Safety Relay Unit
G9S
Ideal for Safety Door and Emergency
Stop Switch Circuits
■ Two-pole, three-pole, and five-pole models are available.
■ Basic Models and OFF-delay models are available
■ Incorporates LED indicators for monitoring built-in relays.
■ Finger-protection construction.
■ Conforms to EN standards and certified by BIA.
■ Both DIN track mounting and screw mounting possible
(two-pole models)
Be sure to read the “Safety Precautions” on page 9.
Model Number Structure
Model Number Legend
G9S-@@@@-@@@
1 2
3
4
5
1. Contact Configuration (Safety Output)
2:
DPST-NO
3:
3PST-NO
5:
5PST-NO
2. Contact Configuration (OFF-delay Output)
0:
None
2:
DPST-NO
3. Contact Configuration (Auxiliary Output)
0:
None
1:
SPST-NC
4. Input Configuration
None: 1-channel or 2-channel input possible
1:
1-channel input
2:
2-channel input
5. OFF-delay Time
None: No OFF-delay
T01: 1 second
T015: 1.5 seconds
T03: 3 seconds
T04: 4 seconds
T05: 5 seconds
T06: 6 seconds
T10: 10 seconds
T30: 30 seconds
Ordering Information
Basic Models
Number of poles
2
Rated voltage
24 VDC
Main contact form
Number of input channels
Model
DPST-NO
2 channels
G9S-2002
24 VDC
24 VAC
100 VAC
3*
120 VAC
3PST-NO
G9S-301
200 VAC
240 VAC
1 channel or 2 channels possible
24 VDC
24 VAC
100 VAC
5*
120 VAC
5PST-NO
G9S-501
200 VAC
240 VAC
* Auxiliary contact is SPST-NC.
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1
G9S
OFF-delay Models
Number of poles
Rated voltage
Main contact
form
OFF-delay form
Number of input
channels
OFF-delay time
1 channel or
2 channels possible
1s
1.5 s
3s
4s
5s
6s
10 s
30 s
24 VDC
24 VAC
100 VAC
3
120 VAC
3PST-NO
DPST-NO
200 VAC
240 VAC
Model
G9S-321-T01
G9S-321-T015
G9S-321-T03
G9S-321-T04
G9S-321-T05
G9S-321-T06
G9S-321-T10
G9S-321-T30
Note: Each model has an SPST-NC auxiliary contact.
Specifications
Ratings
Controller Block
Model
G9S-2002
G9S-301
G9S-501
G9S-321-T@
Rated
voltage
Rated power
consumption
Rated current
24 VDC
66 mAr20%
Approx. 1.6 W
24 VDC
62.5 mAr20%
Approx. 1.5 W
24 VAC
125 mAr20%
100 VAC
30 mAr20%
120 VAC
25 mAr20%
200 VAC
15 mAr20%
240 VAC
12.5 mAr20%
24 VDC
127 mAr20%
24 VAC
229 mAr20%
100 VAC
55 mAr20%
120 VAC
45.8 mAr20%
200 VAC
27.5 mAr20%
240 VAC
22.9 mAr20%
24 VDC
150 mAr20%
24 VAC
254 mAr20%
100 VAC
61 mAr20%
120 VAC
50.8 mAr20%
200 VAC
30.5 mAr20%
240 VAC
25.4 mAr20%
Approx. 3 VA (60 Hz)
Approx. 3 W
Approx. 5.5 VA (60 Hz)
Approx. 3.6 W
Approx. 6.1 VA (60 Hz)
Note: The above ratings are at an ambient temperature of 23qC.
Contact
Model
Item
Load
G9S-301, G9S-501, G9S-321-T@
Resistive load
240 VAC, 3 A *
24 VDC, 3 A
Rated load
Rated carry current
Inductive load
240 VAC, 3 A
(cosI = 0.3)
24 VDC, 1 A
(L/R=100 ms)
G9S-2002
Resistive load Inductive load
240 VAC, 5 A
24 VDC, 5 A
240 VAC, 3 A
(cosI = 0.3)
24 VDC, 1 A
(L/R=100 ms)
5A
* If the load is 5 A at 240 VAC, the durability will be 40,000 operations.
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2
G9S
Characteristics
Item
Model
G9S-2002
Operating time *1
50 ms max.
Response time *2
50 ms max.
Dielectric
strength
G9S-501
G9S-321-T@
300 ms max.
100 ms max.
15% to +10%
Control circuit power supply voltage allowance
Insulation
resistance
(at 500 VDC)
G9S-301
Between control circuits and
safety/auxiliary circuits
100 : min.
Between safety circuits and
auxiliary circuits
100 : min.
Safety circuits
100 : min.
Between control circuits and
safety/auxiliary circuits
2,500 VAC (50/60 Hz, 1 min.)
Between safety circuits and
auxiliary circuits
2,500 VAC (50/60 Hz, 1 min.)
Safety circuits
2,500 VAC (50/60 Hz, 1 min.)
Vibration
resistance
Destruction
10 to 55 to 10 Hz, 0.375-mm single amplitude (0.75-mm double amplitude)
Malfunction
10 to 55 to 10 Hz, 0.25-mm single amplitude (0.5-mm double amplitude)
Shock
resistance
Destruction
300 m/s2
Malfunction
50 m/s2
Min. permissible load (P level) (reference value)
24 VDC, 50 mA
Ambient operating temperature
–25 to 55qC (with no icing or condensation)
Ambient operating humidity
35% to 85%
Terminal tightening torque
0.98 N·m
Weight *3
Approx. 180 g
Approx. 365 g
Approx. 550 g
Approx. 580 g
*1. Not including bounce time.
*2. The response time is the time it takes for the main contact to open after the input is turned OFF. Includes bounce time.
*3. These weights are for DC models. AC models are 200 g heavier.
Durability
Mechanical durability
1,000,000 operations min. with a switching frequency of approx. 1,800 operations/h
Electrical durability
100,000 operations min. at the rated load with a switching frequency of approx. 1,800 operations/h
Note: The durability is for an ambient temperature of 15 to 35qC and an ambient humidity of 25% to 75%.
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3
G9S
Connections
Internal Connections
G9S-2002
G9S-301 (24 VDC)
G9S-301 (AC Model)
G9S-501 (24 VDC)
G9S-501 (AC Model)
G9S-321-T@ (24 VDC)
G9S-321-T@ (AC Model)
OFF-delay
timer
http://www.ia.omron.com/
OFF-delay
timer
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4
G9S
Dimensions
(Unit: mm)
G9S-2002
Terminal Arrangement
G9S-2002
13 23 T31
92
T11 T12 A1
PWR (orange)
K1 (green)
K2 (green)
10
T21 T22 A2
13 23 T31
52.5
T11 T12 A1
101 max.
14 24 T32
Twelve, M3
5.9±0.1
7
4.6 dia.
47.5
76 max.
90±0.3
T21 T22 A2
5.6
42.5
14 24 T32
4.6
2.3R
4.7
* This is an average value.
111 max.
23 max.
(22.5) *
G9S-301
Terminal Arrangement
G9S-301
X1 T11 T12 B1 13 23 33 41 A1
92
PWR (orange)
K1 (green)
K2 (green)
Y1 T21 T22 PE 14 24 34 42 A2
Eighteen, M3
5.9±0.1
X1 T11 T12 B1 13 23 33 41 A1
76 max. 61.2
Y1 T21 T22 PE 14 24 34 42 A2
111 max.
7
56
68 max.
G9S-501
G9S-321-T@
Terminal Arrangement
G9S-501
G9S-321-T@
T11 T12 B1 X1 Y1 13
92
23 33 43 53 61 A1
PWR (orange)
K1 (green)
K2 (green)
K4 (green)
K5 (green)
Twenty four,M3
5.9±0.1
T11 T12 B1 X1 Y1 13
23 33 43 53 61 A1
Y2 X2 T21 T22 PE 14
24 34 44 54 62 A2
Y2 X2 T21 T22 PE 14
24 34 44 54 62 A2
76 max. 63
7
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10
80
91 max.
111 max.
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5
G9S
Application Examples
G9S-2002 with 2-channel Limit Switch Input/Auto-reset
Timing Chart
Limit switch S1,
S2
K1 and K2
(NC)
K1 and K2
(NO)
Feedback loop
KM1 and KM2
(NC)
KM1 and KM2
(NO)
S1:
S2:
Limit switch (NO)
Safety Limit Switch with
direct opening mechanism (NC)
(D4B-N, D4N, D4F)
KM1 and KM2: Magnet Contactor
M:
3-phase motor
Note: This circuit conforms to Safety Category 4.
G9S-301 (24 VDC) with 2-channel Limit Switch Input/Manual Reset
Timing Chart
Limit switches
S1 and S2
Starter switch
S3
Feedback
loop
K3 (NC)
K3 (NO)
K1 and K2
(NC)
Open
K1 and K2
(NO)
KM1 and KM2
(NC)
KM1 and KM2
(NO)
PLC input
PLC output
KM3
S1:
S2:
Limit switch (NO)
Safety Limit Switch
with direct opening mechanism (NC)
(D4B-N, D4N, D4F)
S3:
Reset switch (momentary operation)
KM1 and KM2: Magnet Contactor
KM3:
G3J Solid-state Contactor
M:
3-phase motor
Note: This circuit conforms to Safety Category 4.
