring may lead to loss of the safety function.
Install the actuator in a place where it will not come in contact with your body when opening or closing the guard door. Failure to do so may result in injury.
Do not use the product in any direction other than the specified mounting orientations of the main body and actuator.
Dispose of the product in accordance with the laws set by each country.
When the door is closed (with the actuator inserted), the actuator may be pushed back beyond the mounting play due to the weight of the door or the cushioning rubber of the door. Secure the door with a hook or by similar means so that it stays within the mounting play.
(Refer to the D41G actuator’s Quick Installation Manual.)

Precautions for Correct Use

Do not drop the product to the ground or expose to excessive vibration or mechanical shocks. Doing so may damage the product and cause failure.
Do not store or use the product under the following conditions. Doing so may damage the product and cause failure.
At ambient operating temperatures out of the range of -10 to 55°C
At ambient storage temperatures out of the range of -10 to 55°C
At relative humidity of 93% or more
In direct sunlight
Under drastic temperature changes
In high humidity that causes condensation
Keep the product away from oil or solvent. Oil or solvent make the marking on the product illegible and cause deterioration of some parts.
Do not use in an environment with corrosive gas.
The product may not operate normally in the vicinity of devices that generate strong radio waves or magnetic fields, such as RFID systems, proximity sensors, motors, inverters, and switch-mode power supplies. If the device is used in the vicinity of such devices, check the effect before use.
Installing the switch and the actuator on a metallic material may affect the operating distance. If installation on a metallic material is necessary, be sure to check the effect on the operating distance before use.
Tighten the screws with a specified torque.
Use the wires specified by OMRON to wire the product. (Refer to Connection.)
Do not extend the cables in excess of the specification of this product. Carry out electrical connection according to the wiring examples shown in this document and verify the correct operation of the product.
Do not pull or bend the cable excessively. A disconnection may cause a malfunction.
Risk time remains unchanged by series connection. However, carry out electrical connection according to the wiring examples shown in this document.
Be sure to inspect the product daily and every 6 months. Failure to do so may cause a system failure and serious injury.
When determining the safety distance, take into account the delay of the output of the product caused by the response time. Failure to do so may cause the operator to reach the hazardous source before the machine is stopped, resulting in serious injury.
During installation, make sure that the safety door switch does not come in contact with the actuator due to rattling of the guard door. (The performance of the product may be degraded by a collision caused by opening or closing the guard door.)
Install the product so that the LED indicators of the safety door switch are as visible as possible. Misinterpreting the status of the safety door switch may result in danger.
Do not use the product at an altitude of 2,000 m or higher.
Do not connect a product different from this product in series with this product. Doing so may disturb waveforms of the input and output signals, leading to loss of the safety function.
Do not use the product in the water or continuous water exposure environment. Doing so may cause water to leak into the product. (The degree of protection does not guarantee the protection under continuous water exposure environment.)
Do not tamper the product with a replacement actuator. Store replacement actuators in a safe place where they cannot be easily reached.
Build a safety system using the outputs of both Safety Outputs 1 and 2. Wiring with only one safety output may lead to loss of the safety function due to a single failure.
Wiring should meet the requirements specified in Section 9.4.3 of IEC 60204-1 to prevent malfunction due to ground faults in the safety output lines.
In the power-to-lock type, close the door before energizing the safety door switch.
In the power-to-lock type, the safety door switch is locked only when the solenoid is energized. If the solenoid is de-energized due to a sudden power failure, the operator may be exposed to a hazardous source. Use the power-to-lock type only for process protection.
Do not use the emergency-exit type for switching the machine on and off. Doing so may place operators at risk due to being trapped inside or unexpected operation of the machine. Install the emergency-exit type so that it cannot be operated from outside a safety zone.
Do not apply excessive force on the actuator while the actuator is inserted into the switch body or do not drop the product. Doing so may deform the actuator or damage the switch body.
Insert the actuator with a tolerance of ±1.5mm for X, ±5.0mm for Y and ±1.0mm for Z to the center of the key hole. Misalignment or tilting may cause premature wear or damage. (Refer to the D41G actuator’s Quick Installation Manual for the corresponding actuator.)
The safety function may not operate normally due to a malfunction of the wiring, setting, or switch, and the machine may continue to operate, which may result in personal injury. Make sure that the safety function works before starting operation.
Do not pull on lead wires with excessive force. Doing so may cause loose connection.
The current consumption of the safety door switch is different between when it is turned on and when it is in a normal operation. Apply the supply voltage to the safety door switch in consideration of the voltage drop in the wiring.
Do not turn beyond the latching point. After being put into operation, the manual release must be secured by closing the cover with the seal, which is included in delivery.
After installation of the product, qualified personnel should verify to see that the installation, inspection, and maintenance are properly performed. The qualified personnel should be qualified and authorized to secure the safety on each phase of design, installation, running, maintenance and disposal of system.
Do not turn beyond the latching point. After being put into operation, the manual release must be secured by closing the cover with the seal, which is included in delivery.
After installation of the product, qualified personnel should verify to see that the installation, inspection, and maintenance are properly performed. The qualified personnel should be qualified and authorized to secure the safety on each phase of design, installation, running, maintenance and disposal of system.
Do not wire the product to an input of a safety controller in parallel.
Disconnect the product and the controller connected to the product from power supply when replacing the product. Failure to do so may cause unexpected operation of devices connected to the product.
Install the product to a position near a handle of the guard door. Installing it near a hinge may cause the locking part of the product to receive larger load than the operating force, leading to damage to the locking mechanism.
Do not use the product as a door stopper. (The performance of the product may be degraded due to a collision caused by opening and closing the guard door.)
Do not try to disassemble, repair, or modify the product. Doing so may cause loss of the safety function.
Be sure to attach the cover after wiring work. Also, do not energize with the cover open. There is a risk of electric shock.
Do not operate the product in an environment with flammable or explosive gas.
Auxiliary output is NOT a safety output. Do not use the Auxiliary output individually for any safety function. Such incorrect use causes loss of the safety function of the product and its relevant systems.

