MAYSER SG-EFS 104/2W User manual

EN | Operating instructions
Control unit SG-EFS 104/2W
Original instructions
1005196 SG-EFS 104/2W 24 V=/~
Version 0.9
Mayser GmbH & Co. KG
Örlinger Straße 1–3
89073 Ulm
GERMANY
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.mayser.com
Innovative by tradition.

Page 2/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Copyright
The reproduction, distribution and utilization of this document as well as the communication of its contents with-
out express authorization are prohibited. Oenders 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 2020
Safety first!
•Read the manual carefully before use.
•Warning signs in the manual warn of unexpected dangers. Always ob-
serve warning signs.
•Retain the manual throughout the service life of the product.
•Pass the manual on to every subsequent owner or user of the product.
•Insert every supplement received from the manufacturer into the man-
ual.
•Observe chapter on Safety starting on page 5.
Conformity
The Declaration of Conformity is available in the download section of the website:
www.mayser.com/en/downloads
The design type of the product complies with the basic requirements of the following
directives:
•2006/42/EC (Safety of machinery)
•2011/65/EC (RoHS)
•2014/30/EC (EMC)

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 3/19
Contents
Contents
About this manual .................................................................................................................................................................4
Safety..........................................................................................................................................................................................5
Intended use .........................................................................................................................................................................5
Safety instructions................................................................................................................................................................5
Residual dangers ..................................................................................................................................................................6
Parts supplied ..........................................................................................................................................................................7
Storage ......................................................................................................................................................................................7
Product overview....................................................................................................................................................................7
Connections...........................................................................................................................................................................7
LED indicators........................................................................................................................................................................8
Operation..................................................................................................................................................................................8
Reset........................................................................................................................................................................................9
Automatic reset........................................................................................................................................................9
Manual reset .............................................................................................................................................................9
Installation................................................................................................................................................................................9
Reset..................................................................................................................................................................................... 10
Automatic reset..................................................................................................................................................... 10
Manual reset ..........................................................................................................................................................10
Signal outputs.................................................................................................................................................................... 11
Signal outputs with USAC ..................................................................................................................................11
Signal outputs with US DC................................................................................................................................... 11
Connection examples ......................................................................................................................................................11
Commissioning......................................................................................................................................................................13
Testing.................................................................................................................................................................................. 13
Automatic reset..................................................................................................................................................... 13
Manual reset ..........................................................................................................................................................13
Pressure-sensitive protection device actuated........................................................................................................... 14
Correlations ........................................................................................................................................................................15
Decommissioning .............................................................................................................................................................15
Recommissioning.............................................................................................................................................................. 15
Maintenance and cleaning................................................................................................................................................15
Maintenance ......................................................................................................................................................................15
Cleaning ..............................................................................................................................................................................15
Troubleshooting and remedies ........................................................................................................................................16
Replacement parts ...............................................................................................................................................................17
Disposal ...................................................................................................................................................................................17
Technical data........................................................................................................................................................................18

Page 4/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
About this manual
Symbols used Symbol Meaning
Ä... Action with one or more steps whose order is not rele-
vant.
1. ... Action with several steps whose order is relevant.
• ...
- ...
Bullets first level
Bullets second level
(see Section Installation) Cross-reference
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 inju-
ries.
NOTE Potential danger of property damage or environmental deg-
radation.
Information on easier and safer working practices.
Other applicable
documents
ÄAlso observe the following documents:
-Drawing of the sensor system (optional)
-Wiring diagram (optional)
-Installation instructions of the sensors used
Target group This manual is intended for the owner and electricians. The electrician must be famil-
iar with the installation and commissioning.
Validity This manual is valid only for the product specified on the title page.
This manual is an integral part of the product.
Mayser will assume no liability and provide no guarantee whatsoever for damages
and consequential damages resulting from failure to comply with the manual.
Dimensions in draw-
ings
Unless otherwise indicated, all dimensions are stated in millimetres (mm).
About this manual