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6
G9S
G9S-501 (AC Model) with 2-channel Limit Switch Input/Manual Reset
Timing Chart
Limit switches
S1 and S2
Reset switch
S3
K3 (NC)
Feedback
loop
K3 (NO)
K1 and K2
(NC)
K1 and K2
(NO)
Open
K4 and K5
(NC)
K4 and K5
(NO)
KM1 and KM2
(NC)
KM1 and KM2
(NO)
S1:
S2:
Limit switch (NO)
Safety Limit Switch with
direct opening mechanism (NC)
(D4B-N, D4N, D4F)
S3:
Reset switch (momentary operation)
KM1 and KM2: Magnet Contactor
M:
3-phase motor
Note: This circuit conforms to Safety Category 4.
G9S-321-T@ (24 VDC) with 2-channel Limit Switch Input/Manual Reset
Timing Chart
Limit switches
S1 and S2
Reset switch
S3
K3 (NC)
Feedback loop
KM1 KM2
K3 (NO)
K1 and K2
(NC)
Open
K1 and K2
(NO)
K4 and K5
(NC)
K4 and K5
(NO)
OFF-delay
timer
KM1 and KM2
(NC)
KM1 and KM2
(NO)
Operation
instruction
Motor rotation
OFF-delay time
Operation
instruction
S1:
S2:
Motor controller
Limit switch (NO)
Safety Limit Switch with
direct opening mechanism (NC)
(D4B-N, D4N, D4F)
S3:
Reset switch (momentary operation)
KM1 and KM2: Magnet Contactor
M:
3-phase motor
Note: This circuit conforms to Safety Category 4
except for the OFF-delay output sections,
which conforms to Category 3.
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7
G9S
G9S-301 (24 VDC) with 2-channel Limit Switch Input/Auto-reset
Timing Chart
Limit switches
S1 and S2 (NC)
Limit switches
S1 and S2 (NO)
K3 (NC)
Feedback
loop
K3 (NO)
K1 and K2
(NC)
Open
K1 and K2
(NO)
KM1 and KM2
(NC)
KM1 and KM2
(NO)
S1:
S2:
Limit switch (NO)
Safety Limit Switch with
direct opening mechanism (NC)
(D4B-N, D4N, D4F)
KM1 and KM2: Magnet Contactor
M:
3-phase motor
Note: This circuit conforms to Safety Category 4.
G9S-301 (24 VDC) with 2-channel Emergency Stop Switch Input/Manual Reset
Timing Chart
Emergency stop
switch S1
Feedback
loop
Starter switch
S2
K3 (NC)
K3 (NO)
K1 and K2
(NC)
K1 and K2
(NO)
KM1 and KM2
(NC)
KM1 and KM2
(NO)
PLC input
PLC output
KM3
S1:
S2:
KM1 and KM2:
KM3:
M:
Emergency stop switch
Reset switch (momentary operation)
Magnet Contactor
G3J Solid-state Contactor
3-phase motor
Note: This circuit conforms to Safety Category 4.
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8
G9S
Safety Precautions
Refer to the “Precautions for All Relays” and “Precautions for All Relays with Forcibly Guided Contacts”.
!CAUTION
Turn OFF the G9S before wiring the G9S. Do not touch
the terminals of the G9S while the power is turned ON,
because the terminals are charged and may cause an
electric shock.
Precautions for Correct Use
Installation
x The G9S should be installed perpendicular on a vertical surface
(i.e., vertically so that the markings can be read).
Wiring
x Use the following to wire the G9S.
Stranded wire: 0.75 to 1.5 mm2
Steel wire: 1.0 to 1.5 mm2
x Make sure that each screw is tightened to a torque of 0.78 to
1.18 N·m, or the G9S may malfunction or generate heat.
x External inputs connected to T11 and T12 or T21 and T22 of the
G9S-301 must be no-voltage contact inputs.
x PE is a ground terminal.
When a machine is grounded at the positive, the PE terminal
should not be grounded.
Fuse Replacement
(Three- and Five-pole Models)
x The power input circuit of the G9S includes a fuse to protect the
G9S from damage that may be caused by short-circuiting. The fuse
is mounted to the side panel. Use the following type of fuse as a
replacement. Using a non-specified fuse can cause malfunction or
burning.
x Littel Fuse 218.4 (rated current 0.4 A), IEC127 approval.
x Use a flat-blade screwdriver to remove the fuse cover.
x Be sure to turn OFF the G9S before replacing the fuse.
Fuse
Mounting Multiple Units
x If the output current is 3 A or more, make sure that there is a
minimum distance of 50 mm each between all adjacent G9S Units.
(24-VDC models do not require this spacing.)
50 mm min.
Resetting Inputs
x When only channel 1 of the 2-channel input turns OFF, the safety
output is interrupted. In order to restart when this happens, it is
necessary to turn OFF and ON both input channels. It is not
possible to restart by resetting only channel 1.
Resetting Inputs During OFF Delay Time
Connecting Inputs
x When using more than one G9S Unit, do not connect the same
switch to more than one G9S Unit. This applies to all input
terminals.
Incorrect
T11 T12
T11 T12
G9S
G9S
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The G9S-321-T@ operates as follows according to the reset mode
when the inputs are to be re-entered during the OFF delay time of the
G9S-321-T@:
For auto reset, after the OFF delay time has ended, the outputs will
turn OFF, and then the outputs will turn ON again.
For manual reset, after the OFF delay time has ended, the outputs will
turn OFF, and then the outputs will turn ON again when the reset is
input.
Durability of Contact Outputs
Relay with Forcibly Guided Contact durability depends greatly on the
switching condition. Confirm the actual conditions of operation in
which the Relay will be used in order to make sure the permissible
number of switching operations.
When the accumulated number of operation exceeds its permissible
range, it can cause failure of reset of safety control circuit. In such
case, please replace the Relay immediately. If the Relay is used
continuously without replacing, then it can lead to loss of safety
function.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
9
G9S
Applicable Safety Category (EN954-1)
All G9S-series Relays fall under Safety Category 4 of EN954-1
except the G9S-321-T. The G9S-321-T has an OFF-delay output
block falling under Safety Category 3.
The above is provided according to circuit examples presented by
OMRON. Therefore, the above may not apply to all operating
environments.
The applicable safety category is determined from the whole safety
control system. Make sure that the whole safety control system meets
EN954-1 requirements.
Wire the G9S-2002 for auto-reset. If either one of them is
connected to a manual reset switch, EN954-1 requirements will not
apply.
Safety Category 4 of EN954-1
x Wire the G9S-2002 for auto-reset. If it is connected to a manual
reset switch, EN954-1 requirements will not apply.
x Apply 2-channel external input to the T11 and T12 terminals and
T21 and T22 terminals through switches each incorporating a
force-separation mechanism. If limit switches are used, make sure
that at least one of them incorporates a force-separation
mechanism.
Refer to Application Examples and input a signal for the
normally-closed contact of the contactor (i.e., input to X1 of the
G9S-301, X2 of the G9S-501, or X2 of the G9S-321-T).
x Be sure to ground the PE terminal. If the relay is operating with DC,
the power supply may be grounded instead.
Certified Standards
The G9S-301, G9S-501, G9S-321-T and G9S-2002 conform to the
following standards.
x EN standards, certified by BIA:
EN954-1
EN60204-1
x Conformance to EMC (Electromagnetic Compatibility), certified by
TÜV Product Service:
EMI (Emission): EN55011 Group 1 Class A
EMS (Immunity): EN61000-6-2
x UL standards: UL508 (Industrial Control Equipment)
x CSA standards: CSA C22.2 No. 14 (Industrial Control Equipment)
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10
Precautions for All Relays with Forcibly Guided Contacts
Refer to the “Safety Precautions” section for each Relay for specific precautions applicable to each Relay.
Precautions for Correct Use
Mounting
CE Marking
The Relays with Forcibly Guided Contacts can be mounted in any
direction.
(Source: Guidelines on the Application of Council Directive 73/23/
EEC)
The G7SA, G7S and G7S-@-E have been recognized by the VDE for
meeting the Low Voltage Directive according to EN requirements for
relays and relays with forcibly guided contacts. The Low Voltage
Directive, however, contains no clauses that specify handling
methods for components, and interpretations vary among test sites
and manufacturers. To solve this problem, the European Commission
has created guidelines for the application of the Low Voltage Directive
in EU. These guidelines present concepts for applying the Low
Voltage Directive to components. The G7SA, G7S and G7S-@-E,
however, do not display the CE Marking according to the concepts in
the guidelines.
