Flexible Safety Unit
G9SX
Logical AND Function in combination with clever I/O Expansion and
Diagnosis offers Flexibility, Transparency and Availability
• Facilitates clear and transparent segmentation of
your safety system
• Solid-state outputs for long live, and relay expansion
units for up to 25 outputs per path.
• Detailed LED indications enable easy diagnosis
• Small size saves space.
• Clever Feeback outputs to feed status into control
system
• Approved for compliance to EN954-1 (cat4) and
IEC/EN61508 (SIL3) by TÜV Produkt Service
• Approved by UL and CSA for global market.
Note: Refer to Precautions on pages 15 and 15.
G9SX
1
Ordering Information
List of Models
Advanced Unit
Safety outputs
Instantaneous
3 (solid state)
(See note 3.)
OFF-delayed
(See note 2.)
2 (solid state)
(See note 3.)
Auxiliary
outputs
2 (solid state)
(See note 4.)
No. of input
channels
1 or 2
channels
Max. OFFRated Terminal block type
delay time voltage
(See note 1.)
15 s
24 VDC Screw terminals
Model
G9SX-AD322-T15-RT
Spring-cage terminals G9SX-AD322-T15-RC
Note: 1. The OFF-delay time can be set in 16 steps as follows:
T15: 0/0.2/0.3/0.4/0.5/0.6/0.7/1/1.5/2/3/4/5/7/10/15 s
2. The OFF-delayed output becomes an instantaneous output by setting the OFF-delay time to 0 s.
3. P channel MOS FET transistor output
4. PNP transistor output
Basic Unit
Safety outputs
Instantaneous
2 (solid state)
(See note 1.)
OFF-delayed
---
Auxiliary
outputs
2 (solid state)
(See note 2.)
No. of input
channels
1 or 2
channels
Rated voltage
24 VDC
Terminal block type
Screw terminals
Model
G9SX-BC202-RT
Spring-cage terminals G9SX-BC202-RC
Note: 1. P channel MOS FET transistor output
2. PNP transistor output
Expansion Unit
Safety outputs
Instantaneous
OFF-delayed
4 PST-NO
(contact)
---
---
4 PST-NO
(contact)
Auxiliary
outputs
1 (solid state)
(See note 1.)
OFF-delay
time
---
Rated voltage
24 VDC
Terminal block type
Screw terminals
Model
G9SX-EX401-RT
Spring-cage terminals G9SX-EX401-RC
(See note 2.)
Screw terminals
G9SX-EX041-T-RT
Spring-cage terminals G9SX-EX041-T-RC
Note: 1. PNP transistor output
2. The OFF-delay time is synchronized to the OFF-delay time setting in the connected G9SX-AD-@ Advanced Unit.
2
Flexible Safety Unit
Specifications
Ratings
Power input
Item
G9SX-AD322-@
Rated supply voltage
G9SX-BC202-@
G9SX-EX-@
24 VDC
Operating voltage range
15% to 10% of rated supply voltage
Rated power consumption (See note.) 4 W max.
3 W max.
2 W max.
Note: Power consumption of loads not included.
Inputs
Item
G9SX-AD322-@
Safety input
G9SX-BC202-@
Operating voltage: 20.4 VDC to 26.4 VDC, internal impedance: approx. 2.8 kΩ
Feedback/reset input
Outputs
Item
G9SX-AD322-@
G9SX-BC202-@
Instantaneous safety output
OFF-delayed safety output (See note
1.)
P channel MOS FET transistor output
Load current:
Using 2 outputs or less: 1 A DC max. (See
note 2.)
Using 3 outputs or more: 0.8 A DC max.
Auxiliary output
PNP transistor output
Load current: 100 mA max.
P channel MOS FET transistor output
Load current:
Using 1 output: 1 A DC max. (See note 2.)
Using 2 outputs: 0.8 A DC max.
Note: 1. While safety outputs are in the ON state, the following signal sequence is output continuously for diagnosis. When using the safety outputs
as input signals to control devices (i.e. Programmable Controllers), consider the OFF pulse shown below.
Approx. 100 ms
ON
OFF
360 µs max.
2. The following derating is required when Units are mounted side-by-side.
G9SX-AD322-@/G9SX-BC202-@: 0.4 A max. load current
Expansion Unit
Item
G9SX-EX-@
Rated load
250 VAC, 3A / 30 VDC, 3A (resistive load)
Rated carry current
3A
Maximum switching voltage
250 VAC, 125 VDC
Characteristics
Item
G9SX-AD322-@
G9SX-BC202-@
G9SX-EX-@
Over-voltage category (IEC/EN 60664-1)
II
II (Safety relay outputs 13 to
43 and 14 to 44: III)
Operating time (OFF to ON state)
(See note 1.)
50 ms max. (Safety input: ON) 50 ms max. (Safety input: ON) 30 ms max. (See note 4.)
(See note 2.)
100 ms max. (Logical AND
connection input: ON) (See
note 3.)
Response time (ON to OFF state)
(See note 1.)
15 ms max.
ON-state residual voltage
3.0 V max. (safety output, auxiliary output)
OFF-state leakage current
0.1 mA max. (safety output, auxiliary output)
External connection impedance
100
10 ms max. (See note 4.)
max. and 10 nF max.
---
Reset input time (Reset button pressing time) 100 ms min.
Accuracy of OFF-delay time (See note 5.)
