ASO Safety Solutions ELMON relay 42-622 Owner's manual

ELMON relay 42-622

Betriebsanleitung

ELMON relay 42-622 Sicherheitsschaltgerät

Operang Manual

ELMON relay 42-622 Safety Relais

Manuel d´ulisaon

ELMON relay 42-622 Relais de sécurité

DeutschEnglishFrançais

Seite 3-18

Page 19-34

Page 35-50

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20

1 General informaon

ELMON relay 42-622

Version 1.0

ASO GmbH

Antriebs- und Steuerungstechnik

Hansastraße 52

59557 Lippstadt

All previous versions lose their validity with this version.

The informaon in this document can be changed without previous nocaon.

This operang manual is specically intended for the er of the safety relay ELMON relay 42-622.

The start-up of the control system may only be done by electricians with recognized training who are

familiar with the safety standards of electrical drive and automaon technology.

The safety instrucons must be adhered to uncondionally!

1.1 Symbol explanaon

Careful! The following safety instrucons must be followed strictly to prevent personal injuries.

Warning! The following safety instrucons must be observed uncondionally to prevent

property damage.

Informaon! Addional informaon or a reference to other documentaon is provided here.

1.2 Terminology, denions and abbreviaons

AC .......................... Alternang Current

DC ......................... Direct Current

EMC ....................... Electromagnec compability

EN .......................... European Standard

IP ............................ Protecon type against foreign objects and water (intrusion protecon)

OUT ........................ Safety relay output

AUX ........................ Auxiliary contact

!

STOP

i

ELMON relay 42-622

Safety Relay

21

2 General safety regulaons and protecon measures

• The manufacturer and user of the system/machine on which the protecon system is used are

responsible for coordinang and adhering to all applicable safety rules and regulaons under their

own responsibility.

• The protecon system guarantees funconal safety in combinaon with the superordinate control

system, but not the safety of the enre system/machine. Thus, a safety review of the enre system/

machine in accordance with machine direcve 2006/42/EC or relevant product standards is

necessary prior to use of the device.

• The operang instrucons must be permanently available at the operang locaon of the protecon

device. They must be thoroughly read and applied by every person who is tasked with the operaon,

maintenance or repair of the protecon device.

• The installaon and start-up of the protecon device may only be conducted by specialized personnel

who are familiar with these operang instrucons and the applicable regulaons on job safety and

accident prevenon. The instrucons in these operang instrucons must be followed and adhered

to uncondionally.

• Electrical work may only be carried out by skilled electricians. Safety regulaons for electrical

engineering and from the professional associaon must be followed.

• In case work has to be carried out on the switching device, it must be switched to a voltage-free

posion and checked for freedom from any voltage and secured against being switched back on

again.

• If the potenal-free connecons of the safety switching contacts are supplied with a hazardous

voltage from an external source, it must be ensured that these are also switched o when working

on the switching device.

• The switching device does not contain any components that the user must service. Any warranty or

liability on the part of the manufacturer is forfeited in the event of any unauthorized modicaons or

repairs to the switching device.

• Auxiliary outputs must not execute any safety-orientated funcons. They are not fail-safe and are not

checked either by tesng.

The system must be checked for correct funcon in suitable intervals by qualied persons for

the standard-conform design of the safety system. The check must be documented in a way that

allows it to be traced at any me.

In the case of non-compliance or deliberate abuse, the manufacturer’s liability will

cease.

!

22

3 Intended use

The switching device can only fulll its safety-relevant task, if it is used as intended within

specicaons.

The intended use of the switching device is the use as a protecon system in connecon with safety

contact mats, safety bumpers and safety contact edges with 8.2 kΩ resistance for steady-state

current monitoring.

It is not allowed to use the safety relay in heights over 2000 m above sea level or potenally

explosive atmospheres.

A dierent use or any use going beyond the intended use is not within specicaons. The manufac-

turer does not accept any liability for any damage arising from use not within specicaons.

Any use for special applicaons requires prior release by the manufacturer.

4 General and funcon descripon

The ELMON relay 42-622 switching device is used to evaluate sensors such as safety contact mats,

safety contact edges and safety bumpers for securing crush and shear locaons.

Two ASO sensors can be connected to the switching device. The steady-state current monitoring of

the sensors is made possible by an integrated terminang resistor in the sensors.

If the desired steady-state current ows, the safety relays are driven and the switching contacts

closed. If the sensor is operated or the sensor circuit is interrupted, the relay switching contacts

open.

