Induktives Signalübertragungssystem / Inductive signal transmission system / Système de transmission de signal inductif

INDUS rail 71-242 + INDUS rail 71-942

Deutsch
Betriebsanleitung (Original, Gültigkeit siehe letzte Seite)
INDUS rail 71-242 + INDUS rail 71-942 Sicherheitsschaltgerät Seite 3-14

English
Operating Manual (see last page for validity)
INDUS rail 71-242 + INDUS rail 71-942 Safety Relay Page 15-26

Manuel d’utilisation (Validité voir la dernière page) Français

INDUS rail 71-242 + INDUS rail 71-942 Relais de sécurité Page 27-38
INDUS rail 71-242 + INDUS rail 71-942
Inductive signal transmission system

1. Contents

1. Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. General safety regulations and protective measures . . . . . . 14
3. General and Function . . . . . . . . . . . . . . . . . . . . . . . 15
4. Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. System components fitted to the gate . . . . . . . . . . . . . . 16
6. Device overview . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Signal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Connecting the device . . . . . . . . . . . . . . . . . . . . . . . 17
7.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 Connecting the stationary coil core . . . . . . . . . . . . . . . . . . . . . . 17
7.4 Connecting the stationary safety contact edges . . . . . . . . . . . . . . . . 18
7.5 Connecting the control circuits . . . . . . . . . . . . . . . . . . . . . . . . . 18
8. Connecting the safety contact edges . . . . . . . . . . . . . . . 18
8.1 Connecting to the coil core SPK 54 . . . . . . . . . . . . . . . . . . . . . . . 18
8.2 Connecting multiple safety contact edges per sensor circuit . . . . . . . . . 18

English
9. Commissioning and functional test . . . . . . . . . . . . . . . . 18
10. Error diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11. Taking out of service and disposal . . . . . . . . . . . . . . . . 20
12. Technical specifications . . . . . . . . . . . . . . . . . . . . . . 20
13. EC declaration of conformity . . . . . . . . . . . . . . . . . . . 21

We reserve the right to make technical and operationally relevant changes to the
products and devices described in this documentation at any time and without prior
notice.

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 Inductive signal transmission system

2. General safety regulations and protective measures

• The manufacturer and users of the plant / machine on which the protection is being used are responsible
for implementing and following all applicable safety regulations and rules.
• When used in conjunction with the higher-order controller, the protection guarantees functional safety,
but not the safety of the entire plant / machine. The safety of the entire plant / machine must, therefore,
be assessed in accordance with machinery directive 2006/42/EG or appropriate product norm before
using the device.
• The operating instructions must always be available at the place of installation of the protection.
They must be read thoroughly and observed by all persons involved in the operation, maintenance and
servicing of the protection.
• The protection must only be installed and commissioned by professionals familiar with these opera-
ting instructions and the applicable operational safety and accident prevention regulations. All of the
instructions provided in these operating instructions must be observed and followed.
All electrical work must only be performed by skilled electricians.
• All relevant electrical engineering and Employer's Liability Insurance Association safety regulations must
be observed.
• During work on the switching unit, it is to be switched to zero potential, checked to ensure that it is at
zero potential and protected against being restarted.
• If the potential-free contacts of the relay outputs are supplied externally with a dangerous voltage, make
certain that these outputs are also switched off 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 protection system is to be professionally inspected at appropriate intervals and be documented in
English

such a way that it is comprehensible at all times.

Safety advice
• The switching unit enables operation at 230 V as well as with 24 V AC/DC. Connecting the operating voltage
to the wrong terminals can destroy the switching unit.
• The switching unit is to be installed in a switching cabinet.
• Do not install in the immediate vicinity of strong sources of heat.
• For capacitive and inductive loads, ensure adequate protective circuits.

The switching unit complies with EN ISO 13849-1 "Safety-related parts of control systems", Cat. 3.
To meet Cat. 3 requirements, the switching unit has a redundant structure with two, two-way
polling, forcibly actuated safety relays per channel.

The requirements of EN 12978 "Safety devices for power operated doors and gates" and EN 12453 "Safety
in use of power operated gates" are also fulfilled.
The manufacturer assumes no liability in the event of non-observance or intentional abuse.