Within
5% of the set value
Insulation Between logical AND connection 20 MΩ min. (by 100 VDC
megger)
resistance terminals, and power supply
input terminals and other input
and output terminals connected
together
Between all terminals connected
together and DIN rail
G9SX
---
Within
---
---
5% of the set value
20 MΩ min. (at 100 VDC)
100 MΩ min. (at 500 VDC)
3
Item
Dielectric
strength
G9SX-AD322-@
G9SX-BC202-@
G9SX-EX-@
Between logical AND connection 500 VAC for 1 min
terminals, and power supply
input terminals and other input
and output terminals connected
together
---
---
Between all terminals connected
together and DIN rail
500 VAC for 1 min
1,200 VAC for 1 min
Between different poles of
outputs
---
---
Between safety relay outputs
connected together and other
terminals connected together
2,200 VAC for 1 min
Vibration resistance
Frequency: 10 to 55 to 10 Hz, 0.375-mm single amplitude (0.75-mm double amplitude)
Mechanical Destruction
shock
Malfunction
resistance
300 m/s2
Durability
Electrical
---
100,000 cycles min.
(rated load, switching
frequency: 1,800 cycles/hour)
Mechanical
---
5,000,000 cycles min.
(switching frequency: 7,200
cycles/hour)
Ambient temperature
100 m/s2
10 to 55 C (no icing or condensation)
Ambient humidity
25% to 85%
Terminal tightening torque (See note 6.)
0.5 N·m
Weight
Approx. 160 g
Approx. 100 g
Approx. 145 g
Note: 1. When two or more Units are connected by logical AND, the operating time and response time are the sum total of the operating times
and response times, respectively, of all the Units connected by logical AND.
2. Represents the operating time when the safety input turns ON with all other conditions set.
3. Represents the operating time when the logical AND input turns ON with all other conditions set.
4. This does not include the operating time or response time of Advanced Units that are connected.
5. This does not include the operating time or response time of internal relays in the G9SX-EX-@.
6. For the G9SX-@-RT (with screw terminals) only
4
Flexible Safety Unit
Logical AND Connection
Item
G9SX-AD322-@
Number of Units connected per
logical AND output
G9SX-BC202-@
G9SX-EX-@
4 Units max.
---
Total number of Units connected 20 Units max.
by logical AND (See note 2.)
---
Number of Units connected in
series by logical AND
---
5 Units max.
Max. number of Expansion Units --connected (See note 3.)
5 Units
Maximum cable length for logical 100 m
AND input
---
Note: 1. See Logical AND Connection Combinations below for details.
2. The number of G9SX-EX401-@ Expansion Units or G9SX-EX041-T-@ Expansion Units (OFF-delayed Model) not included.
3. G9SX-EX401-@ Expansion Units and G9SX-EX041-T-@ Expansion Units (OFF-delayed Model) can be mixed.
Logical AND Connection Combinations
1. One logical AND connection output from an Advanced Unit can
be logical AND connected to up to four Advanced Units.
4. The largest possible system configuration contains a total of 20
Advanced and Basic Units. In this configuration, each Advanced
Unit can have up to five Expansion Units.
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-BC
or
G9SX-AD
2. Two logical AND outputs from a Basic Unit can be logical AND
connected to up to eight Advanced Units.
The
G9SX-AD has
one logical
AND output.
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-BC
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
3. Any Advanced Unit with logical AND input can be logical AND
connected to Advanced Units on up to five tiers.
G9SX-BC
or
G9SX-AD
Total number of Units connected by
logical AND: 20 Units max.
G9SX-AD
G9SX-AD
G9SX-AD
G9SX-AD
G9SX
5
Response Time and Operating Time
The following table shows the response time for two or more Units that are logical AND connected.
Item
Block flow diagram
Tier
First tier
Max. response
time (not
including
Expansion
Units)
(See note 1.)
Max. response
time (including
Expansion
Units)
(See note 2.)
Max. operating
time (not
including
Expansion
Units)
(See note 3.)
Max. operating
time (including
Expansion
Units)
(See note 4.)
15 ms
25 ms
50 ms
80 ms
30 ms
40 ms
150 ms
180 ms
45 ms
55 ms
250 ms
280 ms
60 ms
70 ms
350 ms
380 ms
75 ms
85 ms
450 ms
480 ms
Advanced Unit or Basic Unit
Second tier
Advanced Unit
Third tier
Advanced Unit
Fourth tier
Advanced Unit
Fifth tier
Advanced Unit
Note: 1. The maximum response time (not including Expansion Units) in this block flow diagram is the time it takes the output from the Unit on the
lowest tier to switch from ON to OFF after the input to the Unit on the highest tier switches from ON to OFF.
2. The maximum response time (including Expansion Units) in this block flow diagram is the time it takes the output from the Expansion Unit
connected to the Unit on the lowest tier to switch from ON to OFF after the input to the Unit on the highest tier switches from ON to OFF.
3. The maximum operating time (not including Expansion Units) in this block flow diagram is the time it takes the output from the Unit on
the lowest tier to switch from OFF to ON after the input to the Unit on the highest tier switches from OFF to ON.
4. The maximum operating time (including Expansion Units) in this block flow diagram is the time it takes the output from the Expansion
Unit connected to the Unit on the lowest tier to switch from OFF to ON after the input to the Unit on the highest tier switches from OFF to
ON.
6
Flexible Safety Unit
Connections
Internal Connection
G9SX-AD-322-T15-@ (Advanced Unit)
(See
note 1.)
A2
(See note 2.)
S14 S24 S34 S44 S54 L1 X1 X2
Note: 1. Internal power supply circuit is not isolated.
2. Logical AND input is isolated.
3. Outputs S14 to S54 are internally redundant.
G9SX-BC202-@ (Basic Unit)
Note: 1. Internal power supply circuit is not isolated.
2. Outputs S14 and S24 are internally redundant.
G9SX-EX401-@/G9SX-EX041-T-@ (Expansion Unit / Expansion Unit OFF-delayed model)
Note: 1. Internal power supply circuit is not isolated.
2. Relay outputs are isolated
G9SX
7
Dimensions
Note: All units are in millimeters unless otherwise indicated.
Advanced Unit
Basic Unit
Expansion Unit
8
Flexible Safety Unit
Wiring of Inputs and Outputs
Signal name
Terminal name
Description of operation
Wiring
Connect the power supply plus (24 VDC) to the A1
terminal.