VDE recognition, however, has been obtained, so there should be no
problems in obtaining the CE Marking for machines that use the
G7SA, G7S or G7S-@-E. Use the manufacturer’s compliance
declaration to prove standard conformance.
Relays with Forcibly Guided Contacts
While the Relay with Forcibly Guided Contacts has the previously
described forcibly guided contact structure, it is basically the same as
an ordinary relay in other respects. Rather than serving to prevent
malfunctions, the forcibly guided contact structure enables another
circuit to detect the condition following a contact weld or other
malfunction. Accordingly, when a contact weld occurs in a Relay with
Forcibly Guided Contacts, depending on the circuit configuration, the
power may not be interrupted, leaving the Relay in a potentially
dangerous condition (as shown in Fig. 1.)
To configure the power control circuit to interrupt the power when a
contact weld or other malfunction occurs, and to prevent restarting
until the problem has been eliminated, add another Relay with
Forcibly Guided Contacts or similar Relay in combination to provide
redundancy and a self-monitoring function to the circuit (as shown in
Fig. 2).
Refer to the Safety Components Technical Guide (Cat No. Y107).
The G9S/G9SA/G9SB Safety Relay Unit, which combines Relays
such as the Relay with Forcibly Guided Contacts in order to provide
the above-described functions, is available for this purpose. By
connecting a contactor with appropriate input and output to the Safety
Relay Unit, the circuit can be equipped with redundancy and a selfmonitoring function.
Fig 1
Contents of the Guidelines
The Guidelines on the Application of Council Directive 73/23/EEC
apply to components. Relays with PWB terminals are not covered by
the Low Voltage Directive.
Fig 2
S1
S1
21
11
22
12
S2
K1
S2
K1
K1
A1 A2 T11 T12
+ −
B1
Y1 X1
D
Power source
K3 K1
F1
K1
PE T21
K3 K2
K2
T22
K3
13
K1
K1
K2
K2
K3
14
Power source
Durability of Contact Outputs
Relay with Forcibly Guided Contact durability depends greatly on the
switching condition. Confirm the actual conditions of operation in
which the Relay will be used in order to make sure the permissible
number of switching operations.
When the accumulated number of operation exceeds its permissible
range, it can cause failure of reset of safety control circuit. In such
case, please replace the Relay immediately. If the Relay is used
continuously without replacing, then it can lead to loss of safety
function.
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C-1
Precautions for All Relays
Refer to the Safety Precautions section for each Relay for specific precautions applicable to that Relay.
Precautions for Safe Use
These precautions are required to ensure safe operation.
x Do not touch the charged Relay terminal area or the charged
socket terminal area while the power is turned ON. Doing so may
result in electric shock.
x Do not use a Relay for a load that exceeds the Relay's switching
capacity or other contact ratings. Doing so will reduce the specified
performance, causing insulation failure, contact welding, and
contact failure, and the Relay itself may be damaged or burnt.
x Do not drop or disassemble Relays.
Doing so may reduce Relay characteristics and may result in
damage, electric shock, or burning.
x Relay durability depends greatly on the switching conditions.
Confirm operation under the actual conditions in which the Relay
will be used. Make sure the number of switching operations is
within the permissible range. If a Relay is used after performance
has deteriorated, it may result in insulation failure between circuits
and burning of the Relay itself.
x Do not apply overvoltages or incorrect voltages to coils, or
incorrectly wire the terminals. Doing so may prevent the Relay from
functioning properly, may affect external circuits connected to the
Relay, and may cause the Relay itself to be damaged or burnt.
x Do not use Relays where flammable gases or explosive gases may
be present. Doing so may cause combustion or explosion due to
Relay heating or arcing during switching.
x Perform wiring and soldering operations correctly and according to
the instructions contained in Precautions for Correct Use given
below. If a Relay is used with faulty wiring or soldering, it may
cause burning due to abnormal heating when the power is turned
ON.
Precautions for Correct Use
Contents
No.
➊
➋
Area
No. Classification No.
Selecting
Relays
Page
C-3
➀
Mounting
Structure and
Type of
Protection
1
2
3
Type of Protection
Combining Relays and Sockets
Using Relays in Atmospheres Subject to Dust
➁
Drive Circuits
1
2
Providing Power Continuously for Long Periods
Operation Checks for Inspection and Maintenance
➂
Loads
1
2
Contact Ratings
Using Relays with a Microload
1
2
3
4
5
6
7
8
9
10
11
Load Switching
➀ Resistive Loads and Inductive Loads
➁ Switching Voltage
➂ Switching Current
Electrical Durability
Failure Rates
Contact Protection Circuits
Countermeasures for Surge from External Circuits
Connecting Loads for Multi-pole Relays
Motor Forward/Reverse Switching
Power Supply Double Break with Multi-pole Relays
Short-circuiting Due to Arcing between NO and NC Contacts in SPDT Relays
Using SPST-NO/SPST-NC Contact Relays as an SPDT Relay
Connecting Loads of Differing Capacities
Maximum Allowable Voltage
Voltage Applied to Coils
Changes in Must-operate Voltage Due to Coil Temperature
Applied Voltage Waveform for Input Voltage
Preventing Surges when the Coil Is Turned OFF
Leakage Current to Relay Coils
C-7 to C-9
Using with Infrequent Switching
Configuring Sequence Circuits
Connecting Relay Grounds
Individual Specifications for Must-operate/release Voltages and Operate/Release Times
Using DC-operated Relays, (1) Input Power Supply Ripple
Using DC-operated Relays, (2) Coil Polarity
Using DC-operated Relays, (3) Coil Voltage Insufficiency
Lead Wire Diameters
When Sockets are Used
Mounting Direction
When Devices Such as Microcomputers are in Proximity
➀
➌
Item
Using Relays
Load Circuits
➁
Input Circuits
1
2
3
4
5
6
7
8
9
10
11
12
13
➂
Mounting
Design
1
2
3
4
Circuit
Design
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C-4
C-5 to C-7
C-9
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C-2
Precautions for All Relays
No.
Area
No. Classification No.
Item
Page
4
5
6
7
8
Operating, Storage, and Transport
Operating Atmosphere
Using Relays in an Atmosphere Containing Corrosive Gas (Silicon, Sulfuric, or Organic
Gas)
Adhesion of Water, Chemicals, Solvent, and Oil
Vibration and Shock
External Magnetic Fields
External Loads
Adhesion of Magnetic Dust
C-9 to C-10
1
2
3
Panel-mounting Sockets
Relay Removal Direction
Terminal Soldering
1
2
3
➍
➎
➏
➐
Operating and Storage
Environments
Relay
Mounting
Operations
➀
Plug-in
Relays
➁
Printed Circuit
1
Board Relays
➂
1
2
3
4
Removing the Case and Cutting Terminals
Deformed Terminals
Replacing Relays and Performing Wiring Operations
Coating and Packing
1
2
Vibration and Shock
Dropped Products
1
2
3
4
Selecting PCBs, (1) PCB Materials
Selecting PCBs, (2) PCB Thickness
Selecting PCBs, (3) Terminal Hole and Land Diameters
Mounting Space
➀ Ambient Temperature
➁ Mutual Magnetic Interference
Pattern Design for Noise Countermeasures
➀ Noise from Coils
➁ Noise from Contacts
➂ High-frequency Patterns
Shape of Lands
Pattern Conductor Width and Thickness
Conductor Pitch
Securing the PCB
Automatic Mounting of PCB Relays
Common
Items
Handling Relays
Relays for Printed Circuit Boards
(PCBs)
5
6
7
8
9
10
➑
Ultrasonic Cleaning
Troubleshooting
C-10
C-11
C-11 to
C-14
C-15
➊ Using Relays
x When actually using Relays, unanticipated failures may occur. It is
therefore essential to test the operation is as wide of range as
possible.
x Unless otherwise specified in this catalog for a particular rating or
performance value, all values are based on JIS C5442 standard
test conditions (temperature: 15 to 35°C, relative humidity: 25% to
75%, air pressure: 86 to 106 kPa). When checking operation in the
actual application, do not merely test the Relay under the load
conditions, but test it under the same conditions as in the actual
operating environment and using the actual operating conditions.
x The reference data provided in this catalog represent actual
measured values taken from samples of the production line and
shown in diagrams. They are reference values only.
x Ratings and performance values given in this catalog are for
individual tests and do not indicate ratings or performance values
under composite conditions.
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(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-3
Precautions for All Relays
➋ Selecting Relays
➀ Mounting Structure and Type of Protection
➋-➀-1 Type of Protection
If a Relay is selected that does not have the appropriate type of
protection for the atmosphere and the mounting conditions, it may
cause problems, such as contact failure.
Refer to the type of protection classifications shown in the following
table and select a Relay suitable to the atmosphere in which it is to be
used.
Classification by Type of Protection
Item
Mounting
structure
Type of
protection
Atmosphere conditions
Features
Representative model
Dust and dirt
Corrosive
gases
G7SA
Structure that
helps prevent
Flux protection flux from
entering Relays G7SB
during soldering
Some protection
(No large dust or
No protection
dirt particles
inside Relay.)
