MAYSER SG-EFS 104 ZK2/1 8k2 User manual

Polymer Electric
GmbH & Co. KG
Polymer Electric
Örlinger Straße 1–3
89073 Ulm
GERMANY
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.mayser.com
Control Unit SG-EFS 1X4 ZK2/1 8k2
1003100 SG-EFS 104 ZK2/1 8k2 24 V=/~
7500354 SG-EFS 134 ZK2/1 8k2 230 V~
Version 3
Operating Instructions
Original instructions

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Polymer Electric
Contents
Copyright
The reproduction, distribution and utilization of this document as well as the communication of its contents with-
out express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights re-
served in the event of the grant of a patent, utility model or design.
© Mayser Ulm 2016
About these operating instructions......................................................................................................................... 3
Intended use .............................................................................................................................................................. 4
Safety instructions .................................................................................................................................................... 4
Parts supplied............................................................................................................................................................ 5
Transport and storage............................................................................................................................................... 6
Packaging and transport.................................................................................................................................... 6
Storage.............................................................................................................................................................. 6
Product overview....................................................................................................................................................... 6
Connections ...................................................................................................................................................... 6
LEDs information............................................................................................................................................... 6
Function, installation and commissioning .............................................................................................................. 7
Function............................................................................................................................................................. 7
Installation ......................................................................................................................................................... 7
Automatic reset ....................................................................................................................................... 8
Manual reset ........................................................................................................................................... 9
Commissioning.................................................................................................................................................. 9
Test function: automatic reset.................................................................................................................. 9
Test function: manual reset ................................................................................................................... 10
Recommissioning............................................................................................................................................ 10
Automatic reset ..................................................................................................................................... 10
Manual reset ......................................................................................................................................... 10
Connection examples...................................................................................................................................... 11
Contacts continued in two-channel mode ............................................................................................. 11
Contact duplication for automatic reset ................................................................................................. 11
Contact duplication for manual reset..................................................................................................... 11
Maintenance and cleaning...................................................................................................................................... 12
Maintenance.................................................................................................................................................... 12
Cleaning .......................................................................................................................................................... 12
Troubleshooting and remedies .............................................................................................................................. 13
Replacement parts .......................................................................................................................................... 13
Disposal.................................................................................................................................................................... 13
Conformity ............................................................................................................................................................... 14
EC Design Test................................................................................................................................................ 14
Technical Data ......................................................................................................................................................... 14

130116 v3.2 Operating Instructions SG-EFS 1X4 ZK2/1 8k2 Page 3/15
Polymer Electric
About these operating instructions
These operating instructions are only valid for the products specied on the title
page.
These operating instructions are part of the product.
Mayser Polymer Electric accepts no responsibility or warranty claims for damage
and consequential damage due to failure to observe the operating instructions.
ÄRead operating instructions carefully before use.
ÄKeep operating instructions for the complete service life of the product.
ÄPass operating instructions on to every subsequent owner or user of the prod-
uct.
ÄAdd any supplement received from the manufacturer to the operating instruc-
tions.
ÄIn addition to the operating instructions, observe the following documents:
- Drawing of the sensor system (optional)
- Wiring diagram (optional)
- Installation instructions of the sensors used
The target group of these operating instructions are operators and trained specialist
personnel who are familiar with installation and commissioning.
Validity
Target group
Other applicable
documents
Symbols used Symbol Meaning
Ä... Action with one step or with more than one step where
the order is not relevant.
1. ...
2. ...
3. ...
Action with more than one step where the order is rel-
evant.
• ...
- ...
Bullets rst level
Bullets second level
(see section Installation) Cross-reference

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Polymer Electric
Danger symbols and
information
Symbol Meaning
DANGER Immediate danger leading to death or serious injury.
WARNING Imminent danger which may lead to death or serious injury.
CAUTION Possible danger which may lead to minor or moderate
injuries.
Information on easier and safer working practices.
Intended use
The Control Unit is designed for signal processing of a pressure-sensitive protective
device (PSPD). It evaluates the output signals of sensors with monitoring resistor
8k2. The integrated output signal switching device (OSSD) transmits the evaluated
safety signals directly to the downstream control.
Safety instructions
ÄMaintain distance
When installing in the switch cabinet, ensure sufficient distance from heat
sources (at least 2 cm).
ÄCheck supply voltage
Check supply voltage. It must correspond with the connecting voltage USon the
type plate.
The Control Unit complies with ISO13849-1:2006 Category3 PLe. So that the
safety classication is retained, the downstream control must be of the same or a
higher category.
ÄObserve protection class
Only use the Control Unit in rooms with a minimum degree of protection of IP54
(e.g. switch cabinet).
ÄDo not open the Control Unit
Never open, tamper with or alter the Control Unit.