Connect the power supply minus (GND) to the A2
terminal.
Power supply input
A1, A2
The input terminals for power supply.
Connect the power source to the A1 and A2
terminals.
Safety input 1
T11, T12
To set the safety outputs in the ON state, the HIGH Corresponds to
state signals must be input to both safety input 1 and Safety Category
safety input 2. Otherwise the safety outputs cannot 2
be in the ON state.
Safety input 2
T21, T22
+24 V
+24 V
T11 T12 T21 T22
Corresponds to
Safety Category
3
+24 V
Y1
+24 V
+24 V
T11 T12 T21 T22
Y1
T11 T12 T21 T22
Y1
Corresponds to
Safety Category
4
Feedback/reset input T31, T32, T33
To set the safety outputs in the ON state, the ON
state signal must be input to T33.
Otherwise the safety outputs cannot be in the ON
state.
NC
Auto reset
Feedback loop
T31
To set the safety outputs in the ON state, the signal Manual reset
input to T32 must change from the OFF state to the
ON state, and then to the OFF state. Otherwise the
safety outputs cannot be in the ON state.
Logical AND
connection input
T41, T42
The logical AND connection means that one unit
(Unit A) outputs a safety signal "a" to a subsequent
unit (Unit B) and Unit B calculates the logical
multiplication (AND) of the signal "a" and safety
signal "b", which is input to Unit B.
Thereby the logic of the safety output of Unit B is "a"
AND "b".
To set the safety outputs of the subsequent Unit in
the ON state, its logical AND connection preset
switch must be set to AND (enable) and the HIGH
state signal must be input to T41 of the subsequent
unit.
KM
+24 V
Unit A
T32
T33
Feedback loop
Reset
Switch
KM +24 V
T31
T32
T33
Input a
G9SX-BC202 or
G9SX-AD322-T
Output (a) L1 A2
Logical AND connection sig. (1st layer) Next unit (4 unit max.)
Unit B
T41 T42
Input b
G9SX-AD322-T
T41 T42
G9SX-AD322-T
Output (a&b) L1 A2
Logical AND connection sig. (2nd layer) Next unit (4 unit max.)
T41 T42
G9SX-AD322-T
L1 A2
Next unit (5 layers max.)
Cross fault detection Y1
input
Selects the mode for the failure detecting (cross fault Keep Y1 open when using T11, T21. (Wiring
corresponding to category 4)
detecting) function for the safety inputs of G9SX
corresponding to the connection of the cross fault
Connect Y1 to 24 VDC when not using T11, T21.
detection input.
(Wiring corresponding to category 2 or 3, or when
connecting safety sensors)
Instantaneous safety S14, S24, S34
output
Turns ON/OFF according to the state of the safety
inputs, feedback/reset inputs, and logical AND
connection inputs.
During OFF-delay state, the Instantaneous safety
outputs are not able to turn ON.
OFF-delayed safety
output
S44, S54
Keep these outputs open when not used.
OFF-delayed safety outputs.
The OFF-delay time is set by the OFF-delay preset
switch.
When the delay time is set to zero, these outputs can
be used as non-delay outputs.
Logical connection
output
L1, L2
Outputs a signal of the same logic as the
instantaneous safety outputs.
Keep these outputs open when not used.
Auxiliary monitor
output
X1
Outputs a signal of the same logic as the
instantaneous safety outputs
Keep these outputs open when not used.
Outputs when the error indicator is lit or blinking.
Keep these outputs open when not used.
Auxiliary error output X2
G9SX
Keep these outputs open when not used.
9
Connecting Safety Sensors and the G9SX
1. When connecting safety sensors to the G9SX, the Y1 terminal must be connected to 24 VDC.
The G9SX will detect a connection error, if the Y1 terminal is open.
2. In many cases, safety sensor outputs include an OFF-shot pulse for self diagnosis.
The following condition of test pulse is applicable as safety inputs for the G9SX.
• OFF-shot pulse width of the sensor, during the ON-state: 340 s max.
340 µs max.
Operation
Functions
Connecting Expansion Units
Logical AND Connection
The logical AND connection means that the Basic Unit (or Advanced
Unit) outputs a safety signal "a" to an Advanced Unit, and the
Advanced Unit calculates the logical multiplication (AND) of the
safety signal "a" and safety signal "b." The safety output of an
Advanced Unit with the logical AND connection shown in the
following diagram is "a" AND "b".
a
b
• The G9SX-EX and G9SX-EX-T Expansion Units can be connected
to a G9SX-AD-@ Advanced Unit to increase the number of safety
outputs. (They cannot be connected to a Basic Unit.)
• A maximum of five Expansion Units can be connected to one
Advanced Unit. This may be a combination of G9SX-EX
Instantaneous types and G9SX-EX-T OFF-delayed types.
• Remove the terminating connector from the receptacle on the
Advanced Unit and insert the Expansion Unit cable connector into
the receptacle. Insert the terminating connector into the receptacle
on the Expansion Unit at the very end (rightmost).
• When Expansion Units are connected to an Advanced Unit, make
sure that power is supplied to every Expansion Unit. (Refer to the
following diagram for actual Expansion Unit connection.)
Advanced Unit
Basic Unit
T31
T11
T32
T12
T33
Y1
13
X1
X2
23
33
43
13
23
33
43
13
23
33
43
13
23
33
43
A1
G9SX-EX
24VDC
G9SX-AD322-T15
G9SX-EX
24VDC
G9SX-EX
24VDC
G9SX-EX
24VDC
PWR
FB
PWR
PWR
PWR
PWR
T1
T2
ED
ED
ED
ED
AND
a (AND) b
a
EI
0.7
0.6
0.5
0.4
0.3
0.2
This is illustrated using the application in the following diagram as an
example. The equipment here has two hazards identified as Robot 1
and Robot 2, and it is equipped with a safety door switch and an
emergency stop button. You may have overall control where both
Robot 1 and Robot 2 are stopped every time the emergency stop
button is pressed. You may also have partial control where only
Robot 1, which is closest to the door, is stopped when the door is
opened. In that case, Robot 2 will continue to operate.