PCB-mounted
Relay
Unsealed
Structure that
protects against
G7S
contact with
foreign material
by means of
enclosure in a
case (designed
for manual
soldering)
➋-➀-2 Combining Relays and Sockets
Use OMRON Relays in combination with specified OMRON Sockets.
If the Relays are used with sockets from other manufacturers, it may
cause problems, such as abnormal heating at the mating point due to
differences in power capacity and mating properties.
➋-➀-3 Using Relays in Atmospheres Subject to Dust
If a Relay is used in an atmosphere subject to dust, dust will enter the
Relay, become lodged between contacts, and cause the circuit to fail
to close. Moreover, if conductive material such as wire clippings enter
the Relay, it will cause contact failure and short-circuiting.
Implement measures to protect against dust as required by the
application.
➁ Drive Circuits
➋-➁-1 Providing Power Continuously for Long Periods
If power is continuously provided to the coil for a long period,
deterioration of coil insulation will be accelerated due to heating of the
coil. Also see 3-2-7 Using with Infrequent Switching.
➋-➁-2 Operation Checks for Inspection and Maintenance
If a socket with an operation indicator is used, Relay status during
operation can be shown by means of the indicator, thereby facilitating
inspection and maintenance.
Type
Built-in indicator
Description
LED
Examples of
applicable models
G7S
G7SA
Note: The built-in indicator shows that power is being provided to the
coil. The indicator is not based on contact operation.
➂ Loads
➋-➂-1 Contact Ratings
Contact ratings are generally shown for resistance loads and
inductive loads.
➋-➂-2 Using Relays with a Microload
Check the failure rate in the performance tables for individual
products.
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C-4
Precautions for All Relays
➌ Circuit Design
➀ Load Circuits
➌-➀-1 Load Switching
AC Loads and Inrush Current
➀ Resistive Loads and Inductive Loads
The switching power for an inductive load will be lower than the
switching power for a resistive load due to the influence of the
electromagnetic energy stored in the inductive load.
➁ Switching Voltage (Contact Voltage)
The switching power will be lower with DC loads than it will with AC
loads. Applying voltage or current between the contacts exceeding
the maximum values will result in the following:
1. The carbon generated by load switching will accumulate around
the contacts and cause deterioration of insulation.
2. Contact deposits and locking will cause contacts to malfunction.
➂ Switching Current (Contact Current)
Current applied to contacts when they are open or closed will have a
large effect on the contacts. For example, when the load is a motor or
a lamp, the larger the inrush current, the greater the amount of contact
exhaustion and contact transfer will be, leading to deposits, locking,
and other factors causing the contacts to malfunction. (Typical
examples illustrating the relationship between load and inrush current
are given below.)
If a current greater than the rated current is applied and the load is
from a DC power supply, the connection and shorting of arcing
contacts will result in the loss of switching capability.
Current
DC Loads and Inrush Current
Incandescent bulb
(approx. 6 to 11 times
steady-state current)
Motor
(approx. 5 to
10 times steadystate current)
Resistive load
Solenoid
Incandescent
bulb
Motor
Waveform
Approx.
10
Approx.
10 to 15
Approx.
5 to 10
Steadystate
current
Relay
Approx.
2 to 3
Capacitor
Resistive load
Approx.
20 to 50
1
➌-➀-2 Electrical Durability
Electrical durability will greatly depend on factors such as the coil
drive circuit, type of load, switching frequency, switching phase, and
ambient atmosphere. Therefore be sure to check operation in the
actual application.
Coil drive circuit
Rated voltage applied to coil using
instantaneous ON/OFF
Type of load
Rated load
Switching frequency
According to individual ratings
Switching phase
(for AC load)
Random ON, OFF
Ambient atmosphere
According to JIS C5442 standard test
conditions
➌-➀-3 Failure Rates
Relay,
solenoid
Time (t)
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Type of load
Ratio of
inrush
current
to
steadystate
current
Inrush current
In actual Relay operation, the switching capacity, electrical durability,
and applicable load will vary greatly with the type of load, the ambient
conditions, and the switching conditions. Confirm operation under the
actual conditions in which the Relay will be used.
The failure rates provided in this catalog are determined through tests
performed under specified conditions. The values are reference
values only. The values will depend on the operating frequency, the
ambient atmosphere, and the expected level of reliability of the Relay.
Be sure to check relay suitability under actual load conditions.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-5
Precautions for All Relays
➌-➀-4 Contact Protection Circuits
Using a contact protection circuit is effective in increasing contact
durability and minimizing the production of carbides and nitric acid.
The following table shows typical examples of contact protection
circuits. Use them as guidelines for circuit design.
1. Depending on factors such as the nature of the load and the Relay
characteristics, the effects may not occur at all or adverse effects
may result. Therefore be sure to check operation under the actual
load conditions.
2. When a contact protection circuit is used, it may cause the release
time (breaking time) to be increased. Therefore be sure to check
operation under the actual load conditions.
Typical Examples of Contact Protection Circuits
Applicable
current
Circuit example
AC
*
Power
supply
C
R
Features and remarks
Element selection
Use the following as guides for C and R
values:
C: 0.5 to 1 μF per 1 A of contact current (A)
R: 0.5 to 1 : per 1 V of contact voltage (V)
These values depend on various factors,
including the load characteristics and
variations in characteristics. Confirm
optimum values experimentally.
Capacitor C suppresses the discharge
when the contacts are opened, while the
resistor R limits the current applied when
the contacts are closed the next time.
Generally, use a capacitor with a
dielectric strength of 200 to 300 V. For
applications in an AC circuit, use an AC
capacitor (with no polarity).
If there is any question about the ability to
cut off arcing of the contacts in
applications with high DC voltages, it may
be more effective to connect the capacitor
and resistor across the contacts, rather
than across the load. Perform testing with
the actual equipment to determine this.
DC
Inductive
load
*
(Yes)
Yes
* Load impedance must be much smaller
than the CR circuit impedance when
using the Relay for an AC voltage.
When the contacts are open, current
flows to the inductive load via CR.
Inductive
load
Yes
Yes
The release time of the contacts will be
increased if the load is a Relay or
solenoid.
CR
*
C
Power
supply
R
Use a diode having a reverse breakdown
voltage of more than 10 times the circuit
voltage, and a forward current rating
greater than the load current. A diode
having a reverse breakdown voltage two
or three times that of the supply voltage
can be used in an electronic circuit where
the circuit voltage is not particularly high.
Diode
Power
supply
Inductive
load
No
Yes
The electromagnetic energy stored in the
inductive load reaches the inductive load
as current via the diode connected in
parallel, and is dissipated as Joule heat
by the resistance of the inductive load.
This type of circuit increases the release
time more than the CR type.
Diode +
Zener diode
Power
supply
Inductive
load
No
Yes
This circuit effectively shortens the
The breakdown voltage of the Zener
release time in applications where the
diode should be about the same as the
release time of a diode circuit is too slow. supply voltage.
Yes
This circuit prevents a high voltage from
being applied across the contacts by
using the constant-voltage characteristic
of a varistor. This circuit also somewhat
increases the release time.
Connecting the varistor across the load is
effective when the supply voltage is 24 to
48 V, and across the contacts when the
supply voltage is 100 to 200 V.
Varistor
Power
supply
Inductive
load
Yes
The cutoff voltage Vc must satisfy the
following conditions. For AC, it must be
multiplied by 2 .
Vc > (Supply voltage u 1.5)
If Vc is set too high, its effectiveness will
be reduced because it will fail to cut off
high voltages.
Do not use the following types of contact protection circuit.
C
Power
supply
Load
This circuit arrangement is very effective for diminishing
arcing at the contacts when breaking the circuit. However,
since electrical energy is stored in C (capacitor) when the
contacts are open, the current from C flows into the
contacts when they close. This may lead to contact
welding.
Power C
supply
Load
This circuit arrangement is very useful for diminishing
arcing at the contacts when breaking the circuit. However,
since the charging current to C flows into the contacts
when they are closed, contact welding may occur.
Note: Although it is thought that switching a DC inductive load is more difficult than a resistive load, an appropriate contact protection circuit can
achieve almost the same characteristics.
➌-➀-5 Countermeasures for Surge from External Circuits
Install contact protection circuits, such as surge absorbers, at
locations where there is a possibility of surges exceeding the Relay
withstand voltage due to factors such as lightning. If a voltage
exceeding the Relay withstand voltage value is applied, it will cause
line and insulation deterioration between coils and contacts and
between contacts of the same polarity.
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C-6
Precautions for All Relays
➌-➀-6 Connecting Loads for Multi-pole Relays
Connect multi-pole Relay loads according to diagram "a" below to
avoid creating differences in electric potential in the circuits. If a
multi-pole Relay is used with an electric potential difference in the
circuit, it will cause short-circuiting due to arcing between contacts,
damaging the Relays and peripheral devices.