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INDUS rail 71-242 + INDUS rail 71-942
Inductive signal transmission system

3. General and Function

The inductive signal transmission system solves the problem of connecting moveable safety contact edges to
a stationary evaluation system without mechanical stress. Communication between the moveable safety
contact edges and the electronic evaluation system is based on induction. To achieve this, the monitoring
electronics induce a frequency on a coil core, which is integrated in a closed conductor loop.
The second coil core, to which the moveable safety contact edges are connected, receives this frequency and
sends corresponding feedback to the electronic evaluation system in the event of cable break or actuation of
a safety contact edge.
The compact and easy-to-install safety relay is designed for outdoor use and can be operated with 24 V AC/DC
mains voltage.
Up to four safety contact edge circuits can be connected to the switching unit. Two channels (safety contact
edges opening movement and safety contact edges closing movement) are available for the safety contact
edges on the gate leaf; two channels are also available for the safety contact edges on the leading pillar.
The signal transmission system monitors the travelling safety contact edges on the gate leaf without
contact and without abrasion. The stationary safety contact edges are connected directly to the switching
unit.
The switching unit continuously monitors these four safety contact edge circuits for actuation or interruption
(cable break). In the event of a fault, one of the two stop commands (stop in the opening direction or stop in
the closing direction) is issued to the respective safety contact edge circuit. A terminating resistor is integra-
ted into the end edge of the relevant safety contact edge circuit in order to enable the standby current of the
entire system to be monitored. If the specified standby current is flowing, the output relays are activated and
the switching contacts are closed. If the switching element is actuated or the sensor circuit is interrupted,
the relay switching contacts open.
The switching states of the relays and the applied operating voltage are indicated by LEDs.

English
If an error is present, all the safety outputs are not active.

4. Proper use
The INDUS rail 71-242 (INDUS rail 71-942) switching unit can only fulfil its safety-related task if used properly.

The INDUS rail 71-242 (INDUS rail 71-942) safety transmission system is designed for evaluating stationary and
travelling safety contact edges with constant 8.2 kΩ resistance.
Any uses above and beyond these uses constitute 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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 Inductive signal transmission system

5. System components fitted to the gate

1 Gate open
s

safety contact edge OPEN movement Gate close

s
ISK 71-24
2

safety contact edge CLOSE movement

Power

safety contact edge OPEN movement

Transmit Opening
Stationary
Opening

safety contact edge CLOSE movement

safety contact edge CLOSE movement

Transmit

safety contact edge OPEN movement

Stationary

3 11 3 10 1 2

2 2 2

2 4 3
Example of use 1 INDUS rail 71-242 (INDUS rail 71-942) control device
The actual arrangement of the individual components 2 Stationary coil core
depends on the design of the gate in question and the 3 Travelling coil core
conditions at the installation site. 4 Steel cable acting as transmission medium
- with 2 additional wires
6. Device overview
6.1 Signal Indicators
INDUS rail INDUS rail
LED Power (green)
English

71-242 71-942
Operating state (on)
Error message (pulse output)
LED Transmit Opening (red)
travelling edge(s) for opening movement
actuated / interrupted (on)
LED Stationary Opening (red)
stationary edge(s) for opening movement
actuated (on) - interrupted (flashes)
LED Transmit Closing (red)
travelling edge(s) for closing movement
actuated / interrupted (on)
LED Stationary Closing (red)
stationary edge(s) for closing movement
actuated (on) - interrupted (flashes)
V1.0: 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).
During the output of an error message, the number of output pulses indicates the error:
Pulse Error message
1 Voltage supply outside of the valid value range
2 Inductive signal transmission system error
3 Output control Open faulty
4 Output control Close faulty
5 Data transmission with microcontroller faulty
6 Testing sensor input faulty (stationary safety contact edges) (Open/Close)

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 INDUS rail 71-242 + INDUS rail 71-942
Inductive signal transmission system