Two signal outputs with potenal-free switching contacts are available. An operaon of the sensors

causes a reacon of the signal outputs in accordance with the conguraon. The signal outputs must

not execute any safety-orientated funcons. They are not fail-safe and not checked by tesng either.

The switching device has been designed in accordance with EN ISO 13849-1 “Safety-related parts

of control systems” for category 3 performance level e. For compliance with category 3, the safety

outputs are set up redundantly with two independent switching elements. The switching device can

reach performance level d in conjuncon with ASO sensors.

In addion the device has been designed in accordance with EN 62061 “Funconal safety of safe-

ty-related electrical, electronic and programmable electronic control systems“. The switching device

can meet a safety funcon up to SIL 2 in conjuncon with ASO sensors.

The monitoring state of the sensors and the applied operang voltage are indicated by LED.

If there is a fault alarm, all safety outputs are inacve.

The unit can be used in an industrial environment up to an altude of 2000m above mean sea

level. The unit must not be operated in areas with major temperature changes.

!

ELMON relay 42-622

Safety Relay

23

4.1 Block diagram

Simplied representaon of the internal structure and funcons

Block diagram

24

5 Technical data

General informaon

Housing

Polyamide PA 6.6 Self-exnguishing

according to UL 94-V2

Dimensions (HxWxD) 114 x 45 x 99 mm

Protecon type IP 20

Protecon class ll (protecve insulaon)

Polluon Degree 2

Overvoltage category lll

Rated insulaon voltage 250 V

Rated impulse voltage resistance 4,00 kV

Weight 286 g

Temperature range single mounng -20 °C to +55 °C

Temperature range mounng in row max. 35 °C

Connecon cable cross-secon single- or

ne-stranded cable

0,75 - 1,5 mm

2

Temperature class copper conductors 60 / 75 °C

Supply voltage

Mains voltage UNetz 85 - 265 V AC (50 / 60 Hz)

Low voltage UE 24 V AC / DC ± 10 %

Power

consumpon

PNetz_max

120 V AC: 3 VA

230 V AC: 4 VA

PE_max 24 V DC: 1,3 W (1,2 VA)

Back-up fuse

(external)

200 mA middle me-lag fuse

(glass tube 5x20)

Safety relay

Nominal current DC 2 A (24 V)

Nominal current AC 2 A (230 V)

Mechanical service life > 10

6

operaons

Switch-o delay (reacon me) < 11 ms

Switch-on delay 500 ms (Power on < 850 ms)

Ulizaon category

AC-15 (230 V AC; 2 A)

DC-13 (30 V DC; 2 A)

Protecon

2A middle me-lag fuse

(glass tube 5x20)

ELMON relay 42-622

Safety Relay

25

Signal relay

Max. switching current 2 A (230 V AC / 30 V DC)

Mechanical service life > 10

6

operaons

Operang mode RL: Switch-on delay 0,5 sec.

Operang mode RL: Switch-on duraon 3 sec.

Terminang resistor – sensor

Nominal value RNom = 8,2 kΩ

Upper switching value RAO > 12,0 kΩ

Lower switching value RAU < 5,0 kΩ

Cercaons

Overall system

(Sensors + Electronics +

Electromechanics)

EN ISO 13849-1:2015 Category 3 PL d

(MTTFD 80 years, DC 95 %)

EN 62061:2015 SILCL 2

(PFHd 6,40E-07 1/h)

ELMON relay 42-622 EN ISO 13849-1:2015 Category 3 PL e

Electronics MTTFD 545 years, DC 99 %

Electromechanics

output switching device (Relais)

B10D 2.000.000

MTTFD 190 years, DC 99 % (Nop 52.560)

Sensor

(SENTIR mat)

B10D 2.000.000

MTTFD 190 years, DC 90 % (Nop 52.560)

99 mm

45 mm

114 mm

26

6 Device overview

6.1 LED-Signal indicators

The switching device has 5 LED´s for status and error display.