1 1.5 2
0 15
ED
3
4
5
7
10
ERR
T21
S14
T22
S24
S34
No.
No.
OFF-DELAY
T41
S44
T42
S54
A2
L1
14
A1
24
X2
34
No.
A2
44
14
A1
24
X2
34
No.
A2
44
14
A1
24
X2
34
No.
A2
44
14
A1
24
X2
34
A2
44
The actual situation using a G9SX for this application is shown in this
example.
(Note: The logical AND setting on the Advanced Unit must be set to
AND (enabled).)
Robot 2
Robot 1
Emergency
stop button
Safety Door
Switch
Emergency stop button
a
Door Switch
b
Basic Unit
Advanced Unit
Robot 2
10
Robot 1
Flexible Safety Unit
Setting Procedure
4. Setting the OFF-delay Time (Advanced Unit)
1. Cross Fault Detection (Advanced Unit/Basic Unit)
The OFF-delay preset time on an Advanced Unit is set from the OFFdelay time preset switch (1 each on the front and back of the Unit).
Normal operation will only occur if both switches are identically set.
An error will occur if the switches are not identically set.
Set the cross fault detection mode for safety inputs by shorting Y1 to
24 V or leaving it open. When cross fault detection is set to ON,
short-circuit failures are detected between safety inputs T11-T12 and
T21-22. When a cross fault is detected, the following will occur.
Front
1. The safety outputs and logical AND outputs lock out.
2. The LED error indicator is lit.
3. The error output (auxiliary output) turns ON.
T31 T32 T33
T11 T12 Y1
PWR
FB
T1
T2
X1
X2
Back
A1
0.7
0.6
0.5
Cross fault
detection
OFF
Wiring
Switch
0.7
0.6
0.5
0.4
0.3
0.2
ED
1 1.5 2
0 15
0.2 0 15
4
5
7
10
3
Switch
OFF
T41/ T42
3
4
5
7
10
ERR
OFF-DELAY
No.
T21 T22
T41 T42
S14 S24 S34 S44 S54
Corresponds to
Safety Category 2
0.4
OFF-DELAY
AND
EI
A2
L1
+24 V
+24 V
T11
Corresponds to
Safety Category 3
T12
T21
+24 V
T22
T12
+24 V
T21
T22
Refer to the following illustration for details on setting switch
positions.
Y1
+24 V
T11
ON
0.3
AND
Y1
0.7
0.6
0.5
0.4
0.3
0.2
1 1.5 2
0 15
3
4
5
7
10
OFF-DELAY
Example 1: 0-second
OFF-delay
setting
Corresponds to
Safety Category 4
T11
T12
T21
T22
0.7
0.6
0.5
0.4
0.3
0.2
Notch
1 1.5 2
0 15
3
4
5
7
10
OFF-DELAY
Example 2: 1-second
OFF-delay
setting
Y1
2. Reset Mode (Advanced Unit/Basic Unit)
Set the reset mode using feedback/reset input terminals T31, T32,
and T33.
Auto reset mode is selected when terminal T32 is shorted to 24 V
and manual reset mode is selected when terminal T33 is shorted to
24 V.
Auto reset mode
Manual reset mode
KM1
KM1
KM2
+24 V
T31
Reset
switch
KM2
KM3
KM3
KM4
KM4
KM5
KM5
T32
T33
T31
T32
+24 V
T33
3. Setting Logical AND Connection (Advanced Unit)
When connecting two or more Advanced Units (or Basic Units) by
logical AND connection, set the logical AND connection preset
switch on the Advanced Unit that is on the input side (Advanced Unit
B in the following diagram) to AND.
Advanced Unit A
AND
L1
A2
T41
T42
OFF
AND
OFF
Advanced Unit B
Note: 1. A setting error will occur and Advanced Unit B will lock out
if the logical AND setting switch on the Unit is set to OFF.
2. Set the logical AND setting switch on Advanced Unit A to
OFF or an error will occur.
3. A logical AND input cannot be sent to a Basic Unit.
G9SX
11
LED Indicators
Marking
Color
Name
G9SA-AD
G9SX-BC
G9SX-EX
G9SX-EX-T
Function
Reference
PWR
Green
Power supply
indicator
❍
❍
❍
❍
Lights up while power is supplied.
T1
Orange
Safety input #1 ❍
indicator
❍
---
---
Lights up while a HIGH state signal (See note.)
is input to T12.
Blinks when an error relating to
safety input #1 occurs.
T2
Orange
Safety input #2 ❍
indicator
❍
---
---
Lights up while a HIGH state signal
is input to T22.
Blinks when an error relating to
safety input #2 occurs.
FB
Orange
Feedback/
reset input
indicator
❍
❍
---
---
Lights up in the following cases:
With automatic reset while a HIGH
state signal is input to T33.
With manual reset while a HIGH
state signal is input to T32.
Blinks when an error relating to
feedback/reset input occurs.
AND
Orange
Logical AND
❍
input indicator
---
---
---
Lights up while a HIGH state signal
is input to T41.
Blinks when an error relating to
logical AND connection input
occurs.
EI
Orange
Safety output
indicator
❍
❍
❍
---
Lights up while the Instantaneous
safety outputs (S14, S24, S34) are
in the ON-state.
Blinks when an error relating to the
instantaneous safety output occurs.
ED
Orange
OFF-delayed
safety output
indicator
❍
---
---
❍
Lights up while OFF-delayed safety
outputs (S44, S54) are in the ONstate.
Blinks when an error relating to
OFF-delayed safety output occurs.