130116 v3.2 Operating Instructions SG-EFS 1X4 ZK2/1 8k2 Page 5/15
Polymer Electric
ÄIn the event of a fault, put out of operation
In the event of malfunctions and visible damage, put the Control Unit out of op-
eration.
ÄDo not use in ATEX zones
Do not use the Control Unit in potentially explosive environments (ATEX). The
Control Unit is not authorised for use in these zones.
ÄContinue redundancy
Make sure you wire the unit directly in the control circuit or that the downstream
control is also in dual channel mode.
ÄProtect relay contacts
Risk of welding: Protect the relay contacts externally.
ÄDo not overload Control Unit
Ensure that the specied switching current is not exceeded.
ÄObserve pin assignment
Observe pin assignment when connecting the supply voltage.
ÄFit spark absorbers
When connecting inductive loads, t spark absorbers (RC modules) to the con-
sumer.
ÄDo not cross link Control Unit
Do not cross link the Control Unit with other Control Units.
Parts supplied
1× Control Unit
Enclosure with electronics module and plug-in connectors.
1× Operating Instructions
1× Declaration of Conformity
Terminals Y1, Y2 and 5, 6 and 7, 8 are not voltage free.
Upon receipt of the parts supplied, check immediately for completeness and good
condition.

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Polymer Electric
Connections: Terminals:
Supply voltage A1, A2
Switching channel 1 (Channel 1) 13, 14
Switching channel 2 (Channel 2) 23, 24
Signal circuit 31, 32
Reset 5, 6
Auto-Reset 7, 8
Sensor Y1, Y2
• yellow LED “K1 ON“:
Sensor not activated
• yellow LED “K2 ON“:
Sensor not activated
Storage
ÄStore the Control Units in the original packaging in a dry place.
ÄObserve the storage temperatures given in the technical specications.
Transport and storage
Packaging and transport
The Control Units are packed individually in cardboard boxes. Several Control Units
are stacked in one large cardboard box.
The documents are enclosed separately.
Product overview
Connections
LEDs information

130116 v3.2 Operating Instructions SG-EFS 1X4 ZK2/1 8k2 Page 7/15
Polymer Electric
The single-fault-safe electronics module has dual channels (redundant). Each
channel controls a forceguided relay and additionally monitors the relay of the other
channel. The electronic system monitors the electrical resistance of the sensor with
a dened zero signal current.
When the sensor is not actuated and after a reset, the relays K1 and K2 are en-
ergised. The yellow LEDs “K1 ON“ and “K2 ON“ are on, the switching channels 1
and2 are closed and the signal circuit is open. When the sensor is actuated, the K1
and K2 relays are de-energised. The yellow LEDs “K1 ON“ and “K2 ON“ go out, the
switching channels 1 and 2 are open, and the signal circuit is closed.
If the sensor cable breaks, relays K1 and K2 are de-energised. The yellow LEDs
“K1 ON“ and “K2 ON“ go out, the switching channels 1 and 2 are open, and the sig-
nal circuit is closed.
The signal circuit works opposed to the switch channels 1 and 2.
Impaired operation due to overheating or incorrect degree of protection
The operation of the protective device may be impaired due to overheating of the
Control Unit or due to incorrect choice of degree of protection.
ÄWhen installing in the switch cabinet, ensure sufficient distance from hest
sources (at least 2 cm)
ÄOnly use the Control Unit in zones that have a min. protection class of IP54
(eg. switch cabinet)
Function
Function, installation and commissioning
Installation
Danger of injury due to electrocution!
ÄDisconnect all devices and live parts in the immediate environment of the
power supply and protect them against being switched on again (see relevant
operating instructions).
ÄCheck that all devices and parts are disconnected from the power supply.
WARNING
CAUTION

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Polymer Electric
Reset Auto-Reset
Sensor
Switching
channel 1
Signal
circuit
Switching
channel 2
1. The enclosure of the Control Unit can be mounted in any position on a 35 mm
IEC 60715 rail.
Overall safety endangered
The quality and reliability of the interface between the protective device and the
machine inuences the overall safety.
ÄInstall the interface very carefully
CAUTION
2. Wire the sensors, switching channels, signal circuit and supply voltage
to the terminals.
Automatic reset
A bridge is necessary for automatic reset (without reset). The unit is supplied with a
bridge already connected between cable terminals 7 and 8.
ÄCheck if the bridge is set between cable terminals 7 and 8.

