ASO Safety Solutions ELMON rail 34-32 User manual

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1. Contents
1. Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2. General safety regulaons and protecve measures . . . . . 16
3. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. Mechanical mounng . . . . . . . . . . . . . . . . . . . . . . 17
6. Device overview . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1 Signal indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.2 Connecon terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.3 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7. Seng the operang mode via DIP switches. . . . . . . . . . 19
8. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.2 Electrical connecon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3 Connecon of mulple sensors per sensor circuit. . . . . . . . . . . . . . . 21
8.4 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
8.5 Characteriscs of the signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.6 Connecon opons for the test signal . . . . . . . . . . . . . . . . . . . . . 22
8.7 Example of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.8 Funconal test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9. Error diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10. Taking out of service and disposal. . . . . . . . . . . . . . . . 24
11. Technical specicaons. . . . . . . . . . . . . . . . . . . . . . 25
12. EC declaraon of conformity. . . . . . . . . . . . . . . . . . . 26
We reserve the right to make technical and operaonally relevant changes to the pro-
ducts and devices described in this documentaon at any me and without prior noce.
ELMON rail 34-32
Safety Relay
English

16
2. General safety regulaons and protecve measures
• The manufacturer and users of the plant / machine on which the protecon is being used are responsible
for implemenng and following all applicable safety regulaons and rules.
• When used in conjuncon with the higher-order controller, the protecon guarantees funconal safety,
but not the safety of the enre plant / machine. The safety of the enre plant / machine must, therefore,
be assessed in accordance with machinery direcve 2006/42/EC or appropriate product norm before
using the device.
• The operang instrucons must always be available at the place of installaon of the protecon.
They must be read thoroughly and observed by all persons involved in the operaon, maintenance and
servicing of the protecon.
• The protecon must only be installed and commissioned by professionals familiar with these operang
instrucons and the applicable operaonal safety and accident prevenon regulaons. All of the instruc-
ons provided in these operang instrucons must be observed and followed.
All electrical work must only be performed by skilled electricians.
• All relevant electrical engineering and Employer's Liability Insurance Associaon safety regulaons must
be observed.
• During work on the switching unit, it is to be switched to zero potenal, checked to ensure that it is at
zero potenal and protected against being restarted.
• If the potenal-free contacts of the relay outputs are supplied externally with a dangerous voltage, make
certain that these outputs are also switched o during work on the switching unit.
• The switching unit does not contain any components that require servicing by the user.
Unauthorised conversions and repairs made to the switching unit will void all guarantees and the
manufacturer’s liability.
• The protecon system is to be professionally inspected at appropriate intervals and be documented in
such a way that it is comprehensible at all mes.
Safety advice
• The switching unit enables operaon at 230 V or at 24 V. Connecng the operang voltage to the wrong
terminals can destroy the switching unit.
• auxiliary terminal 31, 32 serves only as an auxiliary terminal (display, etc.) and must not be integrated in
the safety circuit.
• The switching unit is to be installed in a switching cabinet.
• Do not install in the immediate vicinity of strong sources of heat.
• For capacive and inducve loads, ensure adequate protecve circuits.
For the design of the safety system to conform to engineer standards acc. to EN
ISO 13849-1:2008 category 2, the safety system must be tested prior to each
dangerous movement of the plant / machine. Without tesng, the operaon or
wiring of the ELMON rail 34-32 safety relay does not sasfy these safety require-
ments.
The manufacturer assumes no liability in the event of non-observance or intenonal
abuse.
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3. General
The ELMON rail 34-32 switching unit, designed with one channel, is used for evaluang safety contact mats and for
safeguarding locaons where there is a risk of crushing and cung through the use of safety contact edges
and safety bumpers (sensors).
Two separate sensor circuits can be connected to the ELMON rail 34-32 switching unit, whereby both act on
one switching output.
The ELMON rail 34-32 switching unit is intended for use on plants/machines that make a test signal available
through a primary controller prior to each dangerous movement and appropriately evaluate the result. In
combinaon with this, the switching unit sases safety category 2 acc. to EN ISO 13849-1:2008 "Safety-
related parts of control systems".
Monitoring of the standby current is made possible by an integrated terminang resistor in the sensor
circuit. If the specied standby current is owing, the output relay is acvated and the switching contact
is closed. If a sensor is actuated or a sensor circuit is interrupted, the relay switching contact opens. The
monitoring state of the sensors and the applied operang voltage are indicated by LEDs.
4. Proper use
The ELMON rail 34-32 switching unit can only full its safety-related task if used properly.
Proper use of the switching unit is the use as protecon in combinaon with safety contact mats, safety
bumpers or safety contact edges.
Any uses above and beyond these uses constute improper use. The manufacturer assumes no liability for
damages arising from improper use.
The device may only be used in special applicaons with the manufacturer’s express consent.
The auxiliary relay contact must not perform any safety funcons!
5. Mechanical mounng
The compact and easy-to-install switching unit is to be professionally mounted on a 35 mm DIN-mounng
rail in a dust- and moisture-protected switching cabinet or housing with a protecon class of at least IP54.
The switching unit may be mounted in any orientaon.
Do not install the switching unit in the immediate vicinity of strong sources of heat.
ELMON rail 34-32
Safety Relay
English