ERR
Red
Error indicator ❍
❍
❍
❍
Lights up or blinks when an error
occurs.
---
Note: Refer to Fault Detection on the next page for details.
Settings Indication (at Power ON)
Settings for the G9SX can be checked by the orange indicators for approx. 3 seconds after the power is turned ON. During this settings indication
period, the ERR indicator will light, however the auxiliary error output will remain OFF
Indicator
T1
FB
AND
12
Item
Cross fault detection mode
Reset mode
Logical AND connection input mode
Setting position
Y1 terminal
T32 or T33 terminal
Logical AND
connection preset
switch
Indicator
status
Setting mode
Setting status
Lit
Detection mode
Y1 = open
Not lit
Non-detection mode
Y1 = 24 VDC
Lit
Manual reset mode
T33 = 24 VDC
Not lit
Auto reset mode
T32 = 24 VDC
Lit
Enable logical AND input
“AND”
Not lit
Disable logical AND input
“OFF”
Flexible Safety Unit
Fault Detection
When the G9SX detects a fault, the ERR indicator and/or other indicators light up or blink to inform the user about the fault.
Check and take necessary measures referring to the following table, and then re-supply power to the G9SX.
(Advanced Unit/Basic Unit)
ERR
Other
indicator indicator
--Blinks
Fault
Fault involved with safety
input 1
1) Failure involving the wiring of safety
1) Check the wiring to T11 and T12.
input 1
2) Check the wiring to Y1.
2) Incorrect setting of cross fault detection 3) Replace with a new product.
input
3) Failure of the circuit of safety input 1
Fault involved with safety
input 2
1) Check the wiring to T21 and T22.
1) Failure involving the wiring of safety
input 2
2) Check the wiring to Y1.
2) Incorrect setting of cross fault detection 3) Replace with a new product.
input
3) Failure of circuits of safety input 2
Faults involved with
feedback/reset input
1) Failures involving the wiring of feedback/ 1) Check the wiring to T31, T32 and T33.
reset input.
2) Replace with a new product.
2) Failures of the circuit of feedback/reset
input
Fault in Expansion Unit
1) Improper feedback signals from
Expansion Unit
2) Abnormal supply voltage to Expansion
Unit
3) Failure of the circuit of safety relay
contact outputs
1) Check the connecting cable of Expansion Unit
and the connection of the termination socket.
2) Check the supply voltage to Expansion Unit.
Note: Make sure that all Expansion units' PWR
indicators are lit.
3) Replace the Expansion Unit with a new one.
Fault involved with
instantaneous safety
outputs or logical
connection outputs or
auxiliary monitor output
1) Failure involving the wiring of
instantaneous safety outputs
2) Failure of the circuit of Instantaneous
safety outputs
3) Failure involving the wiring of the logical
connection output
4) Failure of the circuit of the logical
connection output
5) Failure involving the wiring of the
auxiliary monitor output
6) Impermissible high ambient
temperature
1)
2)
3)
4)
5)
6)
Fault involved with OFFdelayed safety outputs
1) Failure involving the wiring of OFFdelayed safety relay contact outputs
2) Incorrect set values for OFF-delay time
3) Failure of the circuit of OFF-delayed
safety relay contact outputs
4) Impermissible high ambient
temperature
1) Check the wiring to S44 and S54
2) Confirm the set values of the two OFF-delay
time preset switches.
3) Replace with a new product.
4) Check the ambient temperature and spacing
around the G9SX.
Fault involved with logical
AND connection input
1) Failure involving the wiring of the logical 1) Check the wiring to T41 and T42
AND connection input
Note: Make sure that the wiring length for the
2) Incorrect setting for the logical AND
T41 or T42 terminal is less than 100
connection input
meters.
3) Failure of the circuit of the logical AND Note: Make sure that the logical AND connection
connection input
signal is branched for less than 4 units.
2) Confirm the set value of the logical AND
connection preset switch.
3) Replace with a new product.
T2 blinks
FB blinks
Lights up EI blinks
ED blinks
All
indicators
except PWR
blink
G9SX
Check points and measures to take
Fault due to electro1) Excessive electro-magnetic disturbance 1) Check the disturbance level around the G9SX
magnetic disturbance or of 2) Failure of the internal circuit
and the related system.
internal circuits.
2) Replace with a new product.
T1 blinks
AND blinks
Expected causes of the fault
Supply voltage outside the 1) Supply voltage outside the rated value
rated value
Check the wiring to S14, S24, and S34.
Replace with a new product.
Check the wiring to L1 and L2.
Replace with a new product.
Check the wiring to X1.
Check the ambient temperature and spacing
around the G9SX.
1) Check the supply voltage to Expansion Units.
13
When indicators other than the ERR indicator blink, check and take necessary actions referring to the following table.
ERR
Other
indicator indicators
T1
Off
T2
Fault
Expected cause of the fault
Mismatch between input 1 The input status between input 1 and input
and input 2.
2 is different, due to contact failure or a
short circuit of safety input device(s) or a
wiring fault.
Blink
Check points and measures to take
Check the wiring from safety input devices to the
G9SX. Or check the input sequence of safety
input devices. After removing the fault, turn both
safety inputs to the OFF state.
(Expansion Unit)
ERR
Other
indicator indicators
--Light up
14
Fault
Expected cause of the faults
Fault involved with safety 1) Welding of relay contacts
relay outputs of Expansion 2) Failure of the internal circuit
Units
Check points and measures to take
Replace with a new product.
Flexible Safety Unit
Precautions
Precautions for Correct Use
• DC supply satisfies the requirement for class 2 circuits or limited
voltage/current circuit stated in UL 508.
!WARNING
Serious injury may possibly occur due to breakdown of
safety outputs.
Do not connect loads beyond the rated value to the safety
outputs.
Serious injury may possibly occur due to loss of required
safety functions.
