ELMON 32-242 User manual

Sicherheitsschaltgerät / Safety Relay / Relais de sécurité
ELMON relay 32-242
Betriebsanleitung (Original,GülgkeitsieheletzteSeite)
ELMON relay 32-242 Sicherheitsschaltgerät
OperangManual (seelastpageforvalidity)
ELMON relay 32-242 Safety Relay
Manueld´ulisaon (Validitévoirladernièrepage)
ELMON relay 32-242 Relais de sécurité
Page 13-21
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Seite 3-12
Page 22-31

12 13
English
ELMON relay 32-242
Safety Relay
1. Table of contents
1. Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2. Generalsafetyregulaonsandprotecvemeasures . . . . . . .14
3. Generalandoperaonaldescripon. . . . . . . . . . . . . . . . .15
4. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5. Exampleinuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6. Deviceoverview . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.1 Signal displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Conneconterminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Mechanicalmounng . . . . . . . . . . . . . . . . . . . . . . . . .17
8. Electricalconnecon . . . . . . . . . . . . . . . . . . . . . . . . .18
8.1 Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.2 Sensorconnecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.3 Connecngseveralsensorspersensorcircuit . . . . . . . . . . . . . . . . . 18
8.4 Connecngcontrolcircuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9. Commissioningandperformancetesng . . . . . . . . . . . . . .19
10. Error diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
11. Decommissioning and disposal. . . . . . . . . . . . . . . . . . . .19
12. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
13. ECdeclaraonofconformity . . . . . . . . . . . . . . . . . . . . .21
We reserve the right to make technical and operaonally relevant changes to the
products and devices described in this documentaon at any me and without prior
noce.

14
Safety Relay
English
2. General safety regulaons and protecve measures
• Manufacturersandusersoftheplant/machinery,forwhichtheprotecvedeviceisused,arethem-
 selvesresponsibleforcoordinangandobservingalltherelevantsafetyinstruconsandregulaons.
• Theprotecvedeviceensuresoperaonalsafetyincombinaonwiththeoverridingcontrols,butnot
 thesafetyoftheenreplant/machinery. Before usingthedeviceasafetyassessmentofthe enre
 plant/machineryintermsoftheMachineryDirecve2006/42/ECoroftherelevantproductstandard
 isrequired.
• Theoperanginstruconsmustalwaysbeavailableatthelocaonwheretheprotecvedeviceisused.
 Theymustbereadandappliedthoroughlybyeveryonetaskedwiththeoperaon,servicingandmain-
 tenanceoftheprotecvedevice.
• Installaonandcommissioningoftheprotecvedevicemayonlybecarriedoutbyqualiedsta,who
 areacquaintedwiththeseoperanginstruconsandtherelevantinstruconsonoccupaonalsafety
 andaccidentprevenon.Thedireconscontainedin theseoperanginstruconsmustbeobserved
 andadheredtowithoutfail.
• The electrical engineering and professional society safety rules are to be observed.
• Whenworkingontherelay,itmustbedisconnectedfromthepowersupply,testedforzeropotenal
 andsecuredagainstreconnecon.
• Ifthezeropotenalcontactsofthesafetyrelaycontactsaresuppliedbyanexternalhazardousvoltage,
 thismustalsobeswitchedoduringworktotherelay.
• Therelaycontainsnocomponentsforservicingbytheuser.Unauthorisedmodicaonsand/orrepairs
 totherelaywillresultinthecancellaonofallguaranteeorliabilityonthepartofthemanufacturer.
• Theprotecvesystemmustbetestedatappropriateintervalsbyexpertsandmustbedocumentedina
 comprehensiblewayatallmes.
Safety instrucons
• Therelayallowsoperaonfrom24VAC/DC.Connecngtheoperangvoltagetothewrongterminals
may damage the relay.
• Therelaymustbeinstalledinacontrolbox.
• Do not install in the immediate vicinity of an intense heat source.
• Anadequateprotecvecircuitmustbeprovidedwithcapaciveandinducveusers.
Forthestandardiseddesignofthesafetysystem,theequipmentmustbetestedforcorrect
operaonbyexpertsatappropriateintervals.Thetesngmustbecomprehensiblydocumented
atallmes.
In the event of non-compliance or deliberate misuse, the manufacturer’s liability lapses.