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 5/19
Safety
Intended use
ÄDo not open the control unit
Never open, tamper with or alter the control unit.
ÄObserve degree of protection
Only use the control unit in rooms with a minimum degree of protection of IP54
(e.g. switch cabinet).
Safety
Safety instructions
To prevent irreparable damage to the product, the following safety instructions ap-
ply.
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.
ÄDisable in case of error
Disable the safety device in case of malfunctions or visible damage.
ÄPrevent restarting of the machine
As long as a hazard continues to exist, take measures to prevent the machine
from restarting, for example by means of a startup lockout.
ÄPrevent electric shock
When working on electrical systems, always disconnect them from the power
supply and secure them against being switched on again, to prevent injuries from
electric shock.
For your own safety the following safety instructions apply.
ÄEnsure careful configuration of interface
The quality and reliability of the interface between the safety device and the ma-
chine aects the overall safety. Take special care when setting up this interface.
The product complies with ISO13849-1:2015 Category 3 PLd. So that the
safety classification is retained, the downstream control must be of the same or a
higher category.
The control unit is designed for the signal processing of a pressure-sensitive protec-
tive device. It evaluates the initial state of the sensor with monitoring resistor 1k2 or
8k2. The integrated output signal switching device (OSSD) transmit the evaluated
safety signals directly to the downstream control.

Page 6/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Safety
Terminals Y1, Y2 and Y3 are not potential-free
ÄProtect against strong electromagnetic signals
Protect the control unit against excessive EMC radiation. A strong electromagnet-
ic signal can cause the control unit to switch to a safe OFF state.
ÄContinue redundancy
Make sure you wire the unit directly in the control circuit or that the downstream
control is also in dual channel mode.
Residual dangers
There are no known residual dangers associated with this product.
ÄDo not cross link control unit
Do not cross link the control unit with other control units.
ÄFit spark absorbers
When connecting inductive loads, fit spark absorbers (RC modules) to the con-
sumer.
ÄCheck supply voltage
Check supply voltage. It must correspond with the connecting voltage USon the
type plate.
ÄObserve pin assignment
Observe pin assignment when connecting the supply voltage.
ÄProtect relay contacts
Risk of welding: Protect the relay contacts externally.
ÄDo not overload control unit
Ensure that the specified switching current is not exceeded.
ÄDo not exceed the maximum number of sensors
Do not connect more sensors on the control unit, than the number specified in
the installation instructions of the sensors.
ÄMaintain distance
When installing in the switch cabinet, ensure sucient distance from heat sourc-
es (at least 2 cm).

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 7/19
Parts supplied
Connections: Terminals:
A1, A2 Supply voltage
Input sensor:
Y1, Y2 Sensor 1k2
Y1, Y3 or 8k2
13, 14 OSSD 1
23, 24 OSSD 2
41, 42 Signal circuit
Signal output with USAC
M1, S1 Sensor
M2, S1 Fault
Signal output with USDC
M1, A2 Sensor
M2, A2 Fault
S1, S2 Bridge for automatic reset
S1, S3 Button for manual reset
Parts supplied
1× Control unit
Enclosure with electronics module and plug-in connectors.
1× Operating instructions
1× Declaration of Conformity
ÄUpon receipt of the parts supplied, check immediately for completeness and good
condition.
Product overview
Connections
ÄStore the control units in the original package, in a dry place.
ÄComply with the storage temperature specified in the technical data.
Storage

Page 8/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Operation
•Green LED “Power“:
supply voltage connected
•Green LED “Sensor“:
sensor not actuated
•Green LED “Output“:
control unit ready
•Red LED “Fault“:
cable break
If the sensor is actuated, OSSDs 1 and 2 are open. The green LEDs “Sensor“ and “Out-
put“ go out, the signal output M1 is LOW and the signal output M2 is HIGH. The sig-
nal circuit is closed.
The control unit is powered with AC/DC 24 V. When the supply voltage is connect-
ed, the green “Power“ LED is lit. When the sensor is not actuated, and after a reset,
OSSDs 1 and 2 are closed. The green LEDs “Sensor“ and “Output“ are lit and the sig-
nal outputs M1 and M2 are HIGH. The signal circuit is open.
In the case of a cable break at the sensor, OSSDs 1 and 2 are open. The red LED
“Fault“ is on. The green LEDs “Sensor“ and “Output“ go out, the OSSDs 1 and 2 are
open and the signal outputs M1 and M2 are LOW. The signal circuit is closed.
The signal output M1 and the signal circuit operate opposite to OSSDs 1 and 2.
The single-fault-safe electronics module has dual channels (redundant). Each channel
triggers a force-guided relay (OSSD 1 and 2), which additionally monitor each other.
The electronic system monitors the electrical resistance of the sensor with a defined
zero signal current.
Operation
LED indicators
Ready for operation
Sensor activated
Signal output and signal circuit
Sensor cable break