130116 v3.2 Operating Instructions SG-EFS 1X4 ZK2/1 8k2 Page 9/15
Polymer Electric
1. Make sure no sensors are activated.
- yellow LEDs “K1 ON“ and “K2 ON“ are on
- contacts of switching channels 1 and 2 closed
- signal circuit open
2. Activate a sensor.
- yellow LEDs “K1 ON“ and “K2 ON“ go off
- contacts of switching channels 1 and 2 open
- signal circuit closed
3. Repeat step 1.
4. Disconnect the sensor.
- yellow LEDs “K1 ON“ and “K2 ON“ go off
- contacts of switching channels 1 and 2 open
- signal circuit closed
Manual reset
For manual reset (with reset), a switch must be connected between cable terminals
5 and 6. The control unit reacts when the switch changes from “not activated“ to
“activated“, i.e. if the switch sticks, no reset command is initialised.
ÄRemove the bridge between cable terminals 7 and 8.
ÄWire up a switch between cable terminals 5 and 6.
Test function: automatic reset
Commissioning
1. Make sure the plug connections are rmly attached.
2. Connect the supply voltage.
Danger of injury due to electrocution!
ÄNever disconnect terminals with the power on.
ÄNever unplug plug connections with the power on.
WARNING

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Polymer Electric
1. Make sure no sensors are activated.
- yellow LEDs “K1 ON“ and “K2 ON“ are out
- contacts of switching channels 1 and 2 open
- signal circuit closed
2. Activate the reset switch.
- yellow LEDs “K1 ON“ and “K2 ON“ are on
- contacts of switching channels 1 and 2 closed
- signal circuit open
3. Activate a sensor.
- yellow LEDs “K1 ON“ and “K2 ON“ go off
- contacts of switching channels 1 and 2 open
- signal circuit closed
4. repeat steps 1 and 2.
5. Disconnect the sensor.
- yellow LEDs “K1 ON“ and “K2 ON“ go off
- contacts of switching channels 1 and 2 open
- signal circuit closed
Test function: manual reset
Recommissioning
ÄCheck for proper functioning after recommissioning (see section Commission-
ing)
Automatic reset
Manual reset
The Control Unit works without reset. If the sensor is enabled after actuation, relays
K1 and K2 re-energise after a delay tw
ÄCheck for proper functioning after recommissioning (see section Commission-
ing)
The Control Unit works with reset. Relays K1 and K2 are only energised after the
reset switch is actuated.
Danger of injury!
ÄNever start your machine as long as the risk remains.
WARNING

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Polymer Electric
Switching
channel 2
Switching
channel 1
Switching
channel 2
Switching
channel 1
Switching
channel 2
Switching
channel 1
Connection examples
Contacts continued in two-channel mode
Contact duplication for automatic reset
Contact duplication for manual reset

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Polymer Electric
Maintenance and cleaning
Maintenance
The Control Unit is maintenance-free.
ÄRepeat the operational test monthly.
Cleaning
ÄClean the outside of the enclosure with a dry cloth.
Danger of injury due to electrocution!
ÄDisconnect the Control Unit as well as all devices and live parts in the im-
mediate environment of the power supply and protect them against being
switched on again (see relevant operating instructions).
ÄCheck that all devices and parts are disconnected from the power supply.
WARNING

130116 v3.2 Operating Instructions SG-EFS 1X4 ZK2/1 8k2 Page 13/15
Polymer Electric
Troubleshooting and remedies
Prerequisite: the Control Unit is connected to the supply voltage and sensor. No
sensor is activated.
Fault display Possible cause Remedy
yellow LEDs “K1 ON“
and “K2 ON“ are out
No or incorrect supply voltage 1. Check supply voltage, compare with
type plate
2. Check terminal connections
Incorrect monitoring resistor on sensor ÄConnect sensor with monitoring
resistor 8k2
If monitoring resistor is correct: sensor is
faulty
ÄReplace sensor
No sensor connected ÄConnect sensor
Sensor incorrectly connected ÄCheck terminal connections
Cable break ÄReplace sensor
Manual reset: reset switch not actuated ÄActuate reset switch
Manual reset: reset switch sticks ÄReplace switches on terminals 5 and 6
Automatic reset: bridge missing ÄConnect bridge between terminals 7
and 8
Control Unit is faulty ÄReplace Control Unit
Only one LED is on Incorrect supply voltage ÄCheck supply voltage, compare with
type plate
Control Unit is faulty ÄReplace Control Unit
Fault can still not be detected?
ÄContact Mayser-Support: Tel. [phone].
Disposal
The devices produced by Mayser are professional electronic tools exclusively in-
tended for commercial use (so-called B2B devices). Unlike devices mainly used in
private households (B2C), they may not be disposed of at the collection centres of
public sector disposal organisations (e.g. municipal recycling depots). At the end of
their useful life, the devices may be returned to us for disposal.
WEEE reg. no. DE 39141253
Replacement parts
Overall safety endangered
If the sensor and Control Unit are not replaced with original parts from Mayser,
operation of the protective device may be impaired.
ÄOnly use original parts from Mayser.
CAUTION

