ASO 71-242, 71-942 OPERATIONAL INFORMATION

Technical Document Ver 2.0
Valid: 01/01/2018

GENERAL & OPERATIONAL INFORMATION

ELMON KIT MANUAL

ELMON RAIL 71242

The ELMON rail relay is designed for use on sliding gates/doors & machine solutions. The relay evaluates pressure sensors fied to the
systems, including safety contact mats, safety contact strips and safety bumpers, reducing the risk of crush and shearing points.

Four separate sensor circuits can be connected to the Rail 71-242/942 switching unit, whereby they are combined in to two directional
switching outputs.

Monitoring of the standby current is made possible by an integrated terminating resistor in the sensor circuit. If the specified standby current
is flowing, the output relay is activated and the switching contact is closed. If a sensor is actuated or a sensor circuit is interrupted, the relay
switching contact opens.

ELMON RAIL 71942

The relay is designed in accordance with EN ISO 13849-1:2008 for Category 3 Pl e. To comply with Category 3 for compliance, the safety
output is set up redundantly with two independent switching elements which are ressilient to a single point of failure.

The monitoring state of the sensors and the applied operating voltage are indicated by LEDs on the front of the unit.

In the event of a fault alarm, all safety outputs are inactive.

PROPER USE

The ELMON rail 71-242 (ELMON rail 71-942) switching unit can only fulfill its safety-related task if used properly.

The ELMON rail 71-242 (ELMON rail 71-942) safety transmission system is designed for evaluating stationary and traveling safety contact
edges with constant 8.2 kΩ resistance.

Any uses above and beyond these guidelines constitutes improper use. The manufacturer assumes no liability for damages arising from
improper use.

The device may only be used in special applications with the manufacturer’s express consent.

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01

Technical Document Ver 2.0
Valid: 01/01/2018

SYSTEM COMPONENTS FITTED TO THE GATE

ELMON KIT MANUAL

DEVICE OVERVIEW

Signal Displays

During the output of an error message, the number of output
pulses indicates the error:

THE ACTUAL ARRANGEMENT OF THE INDIVIDUAL
COMPONENTS DEPENDS ON THE DESIGN OF THE GATE IN
QUESTION AND THE CONDITIONS AT THE INSTALLATION SITE.

LED POWER (green)

Operation mode (on) - OK

Fault alarm (pulse) - see error diagnostics

LED TRANSMIT OPENING (red)

Fault, opening movement - travelling edge(s)

LED STATIONARY OPENING (red)

Fault, opening movement - stationary edge(s)

LED TRANSMIT CLOSING (red)

Fault, closing movement - travelling edge(s)

LED STATIONARY CLOSING (red)

Fault, closing movement - stationary edge(s)

V3.1> If no error is present, then LED Power shows the
function control (briefly off ).
V4.0 and later: If no error is present, then LED Power shows
the operating state (on).

Pulse Error message diagnostics

1 Voltage supply outside of the valid value range (24V AC/DC +/- 10%)

2 ELMON coils/wire transmission error (see troubleshooting page)

3 Output control Open faulty (replace unit)

4 Output control Close faulty (replace unit)

5 Data transmission with micro-controller faulty (replace unit)

6 Error in testing signal input (see troubleshooting page 9)

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02

ELMON KIT MANUAL

Technical Document Ver 2.0
Valid: 01/01/2018

FITTING GUIDE

So far, the cable of the contact edge (OPEN/CLOSE) had to be installed along the gates entire length
to connect it to the travelling coil core (SPK 54).

A new steel cable with an additional 2 cores is now included in each kit, which helps reduce fiing
time. One end is pre-assembled with connectors for the travelling coil. An extra pair of waterproof
connectors is included at the tensioner to connect the rear travelling safety edge.

This allows safety edges at each end of the gate to be connected to the travelling coil easily, without
the need to run a long connecting cable through or along the gate.