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 9/19
Installation
If the reset button is pressed, the OSSDs switch with a delaytw back to HIGH.
For your safety, the well-known safety rules also apply for assembly:
•Disconnect all devices and live parts in the immediate vicinity from the power
supply.
•Ensure that all devices and live parts cannot be switched back on.
•Test to ensure that all devices and live parts are disconnected from the power
supply.
Reset
Automatic reset
The control unit operates without a reset function. If the pressure-sensitive protection
device is no longer actuated, the output signal switching device of the control unit
automatically changes from the OFF state to the ON state. Without additional start
interlock, the machine would start up again immediately.
Manual reset
The control unit operates with a reset function. If the pressure-sensitive protection
device is no longer actuated, the output signal switching device of the control unit is
in OFF state. This prevents restart of the machine. Only the manual reset command
eectuates the change from the OFF state to the ON state.
Installation
1. Mount the control unit in any position on a 35mm mounting rail type IEC60715.
Caution: Functional impairment due to overheating
If the control unit is overheated due the eects of external heat, this can result in
functional impairment or failure of the pressure-sensitive protection device.
ÄAlways ensure sucient distance from heat sources (at least 2 cm).

Page 10/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Installation
A bridge is necessary for automatic reset (without reset command). The unit is sup-
plied with a bridge already connected between cable terminals S1 and S2 .
ÄCheck if the bridge is set between cable terminals S1 and S2.
For manual reset (with reset command), a button must be connected between cable
terminals S1 and S3. The control unit reacts when the button changes from “not acti-
vated“ to “activated“, i.e. if the button is jammed, the no reset command is initialised.
ÄRemove the bridge between cable terminals S1 and S2.
ÄWire up a button between cable terminals S1 and S3.
Reset
Automatic reset
Manual reset
2. Wire the sensors, relay contacts and supply voltage to the cable terminals.

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 11/19
Installation
Signal outputs with US DC
The signal outputs M1 and M2 are semiconductor outputs (PNP) and short-circuit-
proof. When they are at HIGH status, they have a voltage of 18 to 22 V, depending
on load and supply voltage.
The second connection to the signal outputs is cable terminal A2.
Signal output M1: Sensor
ÄWire the load between cable terminals M1 and A2.
Signal output M2: Fault
ÄWire the load between cable terminals M2 and A2
Signal outputs with USAC
The signal outputs M1 and M2 are semiconductor outputs (PNP) and short-circuit-
proof. When they are at HIGH status, they have a voltage of 20 to 29 V, depending
on load and supply voltage.
The second connection to the signal outputs is cable terminal S1. To prevent damage
to the device, never use cable terminal A2 with UsAC.
Signal output M1: Sensor
ÄWire the load between cable terminals M1 and S1.
Signal output M2: Fault
ÄWire the load between cable terminals M2 and S1.
Signal outputs
Connection examples
Connection examples 1

Page 12/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Installation
Connection examples 2
Contact duplication
with automatic reset
Contact duplication
with manual reset

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 13/19
Commissioning
1. Make sure no sensors are actuated.
-green LEDs “Power“, “Sensor“ and “Output“ are lit
-OSSDs 1 and 2 are closed
-signal circuit is open
-signal outputs M1 and M2 are HIGH
2. Actuate sensor.
-green LEDs “Sensor“ and “Output“ go out
-OSSDs 1 and 2 are open
-signal circuit is closed
-signal output M1 is LOW and M2 is HIGH
3. Repeat step 1.
4. Disconnect the sensor.
-green LEDs “Sensor“ and “Output“ go out
-red LED “Fault“ is on
-OSSDs 1 and 2 are open
-signal circuit is closed
-signal outputs M1 and M2 are LOW
5. Repeat step 1.
1. Make sure no sensors are actuated.
-green LEDs “Power“ and “Sensor“ are lit
-OSSDs 1 and 2 are open
-signal circuit is closed
-signal outputs M1 and M2 are HIGH
Commissioning
1. Make sure the plug connections are firmly attached.
2. Connect the supply voltage.
WARNING: Danger of injury due to electrocution
ÄNever unplug plug connections with the power on.
Automatic reset
Testing
Manual reset
When the functional test has been successfully completed the pressure-sensitive pro-
tection device is ready for operation.
If the functional test was faulty, see chapter Troubleshooting and remedies.