Ratings and Specifications

Model	D41G

D41G-2: High (individual coding re-teaching enabled)

(stabilized PELV power supply)

Connector M12 2 A max.

Safety input| Switching thresholds| -3 to 5 V (low)

15 to 30 V (high)

15 to 30 V (high)

(non-condensing, non-icing)

1.5 mm2 max.

(including conductor ferrules)

Cable entry| M20

D41G-A1 is suitable for sliding safety guards and D41G-A2 is for hinged safety guards.
Only if the information described in this operating instructions manual is realized correctly, the safety function and therefore the compliance with the Machinery Directive are maintained.
Refer to the product catalog for connection specifications with the controller.

Safety classification information

Safety classification (interlocking function)

Standard| ISO 13849-1, IEC 61508, IEC 62061
PL| e
DC| 99 %
Safety category| 4
PFH| 1.9 × 10-9 /h
PFD| 1.6 × 10-4
SIL| Suitable for SIL3 applications
Mission time| 20 years
Safety classification (guard lock function)

Note: 1. The actuation of the interlock must be compared with the external
OSSD enabler. If a shut-down now occurs due to an unintentional unlocking this is detected by an external diagnostic.
Note: 2. The safety consideration of the guard locking function only applies
for monitored safety door switch D41G-*Y.
Note: 3. If for a certain application the power-to-unlock type of a safety door switch cannot be used, then for this exception the power-to-lock type of a safety door switch can be used if additional safety measure need to be realized that have an equivalent safety level.
Note: 4. The safety analysis of the guard locking function refers to the component safety door switch as part of the complete system. In the event of a fault resulting in the unlocking of the guard locking, this is detected by the safety outputs Y1/Y2 of the safety door switch switch off. When such a fault occurs the protection equipment may open immediately, just once, before the safe condition of the machine is reached. The system reaction of category 2 allows that a fault can occur between tests causing the loss of the safety function which is detected by the test.
Note: 5. If multiple safety door switches are involved in the same safety function, the PFH values of the individual components must be added.

Use isolated power supply only.
For use in NFPA 79 Applications only.
Adapters providing field wiring means are available from the manufacturer. Refer to manufacturers information.
This device complies with part 15 of the FCC Rules and Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions:

This device may not cause harmful interference, and
this device must accept any interference received, including interference that may cause undesired operation.

This device complies with the Nerve Stimulation Exposure Limits
(ISED RSS-102) for direct touch operations. Changes or modifications not expressly approved by OMRON Corporation could void the user‘s authority to operate the equipment.

Dimensions

OMRON-D41G-High-Coded-Guard-Lock-Safety-Door-
Switch-1

Mounting

For fitting the safety door switch, two mounting holes for M6 screws with washers (washers included in delivery) are provided. (tightening torque: 8 N•m) The safety door switch must not be used as a door stopper. Any mounting position.
The mounting position however must be chosen so that the ingress of dirt and soiling in the used opening is avoided. The unused actuator opening must be sealed by means of the dust-proof cover (included in delivery). Minimum distance between two safety door switches as well as other systems with same frequency (125 kHz): 100 mm.