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6. Device overview
6.1 Signal indicators
LED Power green
Supply voltage
LED CH1 yellow/red
Sensor 1 acvated yellow
Sensor circuit 1 interrupted red
LED CH2 yellow/red
Sensor 2 acvated yellow
Sensor circuit 2 interrupted red
LED Tesng orange
Test acve
LED Aux. Relay orange
Auxiliary relay closed
6.2 Connecon terminals
A1 A2 Supply voltage 230 V 50/60 Hz
B1 B2 Supply voltage 24 V AC/DC
X1 X2 Connecon sensor circuit 1
Y1 Y2 Connecon sensor circuit 2
13 14 Safety-relay switching contact
31 32 Auxiliary-relay switching contact
Z1 Z2 Input for manual reset
T1 T2 Input for test signal
6.3 Versions
Version ELMON rail 34-32
Housing, 22.5 mm wide, made of polyamide for 35 mm DIN rail mounng acc. to EN 60715.
Supply voltages 230 V 50/60 Hz and 24 V AC/DC.
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7. Seng the operang mode via DIP switches
Located underneath the opening on the right side of the housing are
six DIP switches. Factory sengs are underlined.
S1 Test while voltage is applied (O)/ missing at T1 T2 (On)
S2 Automac reset (O) / error lock with man. reset (On)
S3 Auxiliary relay funcon: RL (On) / RLU (O)
S4 Auxiliary relay ashes on RLU (On) / does not ash (O)
S5 Auxiliary relay responds to CH1 and CH2 (On) / only to CH1 (O)
S6 Auxiliary terminal is closed in the idle state (On) / open (O)
Automac reset (factory seng of S2 = "O")
Upon reccaon of a fault in the sensor circuits or aer a power failure,
the ELMON rail 34-32 automacally closes relay contacts 13 14.
During a fault, the corresponding LEDs CH1 / CH2 illuminate constantly.
Error lock with manual reset (S2 = "On")
Upon reccaon of a fault in the sensor circuit or aer a power failure, the ELMON rail 34-32 does not
close output terminals 13 14 again unl contacts Z1 and Z2, 500 ms aer the eliminaon of the disrupon,
are bridged with a buon. An automac restart is thereby rendered impossible. Permanent bridging of
contacts Z1 Z2 is not possible and is detected by the test.
Aer the sensor is again released, the corresponding LEDs CH1 / CH2 ash unl a man. reset is performed.
During a fault, the corresponding LEDs CH1 / CH2 illuminate constantly.
Auxiliary relay undelayed RLU (factory seng S3 = "O")
In this operang mode, the auxiliary relay contact 31 32 is acvated if any error is signalled. The auxiliary relay
contact can be toggled between normally closed contact and normally open contact with S6 ("On" = normally
open contact), whereby the contacts are always open while the switching unit is in a power-free state.
Errors in channel 2 are only taken into account if S5 is in switch posion "On" (factory seng of S5 = "O").
Auxiliary relay undelayed RLU ashing (S3 "O" , S4 = "On")
With S4, ashing of the relay can be acvated in synch with the LEDs.
DIP switches
approx. 0.5 s approx. 3 s
Safety relay output (symbolic)
Auxiliary relay output (symbolic)
Safety relay output (symbolic)
Auxiliary relay output (symbolic)
Auxiliary relay delayed RL (S3 = "On")
In this operang mode, the auxiliary relay contact 31 32 is acvated with a delay of approx. 0.5 second and
then remains acve for max. 3 seconds if an error is signalled. The auxiliary relay contact can be toggled
between normally closed contact and normally open contact with S6, whereby the contacts are always open
while in a power-free state.
CH2 is only taken into account if S5 is in switch posion "On" (factory seng of S5 = "O"). S4 must be in the
"O" switch posion (factory seng); otherwise, the auxiliary relay is permanently inacve.
ELMON rail 34-32
Safety Relay
English