Page 14/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Commissioning
2. Activate the reset button.
-green LEDs “Power“, “Sensor“ and “Output“ are lit
-OSSDs 1 and 2 are closed
-signal circuit is open
-signal outputs M1 and M2 are HIGH
3. Actuate the sensor. (The described state is visible only during actuation of the
sensor.)
-green LEDs “Sensor“ and “Output“ go out
-OSSDs 1 and 2 are open
-signal circuit is closed
-signal output M1 is LOW and M2 is HIGH
4. Repeat steps 1 and 2.
5. Disconnect the sensor.
-green LEDs “Sensor“ and “Output“ go out
-red LED “Fault“ is on
-OSSDs 1 and 2 are open
-signal circuit is closed
-signal outputs M1 and M2 are LOW
6. Repeat steps 1 and 2.
Pressure-sensitive protection device actuated
As long as the pressure-sensitive protection device remains actuated, the output sig-
nal switching devices of the control unit remain in the safe OFF state.
If actuation of the pressure-sensitive protection device ends, dierent states are pos-
sible on the output signal switching devices of the control unit. This depends on the
selected reset type (see chapter Operation, subchapter Reset).
When the functional test has been successfully completed the pressure-sensitive pro-
tection device is ready for operation.
If the functional test was faulty, see chapter Troubleshooting and remedies.

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 15/19
Maintenance and cleaning
LEDs Outputs Remedy
Power
green
Sensor
green
Output
green
Fault
red
13, 14
23, 24 41, 42 M1 M2 LED o: LED on:
open closed LOW LOW Supply voltage o
open closed HIGH HIGH Supply voltage is on; Sensor not actu-
ated; No reset signal
closed open HIGH HIGH Control unit ready
open closed LOW HIGH Sensor actuated
open closed LOW LOW Faulty sensor (cable break)
Correlations
Recommissioning
Decommissioning
ÄCarry out commissioning (see chapter Commissioning).
ÄSwitch o the pressure-sensitive protection device and safeguard it from being
switched back on unintentionally.
ÄAx a clear warning on the pressure-sensitive protection device warning that
states it is temporarily or definitively decommissioned.
Cleaning
ÄClean the outside of the enclosure with a dry cloth.
Maintenance and cleaning
Maintenance
The control unit is maintenance-free.
ÄRepeat the operational test monthly.

Page 16/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Troubleshooting and remedies
Fault display Possible cause Remedy
Green LED „Power“ is o No or incorrect supply voltage 1. Check supply voltage, compare with
type plate
2. Check terminal connections
If supply voltage is correctly connected:
control unit is faulty
ÄReplace control unit
Green LED “Sensor“ is o
and
signal output M1 is LOW
Incorrect monitoring resistor on the sensor ÄConnect sensor with monitoring resis-
tor 1k2 or 8k2
Sensor incorrectly connected ÄCheck terminal connections
ÄSensor with 1k2 connected to Y1 and
Y2?
ÄSensor with 8k2 connected to Y1 and
Y3?
If monitoring resistor is correct: sensor is
faulty
ÄReplace sensor
Green LED “Sensor“ is on
and
green LED “Output“ is o
Manual reset: reset button not activated Ä Activate reset button
Manual reset: connection to button broken ÄCheck connection to button
Manual reset: jammed button ÄReplace buttons on S1 and S3
Automatic reset: bridge missing ÄConnect bridge between S1 and S2
Control unit is faulty ÄReplace control unit
Green LEDs “Power“,
“Sensor“ and “Output“
are on
and
OSSD 2 is open
Control unit is faulty ÄReplace control unit
Red LED “Fault“ is on
and
signal output M2 is LOW
Incorrect monitoring resistor on the sensor Ä Connect sensor with monitoring re-
sist-or 1k2 or 8k2
Sensor incorrectly connected ÄCheck terminal connections
Ä Sensor with 1k2 connected to Y1 and
Y2?
ÄSensor with 8k2 connected to Y1 and
Y3?
Cable break ÄReplace sensor
Troubleshooting and remedies
Prerequisite: the control unit is connected to the supply voltage and sensor. No sen-
sor is activated.
The fault can still not be removed?
ÄContact Mayser support: Phone [phone].
ÄIn case of queries, have the information on the type plate at hand.
Type plate A type plate for identification of the control unit is axed on the side.

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 17/19
Replacement parts
The devices produced by Mayser are professional electronic tools exclusively intend-
ed 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 sec-
tor 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
Disposal
Control unit
Packaging •Wood, cardboard, plastics
ÄObserve the following with respect to disposal:
-Comply with the relevant national disposal regulations and legal stipulations
for these materials.
-If you engage a disposal firm, make sure that a list of the above materials is
included.
-Materials should be recycled or disposed of in an eco-friendly manner.
Replacement parts
CAUTION Overall safety endangered
If the sensor is not replaced with original Mayser parts, operation of the protec-
tive device may be impaired.
ÄOnly use original parts from Mayser.