COMPONENTS

1

SPK 54 S Mount SPK 55 Coil Core Tension Bracket Mount

REQUIRED TOOLS

2

3

Cuers Drill M4 & M6 Tap bits Alen Keys

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Technical Document Ver 2.0
Valid: 01/01/2018

X=75mm

ELMON KIT MANUAL

FITTING GUIDE

X=25mmX=25mm

X=25mm

min.35mm

M6

min. 25mm

1A

*x*

M4

Drill and tap M4 Hole

1C 1D 2A1B

3A

Drill and tap M6 Hole
or bolt/tek screw

Screw in the provided

allen head bolt.

!DO NOT OVER TIGHTEN!

1,5-2 Nm

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Place the transmission

cable in slot gap.

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Strip back the insulation and plug

cable cores into plug terminals.

!ONLY CLAMP THE STEEL CABLE!

1,5-2 Nm

Pass the cable through
the stationary SPK coil.

03

Technical Document Ver 2.0
Valid: 01/01/2018

ELMON KIT MANUAL

FITTING GUIDE

3B

Fix tension bracket with

an M6 or a similar bolt.

1,5-2 Nm

3C 3D 3E

~ 20mm

18mm

Fit the clamping unit into

the tension bracket

3G 3H3F

Pull the Cable through the tension

bracket and clamp.

!CABLE SHOULD NOT BE LOOSE!

2B

Clamp down the allen

head screw.

!DO NOT OVER TIGHTEN!

1,5 Nm

Trim away excess steel

cable.

Adjust for height.

1,5 Nm

Adjust the clamp unit.

Adjust for position and

secure to the ground.

Tighten the clamp unit to hold

everything in place.

1,5-2 Nm

Cover the components for

protection.

Secure SPK coil bracket

appropriately.

3E2D 1E2C

Cover the tension bracket

for protection.

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03

Technical Document Ver 2.0
Valid: 01/01/2018

ELMON rail 71-242

ELMON KIT MANUAL

CONNECTION TERMINALS

Pin 3 11

Pin 3 10

Pin 4 5

Pin 6 7

Pin 8 9

Stationary coil, SPK54/5Pin 1 2

SCE - Leading pillar - Opening

SCE - Leading pillar - Closing

Relay output for controller - stop opening

Relay output for controller - stop closing

Supply voltage, 24V 24V +/- 10%

ELMON rail 71-942

TransmitPin 4 5

Pin 6 7

Pin 8 9

Stationary open

Stationary close

ELMON Rail

71-24 2

7

8

10

11

ELMON Rail

71 -942

6

5

4

39

2

1

CONNECTING THE DEVICE

Prerequisites

• The supply voltage used for the ELMON rail 71-242 and the ELMON rail 71-942 must comply with the requirements for safety low voltage (SELV).

• Cables installed outdoors or outside of the switching cabinet must be protected appropriately.

• The protection class specified for this device is only ensured if the supply lines have been properly clamped to the screw connections.

ELMON Rail

71-242

Supply Voltage

With the ISK 71-242 and ISK 71-942, 24 V AC/DC is to be connected to terminal pair 8, 9 as voltage
supply. The supply line to the switching unit must be protected with an appropriate fuse.

ELMON Rail

71-942

8

9

~~

-

+

Connecting the stationary coil core - SPK54/5

ELMON rail 71-242: Connect the stationary coil core to terminal pair 1, 2; no special aention is
required for polarity.

ELMON rail 71-942: The stationary coil core is to be connected to the Transmit slot. The cable for the
coil core is connected using the supplied crimp connectors or by directly soldering the wire to the
connectors.

8

9

~~

-

+

Connecting the stationary contact edges

ELMON rail 71-242: The stationary safety contact edge(s) (SCE) on the leading pillar for the opening

2

1

3

10

11

movement is (are) connected to terminal pair 3, 11.

ELMON rail 71-942: The stationary SCE(s) for the opening movement is (are) connected to the
Stationary Opening slot.

If several SCEs are being used, they must be connected in series and the end edge must be terminated
using an 8.2 kΩ resistor.

ELMON rail 71-242: The stationary SCE(s) for the closing movement is (are) connected to terminal
pair 3, 10.