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8. Commissioning
8.1 Prerequisites
• When supplying via terminals B1 and B2, the voltage must comply with the requirements for safety low
voltage (SELV).
• Cables installed outdoors or outside of the switching cabinet must be protected appropriately.
8.2 Electrical connecon
• Connect 24 V DC or AC supply voltage to terminals B1 B2 or 230 V AC supply voltage to terminals A1 A2
• During use mains voltage it´s advisable to include a delay fuse protecon of 1 A.
• Connect sensor to terminals X1 X2 and Y1 Y2; connect 8.2 kΩ resistor to any unused inputs.
• Connect the control circuit that is to be monitored to terminals 13 14.
• Connect the test signal supplied by the primary control to terminals T1 T2 and select the waveform via
DIP slide switch S1.
• For error lock with manual reset: connect release buon for manual reset to terminals Z1 Z2 and select
the funcon via DIP slide switch S2.
The supply voltage at terminals B1 B2 is not galvanically isolated from the sensor inputs.
Following successful commissioning, relay outputs 13 14 are closed. Actuaon of a sensor causes the relay
contact to open.
must not exceed 500 Ω when it is acve.
Sucient fuse protecon must be provided on all output contacts with capacive and
inducve loads.
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Sensor 1 Sensor 2 Sensor „n“
X1
X2 Figure 1: Wiring of mulple sensors; in this example: safety contact edge
2
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8.3 Connecon of mulple sensors per sensor circuit
ASO sensors must not be connected in parallel.
One or more sensors can be connected to sensor inputs X1 X2 or Y1 Y2. For this purpose, the individual
sensors are connected in series according to gure 1.
An unused input can be bridged with an 8.2 kΩ resistor.
Safety edges SENTIR edge:
Up to ve SENTIR edge may be connected in series. The maximum total length o the SENTIR edge shall not
exceed 100 m. The length of one SENTIR edge may be up to 25 m.
The total cable length o the in series connected SENTIR edge must not exceed 25 m.
Safety bumper SENTIR bumper:
Up to ve SENTIR bumper may be connected in series. The maximum total length o the SENTIR bumper shall
not exceed 15 m. The length of one SENTIR bumper may be up to 3 m.
The total cable length o the in series connected SENTIR bumper must not exceed 25 m.
Safety contact mat SENTIR mat:
Up to ten SENTIR mat may be connected in series. The maximum total area shall not exceed 10 m2. The
maximum size of an SENTIR mat is 1350 x 2350 mm.
The total cable length o the in series connected SENTIR mat must not exceed 25 m.
Before connecng the sensors that are connected in series, it is recommended that the resistance value of
the arrangement is to be measured. The resistance must be 8.2 kΩ ± 500 Ω when the sensor is inacve and
ELMON rail 34-32
Safety Relay
English