14 15
ELMON relay 32-242
Safety Relay
English
3. General and operaonal descripon
Therelayisforevaluangsensors,includingsafetycontactmats,safetycontactstripsandsafetybumpers
formakingsafepinchandshearpoints.
Two separate signalling circuits can be connected to the relay, each controlling a switching output. The
quiescentcurrentmonitorofthesensorisenabledbyanintegratedterminatorinthesensor.
Therelaymonitorsthesetwosignallingcircuitspermanentlyforacvaonorbreaking(cablebreak).Ifthe
expectedquiescentcurrentisowing,theoutputrelaysareoperatedandtheswitchcontactsareclosed.If
thesensorisacvatedorthesensorcircuitisbroken,therelayswitchcontactsopen.
TherelayisdesignedinaccordancewithENISO13849-1:2015forCategory3.TocomplywithCategory3
therelayismanufacturedredundantandwithtwomutuallyacvangforciblyguidedsafetyrelays.
ThemonitoringstateofthesensorandtheoperangvoltagesuppliedareshownbyLEDs.
Intheeventofafaultalarm,allsafetyoutputsareinacve.
Theunitcan beusedina household environment as wellas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.
4. Intended use
Therelayisabletofullitssafetytaskonlyifitisusedforthepurposeitwasdesignedfor.
Appropriateulisaonoftherelayisuseasaprotecvedeviceincombinaonwithsafetycontactmats,
safetybumpersandsafetycontactstripsof8.2kΩresistancetoquiescentcurrentmonitoring.
Anyulisaonbeyondthis does notconstuteappropriateintendeduse. The manufactureraccepts no
liability for damage arising from inappropriate use.
Useinspecialapplicaonsrequirestheapprovalofthemanufacturer.
Theuseofthesafetyrelayatheightsabove2000mabovesealevelorinpotenallyexplosiveareasisnot
approved.
ELMON relay 32-242 Block circuit diagram
Stop
Channel 1
Stop
Channel 2
Sensor
Channel 2
Sensor
Channel 1
Rref +Ub
Uref
Rref +Ub
Uref
Rel
Rel
24V AC/DC

16
6. Device overview
6.1 Signal displays
LED Power(green)
Operaonmode(on)
Faultalarm(pulse)
LED Channel 1(red)
Sensoracvated(on)
Sensorcircuitbroken(ashesrapidly)
Faultself-lock(ashesslowly)
LED Channel 2(red)
Sensoracvated(on)
Sensorcircuitbroken(ashesrapidly)
Faultself-lock(ashesslowly)
5. Verwendungsbeispiele
Circuit diagram in zero poten al state. Sensor not ac vated.
ELMON relay 32-242
+24 V DC
0 V DC
Sensor CH1 Sensor CH2
SPS
Machine
Control
8,2kΩ
8,2kΩ
10311
9
8 4 5 6 7
Out CH 1
Out CH 2
K3 K3
K1 K2
A1 A1
A2 A2
24
K3 A1
A2
Q1.1
A2
I1.2I1.1A1
K1 K2
1 3 5 1 3 5
2 4 62 4 6
L1 L2 L3 L1 L2 L3
Safety Relay
English