Wire G9SX properly so that supply voltages or voltages
for loads do NOT touch the safety inputs accidentally or
unintentionally.
Serious injury may possibly occur due to damages of
safety inputs.
Apply protection circuitry against back electromotive
force in case connecting inductive loads to safety outputs.
Serious injury may possibly occur due to loss of safety
functions. Use devices appropriate for the application and
the condition where G9SX is used.
Control Devices
Requirements
Emergency stop switch
Use approved devices with Direct
Opening
Mechanism complying with IEC/EN
60947-5-1
Door interlocking switch
Limit switch
Use approved devices with Direct
Opening
Mechanism complying with IEC/EN
60947-5-1 and capable of switching
micro loads of 24VDC, 5mA.
Safety Sensor
Use approved devices complying with
the relevant product standards,
regulations and rules in the country
where it is used.
Consult a certification body to assess
that the entire system satisfies the
required safety category level.
Relay with forcibly guided
contacts
Use approved devices with forcibly
guided contacts complying with EN
50205. For feedback purpose use
devices with contacts capable of
switching micro loads of 24VDC, 5mA.
Contactor
Use contactors with forcibly guided
mechanism to input the signal to
Feedback/Reset input of G9SX through
the NC contact of the contactor. For
feedback purpose use devices with
contacts capable of switching micro
loads of 24VDC, 5mA. Failure to open
contacts of a contactor cannot be
detected by monitoring its auxiliary NC
contact without forcibly guided
mechanism.
Other devices
Evaluate whether devices used are
appropriate to satisfy the requirements
of safety category level.
Precautions for Safe Use
1. Use G9SX within an enclosure with IP54 protection or higher of
IEC/EN60529.
2. Incorrect wiring may lead to loss of safety function. Wire
conductors correctly and verify the operation of G9SX before
commissioning the system in which G9SX is incorporated.
3. Do not apply DC voltages exceeding the rated voltages, or any
AC voltages to the G9SX power supply input.
4. Use DC supply satisfying requirements below to prevent electric
shock.
• DC power supply with double or reinforced insulation, for
example, according to IED/EN60950 or EN50178 or a
transformer according to IEC/EN61558.
G9SX
5. Apply properly specified voltages to G9SX inputs.
Applying inappropriate voltages cause G9SX to fail to perform its
specified function, which leads to the loss of safety functions or
damages to G9SX
6. Auxiliary error outputs and auxiliary monitoring outputs are NOT
safety outputs. Do not use auxiliary outputs as any safety output.
Such incorrect use causes loss of safety function of G9SX and its
relevant system.
Also Logical connection outputs can only be used for logical
connections between G9SXs.
7. After installation of G9SX, qualified personnel should confirm the
installation, and should conduct test operations and maintenance.
The qualified personnel should be qualified and authorized to
secure the safety on each phases of design, installation, running,
maintenance and disposal of system.
8. A person in charge, who is familiar to the machine in which G9SX
is to be installed, should conduct and verify the installation.
9. Turn OFF the signal to Safety input or Logical AND connection
input every 24hours and make sure G9SX operates without faults
by checking the state of the ERR indicator.
10.Do not dismantle, repair, or modify G9SX. It may lead to loss of its
safety functions.
11.Use only appropriate components or devices complying with
relevant safety standards corresponding to the required level of
safety categories.
Conformity to requirements of safety category is determined as
an entire system.
It is recommended to consult a certification body regarding
assessment of conformity to the required safety level.
12.OMRON shall not be responsible for conformity with any safety
standards regarding to customer's entire system.
13.Disconnect G9SX from power supply when wiring, to prevent
electric shock or unexpected operation.
14.Be cautious not to have your fingers caught when attaching
terminal sockets to the plugs on G9SX.
15.The lifetime of G9SX depends on the conditions of switching of its
outputs. Be sure to conduct its test operation under actual
operating conditions in advance and use it within appropriate
switching cycles
16.Do not use in combustible gases or explosive gases. Arcs or heat
generated by switching elements of G9SX can lead to fire or
explosion.
Precautions for Correct Use
1. Handle with care
Do not drop G9SX to the ground or expose to excessive vibration
or mechanical shocks. G9SX may be damaged and may not
function properly.
2. Conditions of storage
Do not store in such conditions stated below.
a. In direct sunlight
b. At ambient temperatures out of the range of 10 to 55 C.
c. At relative humidity out of the range of 25% to 85% or under
such temperature change that causes condensation.
d. In corrosive or combustible gases
e. With vibration or mechanical shocks out of the rated values.
f. Under splashing of water, oil, chemicals
g. In the atmosphere containing dust, saline or metal powder.
G9SX may be damaged and may not function properly.
3. Mounting
Mount G9SX to DIN rails with attachments (TYPE PFP-M, not
incorporated to this product), not to drop out of rails by vibration
etc. especially when the length of DIN railing is short compared to
the widths of G9SX.
15
4. Following spacing around G9SX should be available to apply
rated current to outputs of G9SX and for enough ventilation and
wiring:
a. At least 25 mm beside side faces of the Advanced Unit (G9SXAD322-@-@) and side faces of the Basic Unit (G9SX-BC202@).
b. At least 50 mm above top face of G9SX and below bottom face
of G9SX.
50 mm min.
T31 T32 T33
T11 T12 X1
Y1
A1
G9SX-BC202
T31
T11
T32
T12
T33
Y1
PWR
PWB
T1
FB
T1
T2
EI
ERR
EI
No.
X2
L1
X2
23
33
43
13
23
33
43
A1
G9SX-EX
24VDC
G9SX-EX
24VDC
PWR
PWR
T2
ED
ED
AND
0.7
0.6
0.5
0.4
0.3
0.2
T21 T22
S14 S24
13
X1
FB
G9SX-AD322-T15
1 1.5 2
0 15
ED
3
4
5
7
10
ERR
25 mm min.
T21
S14
T22
S24
S34
No.