Page 18/19 Operating instructions SG-EFS 104/2W 050320 v2.10-RiA
Technical data
SG-EFS 104/2W AC 24 V DC 24 V
Test principles EN 12978, ISO 13849-1, ISO13856-1, ISO13856-2, ISO13856-3
Supply voltage US
Voltage tolerance -10% to + 10% -10% to +10%
Nominal current 70 mA 60 mA
Nominal frequency 50 to 60 Hz –
External protection 200 mA slow-acting 200 mA slow-acting
Power consumption < 4 VA < 3 W
Times
Reaction time ta < 15 ms < 15 ms
Re-start time tw< 50 ms < 50 ms
Safety classifications
ISO13856: Reset function with/without with/without
ISO 13849-1:2015 Category 3 PL d Category 3 PL d
MTTFd257 a 257 a
DCavg 60% 60%
B10d (Load: DC 24 V / 1 A) 1.8× 1061.8× 106
nop (estimate) 52560 per year 52560 per year
CCF Requirements fulfilled Requirements fulfilled
IEC 60664-1: creep distance and air
gap
Contamination level 2, overvoltage
category III / 250 V, basic insulation
Contamination level 2, overvoltage
category III / 250 V, basic insulation
Inputs
Sensor Y1, Y2 Y1, Y3 Y1, Y2 Y1, Y3
Monitoring resistor 1k2 Ohm 8k2 Ohm 1k2 Ohm 8k2 Ohm
Short-circuit resistance ≤ 400 Ohm ≤ 400 Ohm ≤ 400 Ohm ≤ 400 Ohm
Resistivity ≤ 10 Ohm ≤ 10 Ohm ≤ 10 Ohm ≤ 10 Ohm
Cable length (max.) 100 m 100 m 100 m 100 m
Switching thresholds
Sensor activated < 0.6 kOhm < 4 kOhm < 0.6 kOhm < 4 kOhm
Cable break > 1.8 kOhm > 12 kOhm > 1.8 kOhm > 12 kOhm
Reset
Automatic S1, S2 S1, S2
Manual S1, S3 S1, S3
Cable length (max.) 30 m 30 m
Technical data

050320 v2.10-RiA Operating instructions SG-EFS 104/2W Page 19/19
Technical data
SG-EFS 104/2W AC 24 V DC 24 V
Outputs
OSSD 1 and 2 (NO contact) 13, 14 and 23, 24 13, 14 and 23, 24
Signal circuit (NC contact) 41, 42 41, 42
Utilization category AC-12: 250 V / 4 A AC-12: 250 V / 4 A
as per IEC 60947-5-1 DC-12: 24 V / 4 A DC-12: 24 V / 4 A
Switching voltage (max.) AC 250 V DC 24 V AC 250 V DC 24 V
Switching current (max.) 4 A 4 A 4 A 4 A
Switching capacity (max.) 1000 VA 96 W 1000 VA 96 W
Switching operations, mechanical > 1× 107> 1× 107
Switching operations, electrical > 3.6× 105(DC 24 V / 1 A) > 3.6× 105(DC 24 V / 1 A)
Contact fuse protection, external 6.3 A quick-acting 6.3 A quick-acting
Line length (max.) 30 m 30 m
Signal output (PNP) M1, S1 M2, S1 M1, A2 M2, A2
Type of signal Sensor Fault Sensor Fault
Voltage DC 20 to 29 V DC 20 to 29 V DC 18 to 22 V DC 18 to 22 V
Load current (max.) 100 mA 100 mA 100 mA 100 mA
Line length (max.) 30 m 30 m 30 m 30 m
Mechanical operating conditions
Cable terminals 4× 4-poles 4× 4-poles
solid wire 1× 2.5 mm2or 2× 1.5 mm21× 2.5 mm2or 2× 1.5 mm2
strand with sheath 1× 2.5 mm2or 2× 1.5 mm21× 2.5 mm2or 2× 1.5 mm2
IEC 60529: Degree of protection IP20 IP20
max. humidity (23 °C) 95% 95%
Operating temperature -25 °C to +55 °C -25 °C to +55 °C
Storage temperature -25 °C to +55 °C -25 °C to +55 °C
Impact resistance in operation 2.5 g 2.5 g
2006/42/EC: Emission sound pres-
sure level
< 70dB(A) < 70dB(A)
Dimensions (W × H × D) 22.5 × 99 × 114.5mm 22.5 × 99 × 114.5mm
Weight 180 g 180 g