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With tesng by the control, the ELMON rail 34-32 system sases the Cat. 2 requirements
in accordance with EN ISO 13849-1:2008 "Safety-related parts of control systems".
Without tesng, the operaon or wiring of the ELMON rail 34-32 sases no specic
safety requirements.
English
Safety Relay
8.4 Test
For a standard-compliant design of the protecon, the primary machine control must perform a test prior
to each dangerous movement or during the non-dangerous phase/movement of the machine. The test is
intended to ensure the proper funcon of the safety relay. Aer applicaon of the test signal, the output
terminal of the switching unit must open. This change in switching state must be evaluated by the primary
machine control. If the test result is correct, the machine control then iniates the movement or the next
work step. Otherwise, the control must output an error message and the power-driven work equipment
(e.g. motor) must receive a switch-o signal from the machine control. If the machine control detects an
error fault in the safety device, the machine control must maintain a safe state unl the error is reced.
If DIP switch S1 is in switch posion "O", the test is performed upon applicaon of a voltage to terminals
T1 and T2; if "On", the test is performed if no voltage is applied.
8.5 Characteriscs of the signal
Switching output (symbolic)
Test signal S1 Pos. "On":
Test signal S1 Pos. "O":
8.6 Connecon opons for the test signal
Voltage UTest 12 V ... 28 V DC or AC voltage
Test duraon TTest 120 ms
B1
Z1 Z2 T1 T2
AC/DC
B1
Z1 Z2 T1 T2
AC/DC
B1
Z1 Z2 T1 T2
+DC
B1
Z1 Z2 T1 T2
+DC

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ELMON rail 34-32
Safety Relay
English
8.7 Example of use
Safety-related monitoring of two sensor circuits that act on one switching output, with primary PLC or
machine control.
For a funconal test of the protecon, the PLC/machine control performs a test prior to each dangerous
movement or in the non-dangerous phase/movement of the machine. If the test result is correct, the PLC/
machine control then iniates the movement or the next work step.
8.8 Funconal test
The plant / machine must be tested for proper funcon aer all of the electrical connecons have been
established and the supply voltage has been turned on. To do this, acvate each of the sensors in sequence
and check the corresponding reacons of the switching unit.
The safety system is to be professionally inspected at appropriate intervals and be documented in such a way
that it is comprehensible at all mes. The requirements of the plant/machine manufacturer are to be taken
into account and followed.
SPS
Machine
Control
8,2 ΚΩ
8,2 ΚΩ
+24 V DC
0 V DC
Test
Signal
ELMON rail 34
M
L1 L2 L3
K1 135
2 4 6
Q1.2Q1.1A2
I1.1A2
B1 X1 X2 Y1 Y2
B2 13 14
K2
2
K1 A1
A2
Sensor CH1
Sensor CH2
1
K2 A1
A2

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English
Safety Relay
9. Error diagnosis
Only the green "Power" LED may illuminate if the supply voltage has been correctly connected. If one of the
other LEDs illuminates, there is an error in the system which can be pinpointed using the table.
LED Error Error correcon
LEDs are not
illuminated
The supply voltage is
missing, too low or has been
connected incorrectly
Check connecons and supply voltage:
230 V 50/60 Hz at terminals A1 A2 or 24 V AC/DC at
terminals B1 B2. Tolerance range: ±10%
LED CH1 or CH2
constantly
illuminates
yellow
Sensor 1 or 2 incorrectly
connected, actuated or
defecve
Check connecons, wiring and supply lines of the
respecve sensor for short circuit (squeezed or
brile supply lines, etc.).
Check sensor. [1]
LED CH1 or CH2
constantly
illuminates red
Sensor 1 or 2 incorrectly
connected, interrupted or
defecve
Check connecons, wiring and supply lines of the
sensor for breakage (squeezed or brile supply
lines, etc.).
Check sensor. [1]
LED CH1 or CH2
constantly
ashes yellow
or red
Manual reset release not
present
Check operang mode, reset push-buon, wiring
and supply line. [2]
Tesng LED
constantly
illuminates
orange
Faulty test Check DIP slide switch S1. Adjust or check the test
signal of the primary PLC/controller and set the DIP
slide switch appropriately. [3]
[1] If the error is not in the wiring, the funcon of the electronics can be tested by connecng an 8.2 kΩ
resistor to the appropriate input X1 X2 or Y1 Y2 on the switching unit. If the electronics work perfectly
aer performing the test, the sensors must be checked using an ohmmeter. To do this, the connecon
of the sensor to the safety relay must be disconnected and connected to an ohmmeter. The resistance
must be 8.2 kΩ ±500 Ω when the sensor is inacve and must not exceed 500 Ω when the sensor is acve.
[2] The constant ashing indicates error lock of the switching unit and requires manual release by actuang the
reset buon. Evaluaon of the reset buon occurs dynamically; as a result, constant actuaon or manipula-
on of the reset buon will be detected by the switching unit and release of the output circuits prevented.
[3] The test of the safety system must be coordinated by the primary controller and be designed according to
the technical data specied in this documentaon. If the test fails in spite of appropriate sengs, there
is a defect in the switching unit.
10. Taking out of service and disposal
The products manufactured by ASO are intended solely for commercial use (B2B). At the end of use, the
products are to be disposed of according to all local, regional and naonal regulaons. Products can also be
returned to ASO, which will then dispose of them properly.