Load
Load
a. Correct Connection
Load
b. Incorrect Connection
➌-➀-7 Motor Forward/Reverse Switching
Switching a motor between forward and reverse operation creates an
electric potential difference in the circuit, so a time lag (OFF time)
must be set up using multiple Relays.
Arc short-circuiting occurs.
M
B
Example of Incorrect Circuit
Incorrect
ON
ON
X1
X1
X2
M
B
Reverse
operation
Motor
X1
Example of Correct Circuit
Forward
operation
Correct
Forward
operation
OFF
time
➌-➀-11 Connecting Loads of Differing Capacities
Do not have a single Relay simultaneously switching a large load and
a microload.
The purity of the contacts used for microload switching will be lost as
a result of the contact spattering that occurs during large load
switching, and this may give rise to contact failure during microload
switching.
➁ Input Circuits
➌-➁-1 Maximum Allowable Voltage
The coil's maximum allowable voltage is determined by the coil
temperature increase and the heat withstand temperature of the
insulation material. (If the heat withstand temperature is exceeded, it
will cause coil burning and layer shorting.) There are also important
restrictions imposed to prevent problems such as thermal changes
and deterioration of the insulation, damage to other control devices,
injury to humans, and fires, so be careful not to exceed the specified
values provided in this catalog.
➌-➁-2 Voltage Applied to Coils
Apply only the rated voltage to coils. The Relays will operate at the
must-operate voltage or greater, but the rated voltage must be
applied to the coils in order to obtain the specified performance.
ON
X2
X2
L
Load
Power
supply
Load Load Load
Do not construct a circuit so that overcurrent and burning occur if the
NO, NC and SPDT contacts are short-circuited.
Also, with SPST-NO/SPST-NC Relays, a short-circuit current may
flow for forward/reverse motor operation.
(Short-circuit current)
Power supply
Load
Power
supply
➌-➀-10 Using SPST-NO/SPST-NC Contact Relays as an
SPDT Relay
OFF
time
➌-➀-8 Power Supply Double Break with Multi-pole Relays
If a double break circuit for the power supply is constructed using
multi-pole Relays, take factors into account when selecting models:
Relay structure, creepage distance, clearance between unlike poles,
and the existence of arc barriers. Also, after making the selection,
check operation in the actual application. If an inappropriate model is
selected, short-circuiting will occur between unlike poles even when
the load is within the rated values, particularly due to arcing when
power is turned OFF. This can cause burning and damage to
peripheral devices.
➌-➀-9 Short-circuiting Due to Arcing between NO and NC
Contacts in SPDT Relays
With Relays that have NO and NC contacts, short-circuiting between
contacts will result due to arcing if the space between the NO and NC
contacts is too small or if a large current is switched.
Do not construct a circuit in such a way that overcurrent and burning
occur if the NO, NC, and SPDT contacts are short-circuited.
Arc short-circuiting occurs.
➌-➁-3 Changes in Must-operate Voltage Due to Coil
Temperature
It may not be possible to satisfy this catalog values for must-operate
voltages during a hot start or when the ambient temperature exceeds
23°C, so be sure to check operation under the actual application
conditions.
Coil resistance is increased by a rise in temperature causing the
must-operate voltage to increase. The resistance thermal coefficient
of a copper wire is approximately 0.4% per 1°C, and the coil
resistance also increases at this percentage.
This catalog values for the must-operate voltage and must-release
voltage are given for a coil temperature of 23°C.
➌-➁-4 Applied Voltage Waveform for Input Voltage
As a rule, power supply waveforms are based on the rectangular
(square) waveforms, and do not operate in such a way that the
voltage applied to the coil slowly rises and falls. Also, do not use them
to detect voltage or current limit values (i.e., using them for turning ON
or OFF at the moment a voltage or current limit is reached).
This kind of circuit causes faulty sequence operations. For example,
the simultaneous operability of contacts may not be dependable (for
multi-pole Relays, time variations must occur in contact operations),
and the must-operate voltage varies with each operation. In addition,
the operation and release times are lengthened, causing durability to
drop and contact welding. Be sure to use an instantaneous ON/OFF.
Load
Incorrect
Example of incorrect circuit
X1
X2
ON
X1
ON
Load
X2
Example of correct circuit
Correct
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OFF time
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-7
Precautions for All Relays
➌-➁-5 Preventing Surges when the Coil Is Turned OFF
➌-➁-8 Configuring Sequence Circuits
Counter electromotive force generated from a coil when the coil is
turned OFF causes damage to semiconductor elements and faulty
operation.
As a countermeasure, install surge absorbing circuits at both ends of
the coil. When surge absorbing circuits have been installed, the Relay
release time will be lengthened, so be sure to check operation using
the actual circuits.
External surges must be taken into account for the repetitive peak
reverse voltage and the DC reverse voltage, and a diode with
sufficient capacity used. Also, ensure that the diode has an average
rectified current that is greater than the coil current.
Do not use under conditions in which a surge is included in the power
supply, such as when an inductive load is connected in parallel to the
coil. Doing so will cause damage to the installed (or built-in) coil surge
absorbing diode.
When configuring a sequence circuit, care must be taken to ensure
that abnormal operation does not occur due to faults such as sneak
current.
The following diagram shows an example of sneak current. After
contacts A, B, and C are closed causing Relays X1, X2, and X3 to
operate, and then contacts B and C are opened, a series circuit is
created from A to X1 to X2 to X3. This causes the Relay to hum or to
not release.
➌-➁-6 Leakage Current to Relay Coils
The following diagram shows an example of a circuit that corrects the
above problem. Also, in a DC circuit, the sneak current can be
prevented by means of a diode.
Do not allow leakage current to flow to Relay coils. Construct a
corrective circuit as shown in examples 1 and 2 below.
Example: Circuit with Leakage Current Occurring
A
B
X1
X2
X3
C
Incorrect
C
D
TE
B
A
IO
X1
X2
X3
Correct
Incorrect
➌-➁-9 Connecting Relay Grounds
Corrective Example 1
Do not connect a ground when using a Relay at high temperatures or
high humidity. Depending on the grounding method, electrolytic
corrosion may occur, causing the wire to the coil to sever. If the Relay
must be grounded, use the method shown in the following diagrams.
(1) Ground the positive side of the power supply. (Fig. 1 and Fig. 2)
Correct
For operations using a microload and infrequent switching,
periodically perform continuity tests on the contacts. When switching
is not executed for contacts for long periods of time, it causes contact
instability due to factors such as the formation of film on contact
surfaces.
The frequency with which the inspections are needed will depend on
factors such as the operating environment and the type of load.
Correct
Fig. 1
Correct
Fig. 2
Difference in electric potential
Core
➌-➁-7 Using with Infrequent Switching
Core
(3) Do not ground the negative side and connect a switch to the
negative side.
This will cause electrolytic corrosion to occur. (Fig. 4)
Core
Corrective Example 2:
When an Output Value Is Required in the Same Phase as the
Input Value
(2) If grounding the positive side of the power supply is not possible
and the negative side must be grounded, connect a switch at the
positive side so that the coil is connected to the negative side.
(Fig. 3)
Core
Correct
Correct
Fig. 3
Incorrect
Fig. 4
➌-➁-10 Individual Specifications for Must-operate/
release Voltages and Operate/Release Times
If it is necessary to know the individual specifications of
characteristics, such as must-operate voltages, must-release
voltages, operate times, and release times, please contact your
OMRON representative.
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C-8
Precautions for All Relays
➌-➁-11 Using DC-operated Relays
(1) Input Power Supply Ripple
➌-➂-4 When Devices Such as Microcomputers are in
Proximity
For a DC-operated Relay power supply, use a power supply with a
maximum ripple percentage of 5%. An increase in the ripple
percentage will cause humming.
If a device that is susceptible to external noise, such as a
microcomputer, is located nearby, take noise countermeasures into
consideration when designing the pattern and circuits. If Relays are
driven using a device such as a microcomputer, and a large current is
switched by Relay contacts, noise generated by arcing can cause the
microcomputer to malfunction.
Smoothing
capacitor
Relay
➍ Operating and Storage
Environments
Ripple component
Emin Emax
Emean
DC component
➍-1 Operating, Storage, and Transport
Ripple percentage %=
E max.= Maximum value of ripple component
Emax−Emin
× 100% E min.= Minimum value of ripple component
Emean
E mean= Mean value of DC component
➌-➁-12 Using DC-operated Relays
(2) Coil Polarity
To make the correct connections, first check the individual terminal
numbers and applied power supply polarities provided in this catalog.
If the polarity is connected in reverse for the coil power supply when
Relays with surge suppressor diodes or Relays with operation
indicators are used, it can cause problems such as Relay
malfunctioning, damage to diodes, or failure of indicators. Also, for
Relays with diodes, it can cause damage to devices in the circuit due
to short-circuiting.
Polarized Relays that use a permanent magnet in a magnetic circuit
will not operate if the power supply to the coil is connected in reverse.
➌-➁-13 Using DC-operated Relays
(3) Coil Voltage Insufficiency
If insufficient voltage is applied to the coil, either the Relay will not
operate or operation will be unstable. This will cause problems such
as a drop in the electrical durability of the contacts and contact
welding.