LED Indicator Meaning

Power (green)

o No supply voltage

on Supply voltage applied (ready for operaon)

pulse See table Error messages

CH 1 (red)

o Sensor 1 not actuated

on Sensor 1 actuated

fast ashing Sensor circuit 1 interrupted

slow ashing Restart interlock Sensor circuit 1

CH 2 (red)

o Sensor 2 not actuated

on Sensor 2 actuated

fast ashing Sensor circuit 2 interrupted

slow ashing Restart interlock Sensor circuit 2

AUX 1

(orange)

o Signal output Sensor circuit 1 not acve

on

Signal output Sensor circuit 1 acve =

permanent contact

AUX 2

(orange)

o Signal output Sensor circuit 2 not acve

on

Signal output Sensor circuit 2 acve =

permanent contact

6.2 Connecon terminals

Delivery condion overview (installaon posion)

S1 S2 S3 S4 1.13 1.14 1.23 1.24

X1 X2 Y1 Y2 1.33 1.34

Z1 Z2 2.33 2.34

B1 B2 A1 A2 2.13 2.14 2.23 2.24

Power

CH 1

CH 2

AUX 1

AUX 2

Top

Boom

ELMON relay 42-622

Safety Relay

27

Clamp Funcon

A1 + A2 Supply voltage 85 - 265 V AC

B1 + B2 Supply voltage 24 V AC / DC

X1 + X2 Connecon sensor 1

Y1 + Y2 Connecon sensor 2

1.13 + 1.14 Contacts safety relay 1

Safety circuit sensor 1

1.23 + 1.24 Contacts safety relay 2

2.13 + 2.14 Contacts safety relay 1

Safety circuit sensor 2

2.23 + 2.24 Contacts safety relay 2

1.33 + 1.34 Contacts signal relay safety circuit sensor 1

2.33 + 2.34 Contacts signal relay safety circuit sensor 2

Z1 + Z2 Manual reset (re-start) - Buon NO

S1 + S2 Coding input reset mode (automac / manuell)

S3 + S4 Coding input funcon signal relay (RL / RLU)

7 Mechanical mounng

The switching unit must be mounted correctly:

• On a 35 mm DIN support rail according to EN 50 022.

• In a dust-protected and moisture-protected switch cabinet or casing.

− For use in an environment with level 2 contaminaon.

− With a protecon type of at least IP54.

The switching unit can be installed in any posion.

The unit must not be operated in areas with major temperature changes.

8 Electrical connecon

The switching unit can be destroyed by connecon to the incorrect terminals.

Lines that are routed in the open air or outside the switch cabinet must be protected

accordingly.

The limit values stated in the “Technical Data” for the supply voltage and the switching capabi-

lity of the relay must be observed.

8.1 Supply voltage

The supply voltage can oponally be eected by means of a mains voltage of 85 - 265 V AC

(50/60Hz) or a low voltage of 24 V AC/DC. For a supply with 24 V AC/DC the voltage must corre-

spond to the requirements for protecve low voltages (SELV). The supply line to the switching

device must be protected by means of a 5x20 glass tube fuse 200mA medium me lag.

Never apply both voltages simultaneously!

!

28

The 85 - 265 V supply voltage must be applied to the A1 + A2 terminals. For operaon with 24 V, the

supply voltage must be applied to the B1 + B2 terminals.

For a xed installaon a separang device must be available (for example, a main switch for the

system). A mains plug is sucient as a separang device, if it is freely accessible.

Z1 Z2 2.33 2.34

B1 B2 A1 A2 2.13 2.14 2.23 2.24

Z1 Z2 2.33 2.34

B1 B2 A1 A2 2.13 2.14 2.23 2.24

8.2 Connecon of sensor

The sensor with a terminang resistor of 8.2 kΩ must be connected to the X1 + X2 and/or Y1 + Y2

terminals. If a channel is not used, it must be assigned an 8.2 kΩ resistor (included in delivery).

S1 S2 S3 S4 1.13 1.14 1.23 1.24

X1 X2 Y1 Y2 1.33 1.34

8.3 Connecon of several sensors per sensor circuit

ASO-Sensors must not be connected in parallel.

One or several sensors can be connected to the sensor inputs. For this purpose, the individual

sensors are connected in series.

CH 1 CH 2

!

85 - 265 V AC (50 / 60 Hz)

24 V AC / DC (± 10 %)

S1 S2 S3 S4 1.13 1.14 1.23 1.24

X1 X2 Y1 Y2 1.33 1.34

Sensor 1 Sensor 2 Sensor „n“

2 2 2

CH 1 CH 2

ELMON relay 42-622

Safety Relay

29

Safety contact edge SENTIR edge:

A maximum of 5 SENTIR edge devices can be connected in series. The maximum total length of the

SENTIR edge must not exceed 100 m.

The length of a SENTIR edge can be up to 25 m.

The total line length of the series-connected SENTIR edge must not exceed 25 m.

Safety contact bumper SENTIR bumper:

A maximum of 5 SENTIR bumper devices can be connected in series. The maximum total length of

the SENTIR bumpers must not exceed 15 m.

The length of a SENTIR bumper may be up to 3 m.