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ELMON rail 34-32
Safety Relay
English
Simplied diagram SK 34
11. Technical specicaons
Supply voltage
Mains voltage 230 V AC 50/60 Hz
Fuse protecon 1 A delay fuse
Low voltage 24 V DC/AC ± 10%
Power consumpon
Pmax 3,5 VA 230 V AC
Pmax 1,3 VA 24 V DC/AC
Terminang resistor - sensor
nominal value Rnom 8,2 kΩ
upper switching point RAO > 12,7 kΩ
lower switching point RAU < 4,6 kΩ
Relay outputs
nominal current DC DC-13 / 24 V / 1 A
nominal current AC AC-15 / 250 V / 1 A
Mechanical life-me >105 actuaons
Saey Relais
Fuse type M 1 A 5 x 20 glass tube
Safety relay switching mes
Switching o delay < 5 ms
(response me)
Switching on delay 50 ms typ.
Auxiliary relay switching mes
Switching o delay 0,5 s
(response me)
Switching on delay 3 s
With the RLU funcon, the auxiliary relay
switches in synch with sensor actuaon.
Test input voltage
Input voltage UTest 12 V ... 28 V AC/DC
Input resistance RTest approx. 5 kΩ
Polarity of the input arbitrary
Test run duraon 120 ms typ.
Reset input
Voltage without load UReset 12 V DC
Input resistance RReset approx. 10 kΩ
Housing
polyamide PA 6.6, self-exnguishing acc. to UL 94-V2
Dimensions (HxDxW) 113 x 99 x 22,5 mm
Protecon class IP20
Weight 200 g
Temperature range -20 °C to +55 °C
Connecon cable cross-secon
single- or ne-stranded cable 0,5-1,5 mm2
Safety category
EN ISO 13849-1:2008 Category 2 PL d
MTTFd 110 years, DC 90%
(Electronic) MTTFd 3358 years
(Electromechanics) B10d 200000
MTTFd 114 years (Nop 17520)
Cercate no.
44 205 10 384655-001
Test report no.
10 205 384655-001
ELMON rail 34-32
X1
X1
A1
A1
B1
B1
Y1
Y1
Manual
Reset
Manual
Reset Test
Reset
Latch
Rref
Uref
+Ub
Rref
Uref
+Ub
32
31
14
13
99
114
22,5

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English
Safety Relay
12. EC declaraon of conformity
We hereby declare that the following products of type series:
ELMON rail 34-32 (part no. 203301, serial number format yymmnnnnn)
Safety relay to be used in combinaon with safety edges, safety contact mats and
safety bumpers for prevenng dangers at locaons where there is a risk of crushing
and cung sases the relevant essenal health and safety requirements of the EC
direcves and standards listed below on account of its design and construcon, as
does the version brought to market by us:
EC - machinery direcve 2006/42/EC
EN ISO 13849-1:2008
EN ISO 13849-2:2008
EN 61000-6-2:2002
EN 61000-6-3:2005
EC - type approval
Noed Body 0044
TÜV NORD CERT GmbH
Langemarckstraße 20
D-45141 Essen
EC type approval no.: 44 205 10 384655-001
This declaraon of conformity does not relieve the designer/manufacturer of the
machine from his obligaon to ensure that the conformity of the enre machine to
which this product is aached sases the corresponding EC direcve.
Manufacturer and Authorised Signatory:
ASO, Antriebs- und Steuerungstechnik GmbH,
Hansastraße 52, D 59557 Lippstadt / Germany