In particular, when a load with a large surge current, such as a large
motor, is used, the voltage applied to the coil may drop when a large
inrush current occurs to operate the load as the power is turned ON.
Also, if a Relay is operated while the voltage is insufficient, it will
cause the Relay to malfunction even at vibration and shock values
below the specifications specified in the specification sheets and this
catalog. Therefore, be sure to apply the rated voltage to the coil.
➂ Mounting Design
➌-➂-1 Lead Wire Diameters
Lead wire diameters are determined by the size of the load current.
As a standard, use lead wires at least the size of the cross-sectional
areas shown in the following table. If the lead wire is too thin, it may
cause burning due to abnormal heating of the wire.
Permissible current (A)
Cross-sectional area (mm2)
6
0.75
10
1.25
15
2
20
3.5
➌-➂-2 When Sockets are Used
Check Relay and socket ratings, and use devices at the lower end of
the ratings. Relay and socket rated values may vary, and using
devices at the high end of the ratings can result in abnormal heating
and burning at connections.
During operation, storage, and transport, avoid direct sunlight and
maintain room temperature, humidity, and pressure.
x If Relays are used or stored for a long period of time in an
atmosphere of high temperature and humidity, oxidation and
sulphurization films will form on contact surfaces, causing
problems such as contact failure.
x If the ambient temperature is suddenly changed in an atmosphere
of high temperature and humidity, condensation will develop inside
of the Relay. This condensation may cause insulation failure and
deterioration of insulation due to tracking (an electric phenomenon)
on the surface of the insulation material.
Also, in an atmosphere of high humidity, with load switching
accompanied by a comparatively large arc discharge, a dark green
corrosive product may be generated inside of the Relay. To
prevent this, it is recommended that Relays be used in at low
humidity.
x If Relays are to be used after having been stored for a long period,
first inspect the power transmission before use. Even if Relays are
stored without being used at all, contact instability and obstruction
may occur due to factors such as chemical changes to contact
surfaces, and terminal soldering characteristics may be degraded.
➍-2 Operating Atmosphere
x Do not use Relays in an atmosphere containing flammable or
explosive gas. Arcs and heating resulting from Relay switching
may cause fire or explosion.
x Do not use Relays in an atmosphere containing dust. The dust will
get inside the Relays and cause contact failure.
➍-3 Using Relays in an Atmosphere Containing Corrosive
Gas (Silicon, Sulfuric, or Organic Gas)
Do not use Relays in a location where silicon gas, sulfuric gas (SO2
or H2S), or organic gas is present.
If Relays are stored or used for a long period of time in an atmosphere
of sulfuric gas or organic gas, contact surfaces may become corroded
and cause contact instability and obstruction, and terminal soldering
characteristics may be degraded.
Also, if Relays are stored or used for a long period of time in an
atmosphere of silicon gas, a silicon film will form on contact surfaces,
causing contact failure.
The effects of corrosive gas can be reduced by the processing shown
in the following table.
Item
Processing
Outer case, housing
Seal structure using packing.
PCB, copper plating
Apply coating.
Connectors
Apply gold plating or rhodium
plating.
➌-➂-3 Mounting Direction
Depending on the model, a particular mounting direction may be
specified. Check this catalog and then mount the device in the correct
direction.
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C-9
Precautions for All Relays
➍-4 Adhesion of Water, Chemicals, Solvent, and Oil
➎-➀-2 Relay Removal Direction
Do not use or store Relays in an atmosphere exposed to water,
chemicals, solvent, or oil. If Relays are exposed to water or
chemicals, it can cause rusting, corrosion, resin deterioration, and
burning due to tracking. Also, if they are exposed to solvents such as
thinner or gasoline, it can erase markings and cause components to
deteriorate.
If oil adheres to the transparent case (polycarbonate), it can cause the
case to cloud up or crack.
Insert and remove Relays from the socket perpendicular to the socket
surface.
➍-5 Vibration and Shock
Do not allow Relays to be subjected to vibration or shock that exceeds
the rated values.
If abnormal vibration or shock is received, it will not only cause
malfunctioning but faulty operation due to deformation of components
in Relays, damage, etc. Mount Relays in locations and using methods
that will not let them be affected by devices (such as motors) that
generate vibration so that Relays are not subjected to abnormal
vibration.
➍-6 External Magnetic Fields
Do not use Relays in a location where an external magnetic field of
800 A/m or greater is present.
If they are used in a location with a strong magnetic field, it will cause
malfunctioning.
Also, strong magnetic field may cause the arc discharge between
contacts during switching to be bent or may cause tracking or
insulation failure.
Magnetic
field
Relay or
transformer
Relay
➍-7 External Loads
Do not use or store Relays in such a way that they are subjected to
external loads. The original performance capabilities of the Relays
cannot be maintained if they are subjected to an external load.
➍-8 Adhesion of Magnetic Dust
Do not use Relays in an atmosphere containing a large amount of
magnetic dust. Relay performance cannot be maintained if magnetic
dust adheres to the case.
Correct
Incorrect
If they are inserted or removed at an angle, Relay terminals may be
bent and may not make proper contact with the socket.
➎-➀-3 Terminal Soldering
Solder General-purpose Relays manually following the precautions
described below.
1. Smooth the tip of the solder gun and then begin the soldering.
x Solder: JIS Z3282, H60A or H63A (containing rosin-based flux)
x Soldering iron: Rated at 30 to 60 W
x Tip temperature: 280 to 300°C
x Soldering time: Approx. 3 s max.
Solder
Flux
Note: For lead-free solder, perform
the soldering under conditions that conform to the applicable
specifications.
2. Use a non-corrosive rosin-based flux suitable for the Relay's
structural materials.
For flux solvent, use an alcohol-based solvent, which tends to be
less chemically reactive.
3. As shown in the above illustration, solder is available with a cut
section to prevent flux from splattering.
When soldering Relay terminals, be careful not to allow materials
such as solder, flux, and solvent to adhere to areas outside of the
terminals.
If this occurs, solder, flux, or solvent can penetrate inside of the
Relays and cause degrading of the insulation and contact failure.
➁ Printed Circuit Board Relays
➎-➁-1 Ultrasonic Cleaning
➎ Relay Mounting Operations
Do not use ultrasonic cleaning for Relays that are not designed for it.
Resonance from the ultrasonic waves used in ultrasonic cleaning can
cause damage to a Relay's internal components, including sticking of
contacts and disconnection of coils.
➀ Plug-in Relays
➂ Common Items
➎-➀-1 Panel-mounting Sockets
1. Socket Mounting Screws
When mounting a panel-mounting socket to the mounting holes,
make sure that the screws are tightened securely.
If there is any looseness in the socket mounting screws, vibration
and shock can cause the socket, Relays, and lead wire to detach.
Panel-mounting sockets that can be snapped on to a 35-mm DIN
Track are also available.
2. Lead Wire Screw Connections
Tighten lead wire screws to a torque of 0.78 to 0.98 N·m (P7SA and
P7S).
If the screws connecting a panel-mounting socket are not
sufficiently tightened, the lead wire can become detached and
abnormal heating or fire can be caused by the contact failure.
Conversely, excessive tightening can strip the threads.
➎-➂-1 Removing the Case and Cutting Terminals
Absolutely do not remove the case and cut terminals. Doing so will
cause the Relay's original performance capabilities to be lost.
➎-➂-2 Deformed Terminals
Do not attempt to repair and use a terminal that has been deformed.
Doing so will cause excessive force to be applied to the Relay, and
the Relay's original performance capabilities will be lost.
➎-➂-3 Replacing Relays and Performing Wiring
Operations
Before replacing a Relay or performing a wiring operation, first turn
OFF the power to the coil and the load and check to make sure that
the operation will be safe.
➎-➂-4 Coating and Packing
G7S, G7SA and G7SB Relays are not fully sealed, so do not use a
coating or packing resin.
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C-10
Precautions for All Relays
➏ Handling Relays
➏-1 Vibration and Shock
➏-2 Dropped Products
Relays are precision components. Regardless of whether or not they
are mounted, do not exceed the rated values for vibration and shock.
The vibration and shock values are determined individually for each
Relay, so check the individual Relay specifications in this catalog.
If a Relay is subjected to abnormal vibration or shock, its original
performance capabilities will be lost.
Do not use a product that has been dropped, or that has been taken
apart. Not only may its characteristics not be satisfied, but it may be
susceptible to damage or burning.
➐ Relays for Printed Circuit
Boards (PCBs)
➐-1 Selecting PCBs
(1) PCB Materials
➐-3 Selecting PCBs
(3) Terminal Hole and Land Diameters
PCBs are classified into those made of epoxy and those made of
phenol. The following table lists the characteristics of these PCBs.
Select one, taking into account the application and cost. Epoxy PCBs
are recommended for mounting Relays to prevent the solder from
cracking.