No.
OFF-DELAY
A2
L2
T41
S44
T42
S54
A2
L1
14
A1
24
X2
34
No.
A2
44
14
A1
24
X2
34
A2
44
25 mm min.
50 mm min.
5. Wiring
a. For model G9SX-@-RT (with screw terminals)
• Use the following to wire to G9SX-@-RT.
Solid wire
0.2 to 2.5mm2 AWG24 to AWG12
Stranded wire
(Flexible wire)
0.2 to 2.5mm2 AWG24 to AWG12
• Tighten each screw with a specified torque of 0.5 to 0.6Nm,
or the G9SX may malfunction or generate heat.
• Strip the cover of wire no longer than 7mm.
b. For model G9SX-@-RC (with spring-cage terminals)
• Use the following to wire to G9SX-@-RC
Solid wire
0.2 to 2.5mm2 AWG24 to AWG12
Stranded wire
0.34 to 1.5mm2 AWG22 toAWG16
• It is recommended that stranded wire should be terminated
with insulation-covered bar terminal (DIN 46228-4 standard
compatible type) at its ends before using for connection.
6. When connecting Expansion Units (G9SX-EX@-@) to Advanced
Unit (G9SX-AD322-@-@):
a. Follow the procedure below:
• Remove the termination connector from the receptacle on
Advanced Unit (G9SX-AD322-@-@),
• Insert the head of the connecting cable of Expansion Unit to
the receptacle on the Advanced Unit
• Set the termination connector to the receptacle on the
Expansion Unit at the end position. When Advanced Unit is
used without expansion units, leave the termination connector
set on the Advanced Unit.
b. Do not remove the termination connector or the connecting
cable of the Expansion Unit while the system is operating.
c. Before applying supply voltage, confirm that the connecting
sockets and plugs are locked firmly.
d. All of the Expansion Units should be supplied with its specified
voltages within 10s after the connected Advanced Unit is
supplied with voltage.
Otherwise, Advanced Unit detects the power-supply error for
the Expansion Units.
7. Use cables with length less than 100m to connect to Safety
Inputs, Feed-back/Reset inputs, or between Logical AND
connection inputs and Logical connection outputs, respectively.
8. Set the time duration of OFF-delay to an appropriate value that
does not cause the loss of safety function of system.
9. Logical connection between Units:
a. When using Logical AND connection inputs, set the Logical
connection preset switch to 'AND' position for the units which
the logical connection signal are input to.
16
b. Connect Logical connection outputs appropriately to Logical
AND connection inputs of the relevant unit. Verify the operation
of G9SX before commissioning the system.
c. When configuring the safety related system, be sure to
consider that the delay of response time caused by logical
connections do not degrade the safety function of the system.
10.To determine safety distance to hazards, take into account the
delay of Safety outputs caused by the following time:
a. Response time of Safety inputs
b. Response time of Logical AND connection input
(See also "Ratings and specifications, note 5”)
c. Preset off-delay time
d. Accuracy of off-delay time
11.Start entire system after more than 5s have passed since
applying supply voltage to all G9SXs in the system.
12.G9SX may malfunction due to electro-magnetic disturbances. Be
sure to connect the terminal A2 to ground. To suppress electrical
noise, apply a surge absorber to the coil of inductive load.
13.Devices connected to G9SX may operate unexpectedly. When
replacing G9SX, disconnect it from power supply.
14.Adhesion of solvent such as alcohol, thinner, trichloroethane or
gasoline on the product should be avoided. Such solvents make
the marking on G9SX illegible and cause deterioration of parts.
15.Do NOT mix AC load and DC load to be switched in one G9SXEX@-@. When switching of both AC load and DC load is
necessary, connect more than two G9SX-EX@-@ and use each
unit for AC load and DC load exclusively.
Category of EN 954-1
In the condition shown in Application Examples, G9SX can be used
for the corresponding categories up to category 4.
This does NOT mean that G9SX can always be used for required
category under all the similar conditions and situations.
Conformity to the categories must be assessed as a whole system.
When using G9SX for safety categories, be sure to confirm the
conformity as a whole system.
1. Input the signals to both of the Safety inputs (T11-T12 and T21T22)
2. Input a signal to the Safety inputs (T11-T12 and T21-T22) through
switches with Direct Opening Mechanism.
When using limit switches, at least one of them must have Direct
Opening Mechanism.
3. When connecting Safety sensor with G9SX, use TYPE 4 safety
sensor.
4. Input the signal through a NC contact of the contactor to
Feedback/Reset input (T31-T32 for manual reset or T31-T33 for
auto reset).(Refer to Application Examples)
5. Keep Cross fault detection mode input (Y1) open. However, when
connecting devices with self-diagnosis function, such as safety
sensors, apply 24VDC to Y1.
6. Be sure to Connect A2 to ground.
7. When using a G9SX-EX-@-@ Expansion Unit, connect fuses with
a current rating of 3.15 A max. to the safety relay outputs to
prevent the contacts from welding.
Compliance with International Standards
G9SX-AD-@/G9SX-BC-@/G9SX-EX-@
• Approved by TÜV Product Service
EN50178
IEC/EN60204-1
EN954-1 Cat.4
IEC/EN61508 SIL3
IEC/EN61000-6-2
IEC/EN61000-6-4
• Approved by UL
UL508
UL1998
NFPA79
IEC61508
• Approved by CSA
CAN/CSA C22.2 No.142
Flexible Safety Unit
Application Examples
G9SX-AD322-T15 (24 VDC) (1-channel Emergency Stop Switch Input / Manual Reset)
Feedback Loop
KM1
+24 V
11
KM2
Motor controller
S34
S2
KM3
12
KM1
KM3
KM2
KM4
S1
KM4
Timing chart
+24 V
NC
NC
NC
A1 T11 T12 T21 T22 T31 T32 T33 Y1
NC
AN D
T41 T42
M1
M2
Emergency stop switch S1
OFF
Reset switch S2
G9SX-AD322-T15
KM1, KM2 N.C. contact
+24 V
Control circuit
KM3, KM4 N.C. contact
KM1, KM2 N.O. contact
A2
S14 S24 S34 S44 S54 L1 X1 X2
KM1 KM2
KM3 KM4
KM3, KM4 N.O. contact
PLC etc.