ELMON rail 71-942: The stationary SCE(s) for the closing movement is (are) connected to the
Stationary Closing slot.

If one or both channels for the stationary SCE are not used, the sup-plied 8.2 kΩ resistors are to
be connected to the respective channels.

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04

Technical Document Ver 2.0
Valid: 01/01/2018

Connecting the control circuits

ELMON KIT MANUAL

6

7

5

4

The control circuit to be monitored for the opening movement (stop-opening movement) is to be
connected to terminal pair 4, 5; for the closing movement (stop-closing movement), the appropriate
control circuit is to be connected to terminal pair 6, 7. The control circuits are dependent on the
rated current to protect with an appropriate fuse or the rated current to the control circuits must be
limited by other measures to the maximum value.

CONNECTING THE SENSORS

Connecting to the coil core SPK 54 (figure 1)

The traveling edges (SCE) are connected to the traveling
coil core.

For this purpose, the traveling SCE CLOSING movement is
connected to connection C of the traveling coil core and
the optional SCE OPENING movement is connected to
connection O.

If a channel is not used, it must be connected
to an 8,2 kΩ resistor.

Figure 1: connection at the coil core

6

7

5

4

Opening Movement

Closing Movement

CONNECTING THE SENSORS

Connecting multiple sensors per sensor circuit (figure 2)

One or more sensors can be connected to sensor input O or C. For this purpose, the individual sensors are connected in series according to
figure 2.

Up to five sensors may be connected in series, whereby the total cable length must not exceed 25 m.
The length of one sensor may be up to 25 m.

Before connecting the sensors that are connected in series, it is recommended that the resistance value of the arrangement be measured.

The resistance must be 8.2 kΩ ± 500 Ω when the SCE is inactive and must not exceed 500 Ω when it is active.

ASO sensors must not be connected in parallel.

SENSOR 1 SENSOR 2 SENSOR 3

O

222

C

2

Figure 2: Wiring of multiple sensors; in this example: safety contact edge

The gate system must be tested for proper function after all of the electrical

connections have been established and the supply voltage has been turned

on. To do this, activate each of the safety contact edges one after another

and check the corresponding reactions of the switching unit.

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05

ELMON KIT MANUAL

Technical Document Ver 2.0
Valid: 01/01/2018

ERROR DIAGNOSIS

Only the green LED may illuminate if the supply voltage has been correctly connected. If one of the red LEDs
illuminate, there is an error in the system which can be pinpointed with the aid of the LED.

LED Error Error correction

LEDs are not illuminated The supply voltage is

missing, too low or has been

connected incorrectly

A single Red LED

is illuminated

Both Stationary RED

LEDs

are illuminated

Contact edge(s) not

connected, connected

incorrectly or faulty

One of the contact edge
connections is not being

used

Sensor circuit broken,
sensor not connected,

connected incorrectly or

faulty

Test connections and supply voltage:

- 24 V AC/DC to terminals 8 & 9, tolerance range: ±10%

• Check connections of the relevant sensors
(pinched wiring, brile wiring etc.)

• Check safety contact edge(s) *

Any contact edge connections that are not being used must be
permanently bridged using one of the supplied 8.2 kΩ resistors

• 8.2KOhms on input

Before making any other checks, the first task required for you
to do is meter the Ohms measured at the relay inputs across
terminals 3 & 10 (Close edge input) and 3 & 11 (Opening edge
input). These should be reading around 8K2Ohms. If they are
reading significantly more or less than this value, then this
will indicate the reason for the LED to be lit on the relay. The
acceptable switching tolerances of this relay measure from
5Kohms up to 12Kohms. Anything outside of these values will
result in the inputs relay opening and the relative LED showing lit
on the front of the ISK71-242.

If you are not reading 8K2Ohms and you have a series of safety
edges wired into that circuit, then you will need to deduce which
edge is causing the problem. The quickest fault finding means to
achieve this is by testing each edge in series until you find 8K2.
If you do not find this value at all, then you know that there is an
issue with the end of line edge which will need to be addressed.