Refer to the following table to select the terminal hole and land
diameters based on the Relay mounting dimensions. The land
diameter may be smaller if the land is processed with through-hole
plating.
Material
Item
Electrical
characteristics
Mechanical
characteristics
Minimum land diameter (mm)
Phenol
Nominal value
Glass epoxy (GE) Paper epoxy (PE)
Paper phenol
(PP)
0.6
1.5
0.8
1.8
New PCBs are
highly insulationresistive but easily
affected by
moisture
absorption.
1.0
2.0
x High insulation
resistance.
x Insulation
resistance
hardly affected
by moisture
absorption.
x The
dimensions are
not easily
affected by
temperature or
humidity.
x Suitable for
through-hole or
multi-layer
PCBs.
Relative cost High
Applications
Terminal hole diameter (mm)
Epoxy
Applications that
require high
reliability.
Characteristics
between glass
epoxy and phenol
Characteristics
between glass
epoxy and phenol
x The
dimensions are
easily affected
by temperature
or humidity.
x Not suitable for
through-hole
PCBs.
Moderate
Low
Characteristics
between glass
epoxy and paper
phenol
Applications in
comparatively
good
environments with
low-density wiring.
➐-2 Selecting PCBs
(2) PCB Thickness
The PCB may warp due to the size, mounting method, or ambient
operating temperature of the PCB or the weight of components
mounted to the PCB. Should warping occur, the internal mechanism
of the Relay on the PCB will be deformed and the Relay may not
provide its full capability. Determine the thickness of the PCB by
taking the material of the PCB into consideration.
In general, PCB thickness should be 0.8, 1.2, 1.6, or 2.0 mm. Taking
Relay terminal length into consideration, the optimum thickness is 1.6
mm.
Tolerance
1.2
2.5
±0.1
1.3
2.5
1.5
3.0
1.6
3.0
2.0
3.0
➐-4 Mounting Space
➀ Ambient Temperature
When mounting a Relay, check this catalog for the specified amount
of mounting space for that Relay, and be sure to allow at least that
much space.
When two or more Relays are mounted, their interaction may
generate excessive heat. In addition, if multiple PCBs with Relays are
mounted to a rack, the temperature may rise excessively. When
mounting Relays, leave enough space so that heat will not build up,
and so that the Relays' ambient temperature remains within the
specified operating temperature range.
➁ Mutual Magnetic Interference
When two or more Relays are mounted, Relay characteristics may be
changed by interference from the magnetic fields generated by the
individual Relays. Be sure to conduct tests using the actual devices.
➐-5 Pattern Design for Noise Countermeasures
➀ Noise from Coils
When the coil is turned OFF, reverse power is generated to both ends
of the coil and a noise spike occurs. As a countermeasure, connect a
surge absorbing diode. The diagram below shows an example of a
circuit for reducing noise propagation.
Noise is superimposed
on the power supply line,
so a separate pattern is
connected from a
smoothing capacitor to
supply coil power.
The pattern will
form an antenna
circuit, so make
it as short as
possible.
Terminal length
Power supply line
Smoothing
capacitor
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Relay drive transistor
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C-11
Precautions for All Relays
1. Do not place a signal transmission pattern near the contact pattern.
2. Shorten the length of patterns that may be sources of noise.
3. Block noise from electronic circuits by means such as constructing
ground patterns.
➂ High-frequency Patterns
As the manipulated frequency is increased, pattern mutual
interference also increases. Therefore, take noise countermeasures
into consideration when designing high-frequency pattern and land
shapes.
➐-6 Shape of Lands
1. The land section should be on the center line of the copper-foil
pattern, so that the soldered fillets become uniform.
Correct
Examples
Incorrect
Examples
➐-8 Conductor Pitch
The conductor pitch on a PCB is determined by the insulation
characteristics between conductors and the environmental conditions
under which the PCB is to be used. Refer to the following graph. If the
PCB must conform to safety organization standards (such as UL,
CSA, or IEC), however, priority must be given to fulfilling their
requirements. Also, multi-layer PCBs can be used as a means of
increasing the conductor pitch.
Voltage between Conductors vs. Conductor Pitch
(According to IEC Pub326-3)
Rated Voltage between Conductors (Vdc)
➁ Noise from Contacts
Noise may be transmitted to the electronic circuit when switching a
load, such as a motor or transistor, that generates a surge at the
contacts. When designing patterns, take the following three points
into consideration.
3,000
C
2,000
1,000
700
500
A
D
300
B
200
100
70
50
30
20
2. A break in the circular land area will prevent molten solder from
filling holes reserved for components which must be soldered
manually after the automatic soldering of the PCB is complete.
Break in land
0.2 to 0.5 mm
➐-7 Pattern Conductor Width and Thickness
The following thicknesses of copper foil are standard: 35 μm and
70 μm. The conductor width is determined by the current flow and
allowable temperature rise. Refer to the chart below as a simple
guideline.
50
100°C
75°C
50°C
40°C
30°C
20°C
10°C
30
20
Temperature rise
Permissible current (A)
Conductor Width and Permissible Current
(According to IEC Pub326-3)
10
0.1
0.2 0.3 0.5 0.7 1.0
2
3
5
10
Conductor pitch (mm)
A = Without coating at altitude of 3,000 m max.
B = Without coating at altitude of 3,000 m or higher but lower than 15,000 m
C = With coating at altitude of 3,000 m max.
D = With coating at altitude of 3,000 m or higher
➐-9 Securing the PCB
Although the PCB itself is not normally a source of vibration or shock,
it may prolong vibration or shock by resonating with external vibration
or shock.
Securely fix the PCB, paying attention to the following points.
Mounting
method
Rack mounting
Screw mounting
Process
No gap between rack's guide and PCB
x Securely tighten screw.
Place heavy components such as Relays on
part of PCB near where screws are to be
used.
x Attach rubber washers to screws when
mounting components that are affected by
shock (such as audio devices.)
7
5
3
2
305 /m2
35 μm
Conductor width (mm)
0.03 0.05 0.07 0.1
7
0.3
0.5 0.7 1
Cross-sectional area (mm2)
5
3
610 /m2
70 μm
2
1
0.5
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C-12
Precautions for All Relays
➐-10Automatic Mounting of PCB Relays
➀ Through-hole PCBs
When mounting a Relay to a PCB, take the following points into consideration for each
process. There are also certain mounting precautions for individual Relays, so refer to
the individual Relay precautions as well.
Process 1
1. Do not bend any terminals of the Relay to use it as a self-clinching Relay.
The initial performance characteristics of the Relay will be lost.
2. Execute PCB processing correctly according to the PCB process diagrams.
Placement
Process 2
Flux Application
Flux
Process 3
Preheating
1. The G7S has no protection against flux
penetration, so absolutely do not use the method
shown in the diagram on the right, in which a
sponge is soaked with flux and the PCB pressed
down on the sponge. If this method is used for the
G7S, it will cause the flux to penetrate into the
Relay. Be careful even with the flux-resistant
G7SA or G7SB, because flux can penetrate into
the Relay if it is pressed too deeply into the
sponge.
2. The flux must be a non-corrosive rosin-based flux
suitable for the Relay's structural materials.
For the flux solvent, use an alcohol-based solvent,
which tends to be less chemically reactive.
Apply the flux sparingly and evenly to prevent
penetration into the Relay.
When dipping the Relay terminals into liquid flux,
be sure to adjust the flux level, so that the upper
surface of the PCB is not flooded with flux.
3. Make sure that flux does not adhere anywhere
outside of the Relay terminals. If flux adheres to an
area such as the bottom surface of the Relay, it will
cause the insulation to deteriorate.
1. Preheating is required to create the optimum
conditions for soldering.
2. The following conditions apply for preheating.
3. Do not use a Relay if it has been left at a high
temperature for a long period of time due to a
circumstance such as equipment failure. These
conditions will cause the Relay's initial
characteristics to change.
Temperature
100°C max.
Time
1 min max.
Pressing deeply
PCB
Relay
Sponge soaked with
flux
Example of incorrect method
Applicability of Dipping Method
G7S
NO
G7SA
Applicability of Preheating
G7S
Heater
G7SA
NO
Automatic soldering
Process 4
G7SB
YES
(Must be checked when spray
flexor is used.)
G7SB
YES
Manual soldering
1. Flow soldering is recommended to assure a uniform
1. Smooth the solder with the tip of the iron, and then
solder joint.
perform the soldering under the following conditions.
x Solder: JIS Z3282 or H63A
x Solder: JIS Z3282, H60A, or H63A
x Solder temperature and soldering time: Approx. 250°C
(containing rosin-based flux)
(DWS: Approx. 260°C)
x Soldering iron: Rated at 30 to 60 W
Solder
x Solder time: 5 s max. (DWS: Approx. 2 s for first time
x Tip temperature: 280 to 300°C
Flux
and approx. 3 s for second time)
x Soldering time: Approx. 3 s max.
x Adjust the level of the molten solder so that the PCB is 2. As shown in the above illustration, solder is available
with a cut section to prevent flux from splattering.
not flooded with solder.