6.2 Connection terminals INDUS rail INDUS rail

71-242 71-942
INDUS rail 71-242 INDUS rail 71-942
Pin 1, 2 stationary coil core Transmit 7
6
5
8 4
Pin 3, 11 SCE - leading pillar opening Stationary Op.
Pin 3, 10 SCE - leading pillar closing Stationary Cl.
Pin 4, 5 relay output for controller - stop opening Pin 4, 5
Pin 6, 7
9 3
Pin 6, 7 relay output for controller - stop closing 10 2
11 1

Pin 8, 9 supply voltage 24 V Pin 8, 9

7. Connecting the device

Bottom
7.1 Prerequisites
• The signal cable must not be placed parallel to the motor cable or other power cables.
• The supply voltage used for the INDUS rail 71-242 and the INDUS 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.

INDUS rail INDUS rail

71-242 71-942
7.2 Supply voltage
With the INDUS rail 71‑242 and INDUS rail 71‑942, 24 V AC/DC is to be
8 connected to terminal pair 8, 9 as voltage supply. The supply line to the 8

English
switching unit must be protected with an appropriate fuse.

9 9
7.3 Connecting the stationary coil core
INDUS rail 71-242: Connect the stationary coil core to terminal pair 1, 2;
%- +% no special attention is required for polarity. %- +%
INDUS rail 71-942: The stationary coil core is to be connected to the
Transmit slot.

7.4 Connecting the stationary safety contact edges

INDUS rail 71-242: The stationary safety contact edge(s) on the leading
pillar for the opening movement is (are) connected to terminal pair 3, 11.
INDUS rail 71-942: The stationary safety contact edge(s) for the opening
1 2
movement is (are) connected to the Stationary Opening slot.
If several safety contact edges are being used, they must be connected
in series and the end edge must be terminated using an 8.2 kΩ resistor.
INDUS rail 71-242: The stationary safety contact edge(s) for the closing
movement is (are) connected to terminal pair 3, 10.
INDUS rail 71-942: The stationary safety contact edge(s) for the closing
movement is (are) connected to the Stationary Closing slot.
If one or both channels for the stationary safety contact edge are not
10 3
11 used, the supplied 8.2 kΩ resistors are to be connected to the respec-
tive channels.

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 Inductive signal transmission system

7.5 Connecting the control circuits

The control circuit to be monitored for the opening movement (stop-
7 6 5 opening movement) is to be connected to terminal pair 4, 5 ; for the 7 6 5
4 closing movement (stop-closing movement), the appropriate control 4
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.

ct ed ge
8. Connecting the safety contact edges conta
safety ENING
OP
8.1 Connecting to the coil core SPK 54 (figure 1) ment
move
The travelling safety contact edges are connected to the C O e
travelling coil core. ct edg
conta
For this purpose, the travelling safety contact edge CLOSING safety OSING
CL
movement is connected to connection C of the travelling ment
move
coil core and the optional safety contact edge OPENING
movement is connected to connection O.
Figure 1: Connection at the coil core

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

9.2 Connecting multiple safety contact edges per sensor circuit (figure 2)
English

One or more safety contact edges can be connected to sensor input O or C. For this purpose, the individual
safety contact edges are connected in series according to figure 2.
Up to five safety contact edges may be connected in series, whereby the total cable length must not exceed 25 m.
The length of one safety contact edges may be up to 25 m.
Before connecting the safety contact edges 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 safety contact edge is inactive and must not exceed 500 Ω
when it is active.

ASO safety contact edges must not be connected in parallel.

safety contact edges 1 safety contact edges 2 safety contact edges „n“
O 2 2 2 2
C
Figure 2: Wiring of multiple safety contact edges

9. Commissioning / functional test

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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INDUS rail 71-242 + INDUS rail 71-942
Inductive signal transmission system

10. 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 The supply voltage is missing, too low Check connections and supply voltage:
illuminated or has been connected incorrectly - 24 V AC/DC at terminals 8 9
Tolerance range: ±10%
A single red LED safety contact edge(s) not connected, - Check the connections of the corresponding
is illuminated connected incorrectly or faulty safety contact edge (squeezed or brittle
supply lines, etc.)
- Check safety contact edge(s)*
One of the safety contact edge Any safety contact edge connections that are
connections is not being used not being used must be permanently bridged
using one of the supplied 8.2 kΩ resistors
Both of the red The transmission line is faulty or has - Observe the mech. assembly instructions
Transmit LEDs been installed incorrectly (INDUS safety transmission system)
are illuminated - 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**
safety contact edge(s) not connected, - Check the connections of the corresponding
connected incorrectly or faulty safety contact edge (squeezed or brittle