16
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7. Mechanical moun ng
Theswitchingunitmustbemountedcorrectly:
• Inadust-protectedandmoistureprotectedswitchcabinetorcasing.
• Foruseinanenvironmentwithcontaminaonlevel2.
• WithaprotecontypeofatleastIP54.
• On a 35 mm DIN support rail according to EN 50 022.
Theswitchingunitmustnotbeinstalledintheimmediatevicinityofanintenseheatsource.
Theswitchingunitcanbeinstalledinanyposion.
Theunitmustnotbeoperatedinareaswithmajortemperaturechanges.
ELMON relay 32-242
Safety Relay
English
Ifthereisnofaultalarm,theoperangstateisshownviatheLEDPower(on).Whensignallingafaultalarm
thenumberofpulsesemiedindicatesthenatureofthefault:
Pulse Fault alarm
1 Supply voltage outside the available range
3 Output control Stop Channel 1 faulty
4 Output control Stop Channel 2 faulty
5Datatransferbetweenmicrocontrollersfaulty
6Errorintesngsignalinput(Channel 1 / Channel 2)
6.2 Connec on terminals
Pin 1 2 (Notallocated)
Pin 3 11 Signal input Channel 1
Pin 3 10 Signal input Channel 2
Pin 4 5 Relay output to Channel 1 control
Pin 6 7 Relay output to Channel 2 control
Pin 8 9 Supply voltage 24 V AC/DC
8
765
4
9
10
3
2
111

18
8. Electrical connecon
Connecontothewrongterminalsmaydamagetherelay.
Wiringlaidintheopenoroutsidethecontrolboxmustbeproperlyprotected.
Thesignalwiringmaynotbeconnectedparalleltothemotorwiringorotherpowerwiring.
Thelimitsshowninthe“TechnicalData”forthesupplyvoltageandrelayswitchingcapacitymust
beobserved.Sucientfuseproteconmustbeprovidedonalloutputcontactswithcapacive
andinducveloads.
8.1 Supply voltage
The supply voltage is to be connected to the terminal pair 8 924VAC/DC.Thesupplywiringtotherelaymust
beprotectedbyasuitablecircuitbreaker.Thesupplyvoltagemustmeettherequirementsforlowvoltage
protecon(SELV).
8.2 Sensor connecon
Connect the sensor for Channel 1 to the terminal pair 3 11. Connect the sensor for Channel 2 to the terminal
pair 3 10.
Ifachannelisnotused,itmustbeedwithan8.2kΩresistance.
8.3 Connecng mulple sensors per sensor circuit
ASO sensors must not be connected in parallel.
One or more sensors can be connected to sensor input. For this purpose, the individual sensors are connec-
tedinseriesaccordingtogure1.
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
mustnotexceed500Ωwhenitisacve.
Safety Relay
English
Sensor „n“
Sensor 2
Sensor 1
Opening
Figure 1: Connecon of mulple sensors; in this example: safety contact edge
2
222