Soldering
Applicability of Manual Soldering
Applicability of Automatic Soldering
G7S
NO
Continued next page.
G7SA
G7SB
YES
G7S
YES
G7SA
G7SB
YES
Note: For lead-free solder, perform the soldering under conditions that conform to the applicable specifications.
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C-13
Precautions for All Relays
Process 5
Cooling
Process 6
Cleaning
1. Upon completion of automatic soldering, use a fan
or other device to forcibly cool the PCB. This helps
prevent the Relay and other components from
deteriorating from the residual heat of soldering.
2. Fully sealed relays are washable. Do not, however,
put fully sealed relays in a cold cleaning solvent
immediately after soldering or the seals may be
dameged.
Cooling
G7SA
G7SB
Required
Refer to the following table to select the cleaning
method and solvent.
Cleaning Method
G7S
G7SA
G7SB
Neither boiling cleaning nor immersion cleaning is
possible.
Clean only the back of the PCB with a brush.
Process 7
Coating
1. With the G7S, G7SA or G7SB coating will
penetrate inside Relays and damage the contacts.
Therefore either do not apply coating at all or apply
the coating first, before mounting the Relays.
2. Be very careful in selecting the coating material.
Depending on the type of coating selected, it may
damage the Relay case and chemically dissolve
the seals, causing them to lose their sealing
capability.
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3. Do not secure the entire Relay in resin, or the
Relay's characteristics will be changed.
Do not exceed the maximum value for the coating's
ambient operating temperature.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-14
Precautions for All Relays
➑ Troubleshooting
The following table can be used for troubleshooting when Relay
operation is not normal. Refer to this table when checking the circuit
and other items.
If checking the circuit reveals no abnormality, and it appears that the
fault is caused by a Relay, contact your OMRON representative. (Do
not disassemble the Relay. Doing so will make it impossible to identify
the cause of the problem.)
A Relay is composed of various mechanical parts, including a coil,
contacts, and iron core. Among these, problems occur most often with
the contacts, and next often with the coil.
Fault
These problems, however, mostly occur as a result of external factors
such as methods and conditions of operation, and can generally be
prevented by means of careful consideration before operation and by
selecting the correct Relays.
The following table shows the main faults that may occur, their
probable causes, and suggested countermeasures to correct them.
Probable cause
Countermeasures
1.
2.
3.
4.
5.
Incorrect coil rated voltage selected
Faulty wiring
Input signal not received
Power supply voltage drop
Circuit voltage drop (Be careful in particular of
high-current devices operated nearby or wired at a
distance.)
6. Rise in operating voltage along with rise in ambient
operating temperature (especially for DC)
7. Coil disconnection
1.
2.
3.
4.
5.
1. Input signal OFF fault
2. Voltage is applied to the coil by a sneak current
3. Residual voltage by a combination circuit such as a
semiconductor circuit
4. Release delay due to parallel connection of coil and
capacitor
5. Contact welding
1. Check the voltage between coil terminals.
2. Check the voltage between coil terminals.
3. Check the voltage between coil terminals.
(3) Coil burning
1. Unsuitable voltage applied to coil
2. Incorrect rated voltage selected
3. Short-circuit between coil layers
1. Check the voltage between coil terminals.
2. Select the correct rated voltage.
3. Recheck the operating atmosphere.
1. Check the load capacity.
(4) Contact welding
1. Excessive device load connected (insufficient
contact capacity)
2. Excessive switching frequency
3. Short-circuiting of load circuit
4. Abnormal contact switching due to humming
5. Expected service life of contacts reached
1. Oxidation of contact surfaces
1. x Recheck the operating atmosphere.
x Select the correct Relay.
2. The expected service life of the contacts has been
reached.
3. Be careful of vibration, shock, and soldering
operations.
(1) Operation fault
(2) Release fault
3. Terminal and contact displacement due to faulty
handling
(6) Abnormal contact
consumption
(7) Humming
6. Test individual Relay operation.
7. x For coil burning, see fault (3).
x For disconnection due to electrical corrosion,
check the polarity being applied to the coil voltage.
4. Check the voltage between coil terminals.
5. For contact welding, see fault (4).
2.
3.
4.
5.
2. Contact abrasion and aging
(5) Contact failure
Select the correct rated voltage.
Check the voltage between coil terminals.
Check the voltage between coil terminals.
Check the power supply voltage.
Check the circuit voltage.
Check the number of switches.
Check the load circuits.
For humming, see fault (7).
Check the contact ratings.
1. Unsuitable Relay selection
2. Insufficient consideration of device load (especially
motor, solenoid, and lamp loads)
3. No contact protection circuit
4. Insufficient withstand voltage between adjacent
contacts
1. Select the correct Relay.
2. Select the correct devices.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
Insufficient voltage applied to coil
Excessive power supply ripple (DC)
Incorrect coil rated voltage selected
Slow rise in input voltage
Abrasion in iron core
Foreign material between moveable iron piece and
iron core
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3. Add a circuit such as a spark quenching circuit.
4. Select the correct Relay.
Check the voltage between coil terminals.
Check the ripple percentage.
Select the correct rated voltage.
Make supplemental changes to circuit.
The expected service life has been reached.
Remove the foreign material.
(c)Copyright OMRON Corporation 2007 All Rights Reserved.
C-15
WARNING
This catalog is a guide to help customers select the proper safety products. Observe the following items when choosing
products, select the right products for your devices or equipment, and develop a safety-related system to fully utilize product
functions.
Setting Up a Risk Assessment System
The items listed in this catalog must be used properly in terms of product location as well as product performance and
functionality. Part of the process of selecting and using these products should include the introduction and development of a
risk assessment system early in the design development stage to help identify potential dangers in your equipment that will
optimize safety product selection. A badly designed risk assessment system often results in poor choices when it comes to
safety products.
• Related International Standards:
ISO 14121 Principles of Risk Assessment
Safety Policy
When developing a safety system for the devices and equipment that use safety products, make every effort to understand
and conform to the entire series of international and industrial standards available, such as the examples given below.
• Related International Standards:
ISO 12100 Basic Concepts, General Principles for Design
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
Role of Safety Products
Safety products have functions and mechanisms that ensure safety as defined by standards. These functions and
mechanisms are designed to attain their full potential within safety-related systems. Make sure you fully understand all
functions and mechanisms, and use that understanding to develop systems that will ensure optimal usage.
• Related International Standards:
ISO 14119 Interlocking Devices Associated with Guards-Principles for Design and Selection
Installing Safety Products
Make sure that properly educated and trained engineers are selected to develop your safety-related system and to install
safety products in devices and equipment.
• Related International Standards:
ISO 12100 Basic Concepts, General Principles for Design
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
Observing Laws and Regulations
Safety products should conform to pertinent laws, regulations, and standards, but make sure that they are used in
accordance with the laws, regulations, and standards of the country where the devices and equipment incorporating these
products are distributed.
• Related International Standards:
IEC 60204 Electrical Equipment of Machines
Observing Usage Precautions
Carefully read the specifications and precautions listed in this catalog for your product as well as all items in the Operating
Manual packed with the product to learn usage procedures that will optimize your choice. Any deviation from precautions
will lead to unexpected device or equipment failure not anticipated by safety-related systems or fire originating from
equipment failure.
Transferring Devices and Equipment
When transferring devices and equipment, be sure to keep one copy of the Operating Manual and pack another copy with
the device or equipment so the person receiving it will have no problem operating it.
• Related International Standards:
ISO 12100 Basic Concepts, General Principles for Design
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
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Read and Understand This Catalog
Please read and understand this catalog before purchasing the products. Please consult your OMRON representative if you have any questions or
comments.
Warranty and Limitations of Liability
WARRANTY
OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if
specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR
FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE
HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS, OR COMMERCIAL
LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR
STRICT LIABILITY.
In no event shall responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS
OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT
SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
Application Considerations
SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's
application or use of the product.
At the customer's request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the
products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product,
machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive 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 electrical interference, or conditions or uses not described in this catalog.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety
equipment, and installations subject to separate industry or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE
SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND
INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
Disclaimers
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other reasons.
It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made.
However, some specifications of the product may be changed without any notice. When in doubt, special model numbers may be assigned to fix
or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual
specifications of purchased product.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.
ERRORS AND OMISSIONS
The information in this catalog has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical,
typographical, or proofreading errors, or omissions.
PERFORMANCE DATA
Performance data given in this catalog is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent
the result of OMRON’s test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON
Warranty and Limitations of Liability.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user's programming of a programmable product, or any consequence thereof.
COPYRIGHT AND COPY PERMISSION
This catalog shall not be copied for sales or promotions without permission.
This catalog is protected by copyright and is intended solely for use in conjunction with the product. Please notify us before copying or reproducing this
catalog in any manner, for any other purpose. If copying or transmitting this catalog to another, please copy or transmit it in its entirety.
2007. 11
OMRON Corporation
In the interest of product improvement, specifications are subject to change without notice.
Industrial Automation Company
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