Operation command
Rotation of motor
GND
Motor controller
(Operation command)
OFF-delay time
S1: Emergency stop switch
S2: Reset switch S2
KM1 to KM4: Contactor
M1, M2: 3-phase motor
Note: This example corresponds to category 2 (EN 954-1)
G9SX-AD322-T15 (24 VDC) (2-channel Safety Sensor / Auto Reset)
Emitter
F3SN-A
Feedback Loop
Receiver
KM1
KM2
Motor controller
S34
GND
NC
OSSD2
OSSD1
KM3
KM1
KM3
KM2
KM4
KM4
+24 V
+24 V
NC
NC
A1 T11 T12 T21 T22 T31 T32 T33 Y1
G9SX-AD322-T15
NC
T41 T42
Timing chart
AND
OFF
M1
M2
Safety sensor outputs
+24 V
KM1, KM2 N.C. contact
Control circuit
KM3, KM4 N.C. contact
KM1, KM2 N.O. contact
A2
S14 S24 S34 S44 S54 L1 X1 X2
KM1 KM2
KM3 KM4
PLC etc.
KM3, KM4 N.O. contact
Operation command
Rotation of motor
GND
Motor controller
(Operation command)
Off-delay time
F3SN-A: Safety sensor
KM1 to KM4: Contactor
M1, M2: 3-phase motor
Note: 1. This example corresponds to category 4 (EN 954-1)
2. For further information of settings and wiring, refer to the catalog or instruction manual of the connected sensor.
3. Use safety sensors with PNP outputs.
G9SX
17
G9SX-BC202 (24 VDC) (2-channel Emergency Stop Switch Input / Manual Reset) +
G9SX-AD322-T15 (24 VDC) (2-channel Safety Limit Switch Input / Auto Reset)
Feedback Loop
11
21
12
22
KM1
KM2
S1
KM 1
S2
+24 V
KM2
NC
A1 T11 T12 T21 T22 T31 T32 T33 Y1
M1
G9SX-BC202
+24 V
S1: Emergency Stop Switch
Control circuit
S2: Reset Switch
KM1, KM2: Contactor
A2
S14 S24
L1 L2
M1: 3-phase motor
X1 X2
KM1 KM2
PLC etc.
GND
23
Feedback Loop
S4
24
Motor controller
S34
KM3
11
S3
KM3
KM5
KM 4
KM6
KM4
12
KM5
KM6
open
+24
M2
M3
+24 V
NC
A1 T11 T12 T21 T22 T31 T32 T33 Y1
AND
T41 T42
OFF
G9SX-AD322-T15
Timing chart
(2)
G9SX-BC202 (upper unit)
Emergency stop switch S1
Control circuit
Reset switch S2
KM1, KM2 N.C. contact
A2
S14 S24 S34 S44 S54 L1 X1 X2
KM3 KM4
KM5 KM6
PLC etc.
KM1, KM2 N.O. contact
Logical AND output L1
(1)
G9SX-AD322-T15 (lower unit)
GND
Motor controller
(Operation command)
Logical AND input T41
S3: Safety limit switch
S4: Limit switch
Safety limit switch S3
Limit switch S4
KM3 to KM6: Contactor
M2, M3: 3-phase motor
KM3, KM4 N.C. contact
KM5, KM6 N.C. contact
KM3, KM4 N.O. contact
Note: This example corresponds to category 4 (EN 954-1).
KM5, KM6 N.O. contact
Operation command
Rotation of motor
OFF-delay time
OFF-delay time
(1) Door opened: Only the lower Unit stops
(2) Emergency stop button pressed: Both the upper and lower Unit stop
18
Flexible Safety Unit
G9SX-AD322-T15 (24 VDC) + G9SX-EX041-T (24 VDC)
(Guard Lock Safety Door Switch (Mechanical Lock), 2-channel Safety Limit Switch Inputs / Manual Reset)
Lock release signal
(See note 2.)
Guard
Motor controller
Stop signal
S34
KM1
KM3
KM5
KM2
KM4
KM6
Feedback Loop
M1
KM1
M3
M2
(See note 2.)
S3
KM2
KM6
+24 V
+24 V
NC
A1 T11 T12 T21 T22 T31 T32 T33 Y1
G9SX-AD322-T15
+24 V
Control circuit
NC
NC
T41 T42
AND
OFF
A1
13 23 33 43
G9SX-EX041-T
Control
circuit
K1
K2
A2
S14 S24 S34 S44 S54 L1 X1 X2
KM1 KM2
GND
G9SX
KM3 KM4
PLC etc.
A2
X2
14 24 34 44
KM5
KM6
Motor controller
(Operation command)
19
Warranty and Application Considerations
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 the 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 products.
Take all necessary steps to determine the suitability of the product for the systems, machines, and equipment with which it will
be used.
Know and observe all prohibitions of use applicable to this product.
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
PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR
SYSTEM.
Disclaimers
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.
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other reasons. 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.
ALL DIMENSIONS SHOWN ARE IN MILLIMETERS.
To convert millimeters into inches, multiply by 0.03937. To convert grams into ounces, multiply by 0.03527.
Cat. No. J150-E2-01
In the interest of product improvement, specifications are subject to change without notice.
OMRON EUROPE B.V.
Wegalaan 67-69,
NL-2132 JD, Hoofddorp,
The Netherlands
Phone: +31 23 568 13 00
Fax: +31 23 568 13 88
www.eu.omron.com
20
Flexible Safety Unit