Manual Release

For the machine set-up, the safety door switch can be unlocked in a de- energized condition. After opening of the manual release cover “A” (refer to image “Dimensions”), the triangular key must be turned clockwise to bring the blocking bolt in unlocking condition. The normal locking function is only restored after the triangular key has been returned to its original position . OMRON-D41G-High-Coded-Guard-Lock-Safety-Door-Switch-2

Actuator

Mounting of the safety door switch and the actuator
Refer to the D41G actuator’s Quick Installation Manual for the corresponding actuator. The actuator must be permanently fitted to the guard doors and protected against displacement by suitable measures (tamper-proof screws, gluing, drilling of the screw heads).

Teaching

Individually coded safety door switch and actuators will require the following teach-in procedure:

Keep the actuator away from the detection range and switch the safety door switch’s voltage supply off and back on.
Introduce the actuator in the detection range. The teach-in procedure is signaled at the safety door switch, green LED off, red LED on, yellow LED flashes (1 Hz).
After 10 seconds, the yellow LED gives brief cyclic flashes (3 Hz). Switch off the supply voltage of the safety door switch. (If the voltage is not switched off within 5 minutes, the safety door switch cancels the teach-in procedure and signals a false actuator by 5 red flashes).
Switch the supply voltage back on. The actuator must be detected once more in order to activate the taught actuator code. In this way, the activated code is definitively saved.

For ordering suffix D41G-1, the executed allocation of safety interlock and actuator is irreversible.
For ordering suffix D41G-2, the teach-in procedure for a new actuator can be repeated an unlimited number of times. When a new actuator is taught, the code, which was applicable until that moment, becomes invalid. Subsequent to that, the safety outputs will be disabled for ten minutes, thus providing for an increased protection against intentional tampering.
The green LED will flash until the expiration of the time (10 minutes) of the enabling inhibit and the detection of the new actuator. In case of power failure during the lapse of time, the 10-minutes tampering protection time will restart.

Operating Principle

Magnet control
In the power-to-unlock version of the D41G, the safety door switch is unlocked when the Solenoid Control signal (= 24 V) is set.
In the power-to-lock
version of the D41G, the safety door switch is locked when the Solenoid Control signal (= 24 V) is set.
If the risk analysis indicates the use of a monitored interlock
then a variant (D41G-Y) with the monitored interlock is to be used, labelled with the symbol.
The actuator monitoring variant (D41G-Z) is a safety door switch with an interlock function for process protection.

Mode of operation of the safety outputs
In the D41G-Y, the unlocking of the safety door switch causes the safety outputs to be disabled. The unlocked guard door can be relocked as long as the actuator is inserted in the D41G safety door switch; in that case, the safety outputs are re-enabled. The guard door must not be opened.
In the D41G-Z, the opening of the guard door causes the safety outputs to be disabled.

Connections

Pin assignment

Function

| Pin configuration of the connector| ****

Color code of

the OMRON’s connector to DIN 47100

D41L-8P5-CFM12-9**M

---|---|---
24 V| Ue| 1| WHITE
X1| Safety input 1| 2| BROWN
GND| GND| 3| GREEN
Y1| Safety output 1| 4| YELLOW
OUT| Auxiliary output| 5| GRAY
X2| Safety input 2| 6| PINK
Y2| Safety output 2| 7| BLUE
IN| Solenoid control| 8| RED

Terminal block (suffix T1)

24V	24V	X1	X2	IN

D41G-****-T1
GND| | Y1| Y2| OUT

Connector plug (suffix N2)

The cable entry is realized by a metric M20 gland. This gland must be measured by the user so that it is suitable for the cable used. A cable gland with strain relief and suitable IP protection class must be used. Length X of the cable at terminals: 8.0 mm (for screw terminals of -T1) OMRON-D41G-High-
Coded-Guard-Lock-Safety-Door-Switch-5

Wiring Example

The application examples shown are suggestions. They however do not release the user from carefully checking whether the safety door switch and its set-up are suitable for the individual application.
The power supply for the safety door switch must provide protection against permanent overvoltage. To that effect, stabilized PELV supply units must be used. The safety outputs can be directly integrated in the safety circuit of the control system. For applications of PL e / safety category 4 in accordance with ISO 13849-1, the safety outputs of safety door switch or safety door switch of the chain must be connected to a safety controller or safety relay unit of the same Safety Category. Inductive loads (e.g. contactors, relays, etc.) are to be provided with suitable interference suppression circuitry.
If the safety door switch is wired to relays or to non-safety relevant control components, a new risk analysis must be carried out.
If the safety door switch is connected to the safety input of a safety controller or safety relay unit, the controller must have a dual-channel monitoring time of at least 100 ms and the accepted test pulse duration of at least 1 ms. Also, the cross-wire-short monitoring function must be disabled.

D41G series connection

Referred to as a safety PLC. between switch and power supply
Note: 1. Configuration of the safety For the recommended safety controller, refer to the product catalog of this product.

Diagnostic Function

Diagnostic LEDs
The safety door switch indicates the operating condition and faults by means of three-color LEDs located in the front surface of the safety door switch.