The total line length of the series-connected SENTIR bumpers must not exceed 25 m.

Safety contact mat SENTIR mat:

A maximum of 10 SENTIR mats can be connected in series. The maximum total surface area must not

exceed 10 m².

The total line length of the series-connected SENTIR mat must not exceed 25 m.

Before connecng the series-connected sensors, it is recommended to measure the resistance value

of the wiring. In the case of non-operated sensors the resistance must be 8.2 kΩ ± 500 Ω. If the

sensor is operated, the resistance must not exceed 500 Ω.

8.4 Connecon of control circuits

The outputs of the redundant relays are separately led out.

Connect the control circuit to be monitored to the 1.13 + 1.24 and/or 2.13 + 2.24 terminals. If the

switching contacts are redundantly connued, the factory-inserted bridge between the 1.14 + 1.23

and/or 2.14 + 2.23 terminals must be removed.

In the event of any separate use of the switching contacts only voltages with the same potenal

may be connected (same safety funcon). The use of dierent voltage potenals does not

correspond to the intended use.

Depending on the nominal current, the control circuits are to be protected by a corresponding fuse,

or the nominal current on the control circuits must be limited to the maximum switching current by

other measures.

!

S1 S2 S3 S4 1.13 1.14 1.23 1.24

X1 X2 Y1 Y2 1.33 1.34

Z1 Z2 2.33 2.34

B1 B2 A1 A2 2.13 2.14 2.23 2.24

Input SPS

K1

K2

Channel 1

Channel 2

K1

K2

L1 L2 L3

M

30

8.5 Connecon Reset

There are two operang modes for the reset funcon, automac and manual.

The manual reset is acvated on delivery condion.

-> Manual release of the outputs aer eliminaon of a fault!

For the „automac reset“ operang mode, a bridge must be inserted between the clamps S1 + S2.

S1 S2 S3 S4 1.13 1.14 1.23 1.24

X1 X2 Y1 Y2 1.33 1.34

For the „manual reset“ operang mode, a bridge S1 + S2 must be removed (factory seng) and the

reset buon (normaly open) must be connected to the clamps Z1 + Z2.

Z1 Z2 2.33 2.34

B1 B2 A1 A2 2.13 2.14 2.23 2.24

8.6 Connecon of signaling contact

The 1.33 + 1.34 and 2.33 + 2.34 signaling contacts only serve as auxiliary contacts (signaling, display

etc.) and must not be integrated into the safety circuit.

Extra Low voltages (24 V) and low voltages (230 V) may be switched with the signal contacts

(mixed operaon permied).

Buon „Release“

!

S1 S2 S3 S4 1.13 1.14 1.23 1.24

X1 X2 Y1 Y2 1.33 1.34

Z1 Z2 2.33 2.34

B1 B2 A1 A2 2.13 2.14 2.23 2.24

+ 24 V

0 V

CH 1

CH 2

!

ELMON relay 42-622

Safety Relay

31

9 Commissioning and funcon tesng

All operang modes may only be changed in a de-energized state! Otherwise the switching

device goes into the safe state and signals the faulty conguraon with fault code 7.

Aer the appropriate connecon of all electrical connecons and switching on the supply voltage,

the switching device must be checked for correct funconing.

Aer successful commissioning the safety outputs are controlled (relay contact “closed“). An

operaon of the sensors causes an opening of the relay contacts.

The signalling relays switch according to the state of the safety outputs according to the conguraon

made.

All states are displayed with the help of LED´s (CH 1, CH 2, AUX 1 and AUX 2).

9.1 Operang modes safety outputs

9.1.1 Combined use

On delivery state, the relays of the safety outputs for each channel are connected in series (bridges

1.14 + 1.23 and 2.14 + 2.23).

In this case, the control circuits are connected as follows:

CH1 = 1.13 + 1.24

CH2 = 2.13 + 2.24

9.1.2 Separate use

If the relays of the safety outputs are to be used separately(redundant connuaon of the switching

contacts), the bridges must be removed (1.14 + 1.23 and/or 2.14 + 2.23).

In this case, the control circuits are connected as follows:

CH 1 = 1.13 + 1.14 und 1.23 + 1.24

CH 2 = 2.13 + 2.14 und 2.23 + 2.24

9.2 Operang modes reset

9.2.1 Automac reset

Aer eliminang a fault in a sensor circuit or aer a power failure, the switching device automacally

releases the outputs again.