18 19
ELMON relay 32-242
Safety Relay
English
Figure 1: Connecon of mulple sensors; in this example: safety contact edge
8.4 Connecng control circuits
The control circuit to be monitored for Channel 1 is to be connected to the terminal pair 4, 5and the corre-
sponding control circuit for Channel 2 is to be connected to the terminal pair 6, 7.
Thecontrolcircuitsmustbeprotectedbyacorrespondingcircuitbreakerdependingontheratedcurrentor
theratedcurrentinthecontrolcircuitsmustbelimitedtothemaximumvaluebyothermeans.
Therelaycontactmayonlyswitchextralowvoltages(30V).Theswitchingoflowvoltages(230V)
is not permissible.
9. Commissioning and performance tesng
Aeralltheelectricalcontactshavebeenconnectedandthesupplyvoltageswitchedon,theplant/machinery
mustbetestedforproperfunconing.
Followingsuccessfulcommissioningthesafetyoutputs4, 5and 6, 7areacvated(relaycontacts“closed”).
Acvangtheannunciatorresultsinopeningtherelaycontacts.
Thesafetysystemmustbetestedbyqualiedstaatappropriateintervals.Thetesngmustbecomprehen-
siblydocumentedatallmes.Therequirementsoftheplant/machinerymanufacturermustbeobserved
and adhered to.
10. Error diagnosis
Ifthewiringandconnecngupofthesupplyvoltageiscorrect,onlythegreenLEDPowershouldlightup.Ifthe
redLEDlightsupthereisafaultinthesystem,whichcanbeisolatedwiththeaidoftheLED.
* Ifthefaultisnotinthewiring,thefunconingoftheelectronicsmaybecheckedbyngan8.2kΩ
resistancetotheannunciatorinputontherelay.Iftheelectronicsthenworkproperly,theannunciator
mustbetestedwithanohmmeter.Forthistheconneconbetweentheannunciatorandtherelaymust
bedisconnectedandconnectedtoanohmmeter.Withaninacvatedannunciatortheresistanceshould
be8.2kΩ±500Ω.Iftheannunciatorisacvated,theresistanceshouldnotexceed500Ω.
11. Decommissioning and disposal
ProductsmanufacturedbyASOareintendedexclusivelyforcommercialuse(B2B).Attheendoftheirservice
theproductsshouldbedisposedofinaccordancewiththelocal,regionalandnaonalregulaons.ASOwill
bepleasedtocollecttheproductsfordisposalinaccordancewiththeregulaons.
LED Error Error correcon
green LED
Power
does not light up
Supply voltage absent,
toolow
orwronglyconnected.
Testconneconsandsupplyvoltage:
- 24 V AC/DC to terminals 8 9, tolerancerange:±10%
green LED
Power
ashescyclically(pulse)
Internalfaultisshownbythe
number of pulses. See -> Signal displays
red LED
Channel 1 / Channel 2
lights up
The relevant sensor
isrecognisedasacvated.
-Checkconneconsoftherelevantsensors
(pinchedwiring,brilewiringetc.)
-Checksensor*
red LED
Channel 1 / Channel 2
ashesrapidly
Sensorcircuitbroken,
sensor not connected,
connected incorrectly or faulty
-Checkconneconsoftherelevantsensors
(pinchedwiring,brilewiringetc.)
-Checksensor*

20
Safety Relay
English
12. Technical Data
Supply voltage
 Lowvoltage: UE 24VAC/DC±10%
IE85 mA
Imax 180mA(100ms)
 Inputpower: PE-max 3 W 24 V DC
PE-max 3 VA 24 V AC
 Ensuringlow
 voltage(external): 125mAMediumacngfuse
  125mAFlinkcanbeused
  alternavely
Terminal resistance o the sensor
nominal value Rnom 8,2kΩ
 upperswitchingpoint RAO >12,0kΩ
 lowerswitchingpoint RAU <5,0kΩ
Safety relay
Nominal current DC DC-13 / 24 V / 2 A
Nominal current AC AC-15 / 30 V / 2 A
 Mechanicallife-me  >106actuaons
Sa ey Relay
 Fusetype  M2A5x20glasstube*
Safety relay switching  mes
 Switchingodelay  <12ms
(responseme)
 Turn-ome  500ms(ELMONrelay32-242)
   100ms(ELMONrelay32-242K)
   (Poweron700ms)
Assembly Plug-insocketto35mmDINsnap-onrail
Housing 11pol.DINplug-insockethousing
   withplug-insocketfor35mmassemblyrail
Dimensions (HxWxD)
Housing
82x38x84mm
 Housingincl.plug-insocket 82x38x110mm
Protec on class IP20
Weight 225 g
Temperature range -25°C to +55°C
Connec on terminals
 ghteningtorque   0,5Nm
Connec on cable cross-sec on single-orne-strandedcable0,75-1,5mm2
Cer  ca ons
EN ISO 13849-1:2015
Categorie 3 PL e
  MTTFd180years,DC90%
 Electronics MTTFd3757years,DC90%
 Electromechanics B10d1000000/MTTFd190years(Nop52560)
All voltages connected to the switching unit must be safely isolated!
*Not included in the scope of delivery
84
82
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20 21
ELMON relay 32-242
Safety Relay
English
13. EC declaraon of conformity
ELMON relay 32-302*
ELMON relay 32-312* **
ELMON relay 32-242**
ELMON relay 32-332*
ELMON relay 32-302*
ELMON relay 32-312* **
ELMON relay 32-242**
ELMON relay 32-332*
ELMON relay 32-302*
ELMON relay 32-312* **
ELMON relay 32-242**
ELMON relay 32-332*