Green (Power): Supply voltage on
Yellow (Status): Operating condition
Red (Fault): Error (refer to Table 2)

Safety door switch with auxiliary output
The auxiliary output OUT can be used for central visualization of operating states or control functions, e.g. in a PLC.
The auxiliary output is not a safety-related output.

Behavior of the auxiliary output
(Example: power-to-unlock version)

Input signal magnet control

Set-up and Maintenance

Functional testing
The safety function of the safety components must be tested. The following conditions must be previously checked and met:

Fitting of the safety door switch and the actuator
Check the integrity of the cable entry and connections
Check the switch enclosure for damage

Maintenance
Maintenance frequency
SIL3 / PLe at least once a month SIL2 / PLd at least once a year

(Daily inspection)

For each guard door, check that the machine stops when the guard door opens. (Inspection every 6 months)

Check for tight installation of the safety door switch and the actuator.
Check maximum axial offset of the safety door switch and the actuator.
Remove particles of dust and soiling
Check cable entry and connections

Disassembly and Disposal

Disassembly
The product must be disassembled in a de-energized condition only.
Disposal
The product must be disposed of in an appropriate manner in accordance with the national prescriptions and legislations.

Troubleshooting

Error
Errors, which no longer guarantee the function of the safety door switch (internal errors) cause the safety outputs to be disabled immediately.
Any error that does not immediately affect the safe functionality of the safety door switch (e.g. too high ambient temperature, interference potential at the safety outputs, cross-wire short) will lead to a warning message, disabling of the auxiliary output and a delayed shutdown of the safety outputs. (Refer to Table 2.) After fault rectification, the sensor can be reset by opening and relocking the relevant guard door. The safety outputs enable and allow a restart. An interlocking chain of the safety door switch must be “locked” to enable the reactivation. Automatic, electronic locking takes place if more than one fault is detected at the safety outputs or a cross circuit is detected between Y1 and Y2.
To reset this type of interlocking, the safety door switch must be isolated from the power supply after elimination of the error causes.

Error warning
A fault has occurred, which causes the safety outputs to be disabled after 30 minutes. The safety outputs initially remain enabled. This signal combination, auxiliary output disabled, and safety channels still enabled, can be used to stop the production process in a controlled manner. An error warning is deleted when the cause of error is eliminated.

Table 1: Diagnostic information for safety door switch
The safety door switch signals the switching condition as well as malfunctions via three colored LEDs installed on the device.

System condition

| Solenoid control (IN)| LED| Safety outputs Y1, Y2|

Auxiliary output OUT

---|---|---|---|---
Power-to-

unlock

| Power-to-

lock

Green

Red

Yellow

*D41G-Y**

*D41G-Z**

Door open| 24 V (0 V)| 0 V (24 V)| On| Off| Off| 0 V| 0 V| 0 V
Door closed, actuator not inserted| 24 V| 0 V| On| Off| Off| 0 V| 0 V| 0 V
Door closed, actuator inserted,

not locked

| 24 V| 0 V| On| Off| Flashes| 0 V| 24 V| 24 V
Door closed, actuator inserted,

interlocking blocked

| 0 V| 24 V| On| Off| Flashes| 0 V| 24 V| 0 V
Guard closed,

actuator inserted and locked

| 0 V| 24 V| On| Off| On| 24 V| 24 V| 24 V
*Error warning (1) safety door switch locked| 0 V| 24 V| On| Flashes (2)| On| 24 V(1)| 24 V(1)| 0 V
Error| 0 V (24 V)| 24 V (0 V)| On| Flashes (2)| Off| 0 V| 0 V| 0 V
Additionally for variant D41G-1/-2:*
Teach-in procedure actuator started| | | Off| On| Flashes| 0 V| 0 V| 0 V
Only D41G-2: Tampering protection time (3)| | | Flashes| Off| Off| 0 V| 0 V| 0 V

After 30 min: disabling due to fault
Refer to flash code
Refer to Teaching.

Table 2: Error messages / flash codes red diagnostic LED

Flash codes (Red)| Designation| Autonomous switch-off after| Error cause
---|---|---|---
1 flash pulse| Error (warning) at output Y1| 30 min| Fault in output test or voltage at output Y1,

although the output is disabled.

2 flash pulses| Error (warning) at output Y2| 30 min| Fault in output test or voltage at output Y2,

although the output is disabled.

is too high

(blocking bolt detection or tamper attempt).

Continuous red| Internal fault /

overvoltage or undervoltage fault

| 0 min| Device defective /

supply voltage not within specifications

Declaration of Conformity

OMRON-D41G-High-Coded-Guard-Lock-Safety-Door-
Switch-8

References

OMRON Industrial Automation

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