English
supply lines, etc.)
- Check safety contact edge(s)*

* 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 safety contact edge inputs on the INDUS rail 71-242 (INDUS rai 71-942) electronic
evaluation system (terminals 3, 10 and terminals 3, 11) and to the travelling 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 safety contact edge for the
electronic evaluation system or for the travelling 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 travelling safety contact edges (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 INDUS
rail safety transmission system assembly instructions) or an impermissibly 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 terminal and then measuring the resistance
between the end of the steel cable and ground terminal.

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 Inductive signal transmission system

11. 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 national regulations. Products can also be
returned to ASO, which will then dispose of them properly.

12. Technical specifications

Supply voltage UE 24 V AC/DC ±10%
IE = 85 mA; Imax = 180mA (100ms)
Terminal resistance of the safety contact edges
Stationary Travelling

82
contact edge contact edge
nominal value Rnom = 8,2 kΩ = 8,2 kΩ
upper switching point RAO > 12 kΩ > 20 kΩ
lower switching point RAU < 5 kΩ < 2,5 kΩ
84
Relay stages 38
0
Nominal current DC 3A 30 V DC 11
Nominal current AC 3A 30 V AC
Mech. life-time >106 actuations
INDUS rail 71-242
Safety relay switching times
Stationary Travelling
contact edge contact edge
Switching off delay (response time) < 10 ms < 30 ms
English

Switching on delay 500 ms (Power on 700 ms)

Assembly
82

Plug base for 35 mm DIN snap-on rail mounting

Housing 11-pin DIN plug-base housing with plug
base for 35 mm mounting rail (DIN rail)
Dimensions: (HxWxD)
Housing 82 x 38 x 84 mm 84
38
Housing incl. plug base 82 x 38 x 110 mm 11
0
Protection class IP20
Weight 225 g
Temperature range -25°C to +55°C INDUS rail 71-942
Connection cable cross-section
single- or fine-stranded cable 0,75-1,5 mm2
Certifications DIN EN ISO 13849-1:2008 Category 3 PL e
MTTFd 170 years, DC 91% EC type-examination no.:
Elektronik MTTFd 1616 years, DC 99 % 44 205 12 399386
Elektromechanik B10d 1000000 Certificate no.:
MTTFd 190 years (Nop 52560) 44 780 12 399386
Safety device acc. to DIN EN 12978
Test report no.:
All voltages connected to the switching unit must 12 205 399386-000
be safely isolated!

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INDUS rail 71-242 + INDUS rail 71-942
Inductive signal transmission system

13. EC declaration of conformity

We hereby declare that the following product:

INDUS rail 71-242 (part no. 1204-0100, serial number format yymmnnnnn)
INDUS rail 71-942 (part no. 1204-0110, serial number format yymmnnnnn)
Inductive transmission device with safety switching system to be used in combination
with safety contact edges for preventing dangers at locations on gate systems where
there is a risk of crushing and cutting satisfies the relevant essential health and safety
requirements of the EC directives and standards listed below on account of its design
and construction, as does the version brought to market by us:

EC - machinery directive 2006/42/EC

EN ISO 13849‑1:2008
EN ISO 13849-2:2008
EN 61000-6-2:2005
EN 61000-6-3:2007

EC - type approval
Notified Body 0044
TÜV NORD CERT GmbH

English
Langemarckstraße 20
D-45141 Essen
EC type-examination no.: 44 205 12 399386

This declaration of conformity does not relieve the designer/manufacturer of the

machine from his obligation to ensure that the conformity of the entire machine to
which this product is attached satisfies the corresponding EC directive.

Manufacturer and Authorised Signatory:

ASO, Antriebs- und Steuerungstechnik GmbH,
Hansastraße 52, D-59557 Lippstadt / Germany

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