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Polymer Electric
Technical Data
SG-EFS 1X4 ZK2/1 8k2 AC 24 V / DC 24 V AC 230 V
Testing basis EN 12978, ISO 13849-1, ISO13856-1, ISO13856-2, ISO13856-3
Supply voltage US
Voltage tolerance
Nominal current
Nominal frequency
External protection
Short-circuit current (max.)
Power consumption
-15% to +10% / -15% to +20%
220 mA / 112 mA
48 to 62 Hz / –
250 mA slow-acting
–
< 6 VA / < 4 W
-15% to +10%
28 mA
48 to 62 Hz
250 mA slow-acting
–
< 7 VA
Times
Reaction time ta
Re-start time tw
< 10 ms
< 190 ms
< 10 ms
< 190 ms
Safety classications
ISO13856: Reset
ISO 13849-1:2006
MTTFd
PFHd
DCavg
B10d (Load: DC 24 V / 2 A)
nop (estimate)
CCF
EN 60664-1: Creep distance and air
gap
with/without
Category 3 PL e
313 years
4.29× 10-8 1/h
90%
2× 106
52560 per year
Requirements fullled
soiling degree 2, overvoltage
category II / 230 V, basic insulation
with/without
Category 3 PL e
313 years
4.29× 10-8 1/h
90%
2× 106
52560 per year
Requirements fullled
soiling degree 2, overvoltage
category II / 230 V, basic insulation
The design type of the product complies with the basic requirements of the follow-
ing directives:
• 2006/42/EC (Safety of Machinery)
• 2004/108/EC (EMC)
Conformity
The Declaration of Conformity is available in the Downloads section of the website:
www.mayser-sicherheitstechnik.de
The product was tested by an independent institute.
An EC design type test certicate conrms conformity.
EC Design Test
The EC design type test certicate is available in the Downloads section of the
website:
www.mayser-sicherheitstechnik.de

130116 v3.2 Operating Instructions SG-EFS 1X4 ZK2/1 8k2 Page 15/15
Polymer Electric
SG-EFS 1X4 ZK2/1 8k2 AC 24 V / DC 24 V AC 230 V
Inputs
Sensor
Monitoring resistor
Short-circuit resistance
Line resistance
Line length (max.)
Switching thresholds
Sensor activated
Cable break
Y1, Y2
8k2 Ohm
≤ 400 Ohm
≤ 100 Ohm
100 m
< 3k9 Ohm
> 12k5 Ohm
Y1, Y2
8k2 Ohm
≤ 400 Ohm
≤ 100 Ohm
100 m
< 3k9 Ohm
> 12k5 Ohm
Outputs
Switching channel 1 and 2 (NO contact)
Utilization category
as per EN 60947-5-1
Switching voltage (max.)
Switching current (max.)
Switching current (min.)
Switching capacity (max.)
Switching operations, mechanical
Switching operations, electrical
Contact fuse protection external
Signal circuit (NC contact)
Switching voltage (max.)
Switching current (max.)
Switching operations, mechanical
Switching operations, electrical
Contact fuse protection external
13, 14 / 23, 24
AC-12: 250 V / 2 A
DC-12: 24 V / 2 A
AC 250 V DC 24 V
2 A 2 A
10 mA 10 mA
500 VA 48 W
> 5× 107
> 3× 105(AC 250 V / 2 A)
2 A quick-acting
31, 32
AC 42 V DC 42 V
100 mA 100 mA
> 5× 106
> 1× 106(AC 42 V)
0.1 A quick-acting
13, 14 / 23, 24
AC-12: 250 V / 2 A
DC-12: 24 V / 2 A
AC 250 V DC 24 V
2 A 2 A
10 mA 10 mA
500 VA 48 W
> 5× 107
> 3× 105(AC 250 V / 2 A)
2 A quick-acting
31, 32
AC 42 V DC 42 V
100 mA 100 mA
> 5× 106
> 1× 106(AC 42 V)
0.1 A quick-acting
Mechanical operating conditions
Cable terminals
solid wire
strand without sheath
strand with sheath
Degree of protection as per IEC 60529
max. humidity (23 °C)
Operating temperature
Storage temperature
Impact resistance in operation
Impact resistance transport
Dimensions (W × H × D)
Weight
1× 2.5 mm2or 2× 1 mm2
1× 2.5 mm2or 2× 1.5 mm2
1× 2.5 mm2or 2× 1 mm2
IP20
95%
-20 to +50 °C
-20 to +50 °C
2.5 g
10 g
45 × 75 × 105 mm
180 g
1× 2.5 mm2or 2× 1 mm2
1× 2.5 mm2or 2× 1.5 mm2
1× 2.5 mm2or 2× 1 mm2
IP20
95%
-20 to +50 °C
-20 to +50 °C
2.5 g
10 g
45 × 75 × 105 mm
282 g