• Water within a safety edge

Check all drainage holes have been cut at the boom of the
vertical edges and either side of the horizontal edges.

• Damaged edge / earthed connections

Check to ensure no cables have been wearing on joints where
movement may incur or in junction boxes which may have other
wiring in place. Carry out a full inspection of each edge to ensure
no signs of obvious damage.

• Cuts / Rips on the edge

Check that all edges have no obvious visible signs of damage /
vandalism. If the safety edge has any short or broken contact, the
relay will read 0.0 Ohms and the corresponding input LED will be
lit.

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06

Technical Document Ver 2.0
Valid: 01/01/2018

LED Error Error correction

ELMON KIT MANUAL

Both Transmit RED LEDs

are illuminated

The transmission line is

faulty or has been installed

incorrectly

Contact edge(s) not

connected, connected

incorrectly or faulty

• Observe the mechanical assembly instructions on page 2,3 & 4.

• Check transmission coil cores for abrasion.

• Check cable loop; make certain that both transmission coil cores
are in the cable loop

• Check cable / gate leaf contact points.

• Check supply voltage**

• Check for earth to the gate

The ELMON kit fundamentally uses inductive technology. This
requires the use of a coil and cable which MUST be earthed to the
frame of the steel gate. At the one end of the gate you will have
a coil which the leading and trailing edge both must wire in to. If
you do not have a trailing edge, then you will need to link out the
other input by means of an 8.2KOhm resistor supplied on the side
of the ISK71-242. At the other end you will have a tensioning unit
which keeps the cable tort so as no slack will wear away a groove
in the stationary coil, or even worse, catch on any moving parts.
Both the tensioning unit and the travelling coil must be making
contact with the frame of the gate. Any paint or galvanization will
need to be stripped back for this contact to be true. You will also
need to ensure that the wire which runs the length of the gate is
also earthed to the gate by means of the lile grub screws on the
travelling coil and the tensioning unit. They must pierce the plastic
sheathing to make contact in the eventuality you find yourself with
a wooden gate that you wish to apply the ELMON kit to, the best
means of doing this will be to create a ‘false loop’ on the gate. To
do this you will need to run a separate cable down the back of the
gate and run this from the SPK54S (travelling coil) and aach it to
the tensioning unit via whichever way is best possible according
to the design of the gate.

• Check for any obvious signs of damage to the SPK55 (Static coil)

If the bracket for the SPK55 has not been mounted in a way
where the cable that runs through it is level, then this may cause
the cable to have a ‘sawing’ effect in the hole that it runs through.
To easily prevent this, make sure that the bracket is aached to
a fixed level ground using two bolts to prevent the likelihood of it
pulling to one side.

• Check for any obvious signs of damage to the cable running the
length of the gate

On many installations, the cable which is earthed to the gate
will be mounted fairly low to accommodate the stationary coil
which more often than not it mounted to the floor. If the gates
are located somewhere where vandalism is likely to occur,then
one of the most susceptible parts of the ELMON is the exposed
cable. Any signs of damage should be obvious and may affect
the inductive circuit. To get around this problem, you may wish
to relocate the cable to a less obvious position. This can be
anywhere on the gate which may offer less incentive to damage.
You will need to relocate the coil however and thus make some
alterations to the bracket it houses into.

• Check for 8.2KOhms on the edge inputs on SPK54S travelling coil

The travelling coil has two inputs. One which monitors the edge
on the opening direction and one which monitors the edge for
the closing direction. Both of these inputs must see 8.2KOhms. If
one of the inputs has not been used, then this should be linked out
with an 8.2KOhm resister supplied on the side of the ISK relay.

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07

Technical Document Ver 2.0
Valid: 01/01/2018

LED Error Error correction

ELMON KIT MANUAL

Power Green LED

flashes cyclically (pulse)

6 pulses from power LED -

this code can be caused by a

number of issues

• Water within a safety edge

Check all drainage holes have been cut at the boom of the
vertical edges and either side of the horizontal edges.