9.2.2 Manual reset (restart lock)

Aer eliminang a fault in the sensor circuit or aer a power failure, the switching device only

releases the output(s) when contacts Z1 + Z2 are closed with a buon. A permanent bridging of

contacts Z1 + Z2 does not lead to an automac reset. An fault message (fault code 8) is generated if

contacts Z1 + Z2 are bridged for longer than 3s.

9.2.3 Conguraon change reset

If the conguraon is changed during operaon, an fault message is generated (fault code 7).

!

32

9.3 Operaon modes signal output

9.3.1 Signal output undelayed (RLU)

In this operang mode, the corresponding signal output is

acvated undelayed if there is any fault on the corresponding

channel of the sensor. The output is always inacve (contact

open) in the currentless state of the switching device. For

this operang mode, a bridge must be inserted between the

clamps S3 + S4.

9.3.2 Signal output delayed (RL)

In the delivery state, the corresponding signal output is

acvated delayed by 0.5 s and then remains acve for

max. 3 s if an fault is signalled. For this operang mode bridge

S3 + S4 must be removed (factory seng).

10 Fault diagnosis

If the supply voltage is correctly wired and applied, only the green Power LED may be lit up. If the red

LED illuminates, there is a fault in the system which can be delimited by means of the LED.

LED Fault Fault removal

Green LED

Power

does not

light up

Supply voltage is missing, too

low or incorrectly connected

Check connecons and supply voltage:

• 85 - 265 V AC at terminals A1 + A2 or

• 24 V AC / DC at terminals B1 + B2

Tolerance range: ±10%

Green LED

Power

ashes cycli-

cally (Pulse)

Internal fault is indicated by the

number of pulses

See -> signal indicators

Red LED

CH1 / CH2

lights up

The corresponding sensor is

recognized as being operated

- Check the connecons of the corresponding

sensors (squeezed or brile supply lines, etc.)

- Check signal sensor *

Red LED

CH1 / CH2

fast ashing

Sensor circuit interrupted,

sensor not connected, defec-

vely connected or defecve

- Check the connecons of the corresponding

sensors (squeezed or brile supply lines, etc.)

- Check signal sensor *

Red LED

CH1

slow ashing

Restart lock Carry out manual reset

* If the fault is not found in the wiring, the funcon of the electronic system can be checked by

applying a resistance of 8.2 kΩ to the sensor-input on the switching device. Subsequently, if the

electronics work perfectly, the sensor must be checked by means of an ohmmeter. For this purpose,

the connecon of the sensor to the switching device must be separated and connected by means

of an ohmmeter. In the case of a non-operated sensor the resistance must be 8.2 kΩ ± 500 Ω. If the

sensor is operated, the resistance must not exceed 500 Ω.

Output

Aux. Relay

Safety output (symbolic)

Signal output (symbolic)

Safety output (symbolic)

Signal output (symbolic)

Output

Aux. Relay

0,5s 3s

ELMON relay 42-622

Safety Relay

33

10.1 Signal indicators

Corresponding fault messages are indicated by the output of ashing sequences via the green LED.

LED Pulse Meaning

Power

(green)

1x Voltage supply outside the valid value range

3x Output control CH1 faulty

4x Output control CH2 faulty

5x Data transmission between micro-controllers faulty

6x Fault when tesng signal input

7x Fault Change conguraon Reset or signal relay

8x Fault message Handling Reset Input

Note: If an fault message is present, all safety outputs are inacve!

11 Decommissioning and disposal

The products manufactured by ASO are exclusively intended for commercial use (B2B). At the end of

use, the products must be disposed of according to all local, regional and naonal regulaons. ASO is

also happy to take back the products and disposes of them properly.

34

12 EC declaraon of conformity

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Nozen / Notes / Notes

ELMON relay 42-622

52

11.DB.21.001 Betriebsanleitung Rev 00

Technische Änderungen vorbehalten.

Für Irrtümer und Druckfehler kann keine Haung übernommen werden.

Deutsch

Antriebs- und Steuerungstechnik

Hansastraße 52 • D 59557 Lippstadt

Tel.: +49 2941 9793-0 • Fax: +49 2941 9793 299

www.asosafety.de • e-mail: ASO-EU@asosafety.com

11.DB.21.001 Operang Manual Rev 00

Subject to technical modicaons.

No liability can be assumed for errors or misprints.

English

11.DB.21.001 Manuel d’ulisaon Rev 00

Sous réserve de modicaons techniques.

Nous déclinons toute responsabilité en cas d‘erreurs et de fautes d‘impression.

Français

ASO Safety Solutions ELMON relay 42-622 Owner's manual

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