• Damaged edge / earthed connections

Check to ensure no cables have been wearing on joints where
movement may incur or in junction boxes which may have other
wiring in place. Carry out a full inspection of each edge to ensure
no signs of obvious damage.

• ISK relay has been housed / positioned next to high EMF I.E. large
transformer.

In some installations, a separate cabinet may not have been fied
to house other electrical components. This may result in the ISK
relay sharing the same housing as the mains transformer for the
motor. In some cases this has caused the circuitry of the relay
to fail. Remove the relay from the motors housing and reset the
power to check for improvement.

• Cabling has been shared with DC voltage apparatus which is
causing interference.

Check that the safety edges are not sharing the same cabling
/ conduits with anything which may be carrying a DC mains or
pulse voltage. This may result in the static edge inputs (3,10 & 3,11)
having a back feed of interference which the controller identifies
as a fault.

If the error is not in the wiring, the function of the electronics can be tested by connecting an 8.2 kΩ resistor to all SCE inputs on the
ELMON rail 71-242 (ELMON rail 71-942) electronic evaluation system (terminals 3, 10 and terminals 3, 11) and to the traveling coil core
(connections O and C). If the electronics work perfectly after performing the test, the safety contact edges must be checked using an
ohmmeter. To do this, the respective connection on the SCE for the electronic evaluation system or for the traveling coil core must be
disconnected and connected to an ohmmeter.

The resistance must be 8.2 kΩ ±500 Ω when the safety contact edge is inactive and must not exceed 500 Ω when it is active.

If both of the LEDs for the traveling SCEs (Transmit Opening and Transmit Closing) illuminate, there is an error in the inductive signal
transmission system. The most frequent causes of these errors are bad coil core connections, incorrectly installed cable system
components (see ELMON rail safety transmission system assembly instructions) or an impermissible low supply voltage.

The maximum resistance value of the cable loop must not exceed 3 Ω . The resistance value can be measured by disconnecting the
steel cable from the ground

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08

Technical Document Ver 2.0
Valid: 01/01/2018

ELMON KIT MANUAL

TECHNICAL DATA

82

EC type-examination no.:

44 205 12 399386

Certificate no.:

44 780 12 399386

Test report no.:

12 205 399386-000

38

Supply Voltage

Low Voltage: 24V AC/DC ± 10%

U

E

I

E

I

max

180mA (100ms)

85mA

Relay Stages

84

110

Terminal Resistance of the SCEs

nominal value

upper switching point

lower switching point

R

nom

R

R

Safety Relay Switching Times

82

38

ELMON RAIL 71942ELMON RAIL 71242

Stationary SCE Travelling SCE

= 8,2 kΩ = 8,2 kΩ

AO

AU

> 12,0 kΩ > 20,0 kΩ

< 5,0 kΩ < 2,5 kΩ

84

110

Nominal current DC
Nominal current AC
Mechanical life-time

Assembly
Housing
Dimensions (HxWxD)

Housing
Housing (incl. plug in socket)

Protection Class
Weight
Temperature Range
Connection Cable cross-section
Certifications

Electronics
Electromechanics

Safety device acc. to

All voltages connected to the switching unit must be safely isolated

3 A (30 V DC)

3 A (30 V AC)

6

actuations

>10

11-pin DIN plug-base housing with plug base for 35 mm mounting rail (DIN rail)

Stationary SCE Travelling SCE

Switching off delay <10 ms <30 ms

Switching on delay 500 ms (Power on 700 ms)

Plug base for 35 mm DIN snap-on rail mounting

82 x 38 x 84 mm

82 x 38 x 110 mm

-25ºC to + 55ºC

Single or fine-stranded cable 0.75 -1.5mm

DIN EN ISO 3849-1:2008 Category 3 PL e

MTTFd 170 years, DC 91%

MTTFd 1616 years, DC 99 %

B10d 1000000

MTTFd 190 years (Nop 52560)

DIN EN 12978

IP20
225g

2

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09