MAYSER SG-EFS 104/2W User manual

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

081222 v2.11-RiA Operating instructions SG-EFS 104/2W Page 2/19
Copyright
The reproduction, distribution and utilisation of this document as well as the communication of its contents
without express authorisation is prohibited. Oenders will be held liable for the payment of damages. All
rights reserved in the event of the grant of a patent, utility model or design.
© Mayser Ulm 2022
Safety first!
•Read the instructions carefully before use.
•The warnings in the instructions are there to warn you of any unex-
pected dangers. Always heed the warnings.
•Keep the instructions somewhere safe so you can refer to them
throughout the product’s entire service life.
•Pass the instructions on to every subsequent owner or user of the
product.
•Add any supplement received from the manufacturer to the instruc-
tions.
•Observe the information under “Safety” (starting on
page5).
Conformity
The Declaration of Conformity is available in the Downloads section of our web-
site: www.mayser.com.
The design type of the product complies with the basic requirements of the fol-
lowing directives:
•2006/42/EC (Safety of Machinery)
•2011/65/EU (RoHS)
•2014/30/EU (EMC)
EC type examination
The product was tested by an independent institute.
There is an EC type examination certificate to confirm conformity.
The EC type examination certificate is stored in the Downloads section of our
website: www.mayser.com.
The Declaration of Conformity is available in the Downloads section of our web-
site: www.mayser.com.
The design type of the product complies with the basic requirements of the fol-
lowing UK Statutory Instruments:
•2008 No. 1597 (Machinery)
•2012 No. 3032 (RoHS)
•2016 No. 1091 (EMC)

081222 v2.11-RiA Operating instructions SG-EFS 104/2W Page 3/19
Table of contents
Table of contents
About these instructions......................................................................................................................................................4
Safety..........................................................................................................................................................................................5
Intended use .........................................................................................................................................................................5
Safety instructions................................................................................................................................................................5
Residual dangers ..................................................................................................................................................................7
Parts supplied ..........................................................................................................................................................................7
Storage ......................................................................................................................................................................................7
Product overview....................................................................................................................................................................7
Connections...........................................................................................................................................................................7
LED information....................................................................................................................................................................8
Function ....................................................................................................................................................................................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 the function..........................................................................................................................................................13
Automatic reset..................................................................................................................................................... 13
Manual reset ..........................................................................................................................................................13
Protective device activated............................................................................................................................................. 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

081222 v2.11-RiA Operating instructions SG-EFS 104/2W Page 4/19
About these instructions
Symbols used Symbol Meaning
Ä... Action with one step or with more than one step
where the order is not relevant.
1. ... Action with more than one step where the order is
relevant.
• ...
-...
Bullets first level
Bullets second level
(See 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 moder-
ate injuries.
NOTE Potential risk of damage to property or the environ-
ment.
Information on easier and safer working practices.
Other applicable
documents
ÄPlease also observe the following documents:
-Drawing of the sensor system (optional)
-Wiring diagram (optional)
-Installation instructions for the sensors used
Target group These instructions are intended for the operating company and for electrically
skilled persons. The electrically skilled person must be familiar with installation
and commissioning.
Validity These instructions are only valid for the products specified on the title page.
These instructions are part of the product.
Mayser accepts no responsibility or warranty claims for damage and consequen-
tial damage due to failure to observe the instructions.
About these instructions
Measurements used in
drawings
Unless otherwise stated, all measurements are in millimetres (mm).

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Safety
Intended use
ÄDo not open the control unit
Never open, tamper with or alter the control unit.
The control unit is designed for processing the signals of a pressure-sensitive pro-
tection device (PSPD). It evaluates the output signals of sensors with monitoring
resistor 8k2 or 10k. The integrated output signal switching devices (OSSDs) trans-
mit the evaluated safety signals directly to the downstream control.
Safety
Safety instructions
To prevent irreparable damage to the product, you must observe the following
safety instructions.
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.
ÄIn the event of a fault, put out of operation
In the event of malfunctions and visible damage, put the control unit out of
operation by decommissioning it.
ÄPrevent the machine from restarting
Prevent the machine from restarting while a hazard exists, e.g. by using a
starting lockout.
ÄAvoid electric shocks
Before working on electrical systems, disconnect them from the power supply
and secure them to prevent them being switched back on to avoid electrical
injuries.
For your own safety, you must adhere to the following safety instructions.
ÄTake care when setting up the interface
Overall safety is aected by the quality and reliability of the interface between
the protection device and the machine. Take particular care when setting up
the interface.
The product complies with ISO13849-1:2015 category3 PLd. To prevent any re-
duction in the safety classification, the downstream control must be of the same
category or higher.

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Safety
Terminals Y1, Y2 and Y3 are not voltage-free.
ÄContinue redundancy
Make sure you wire the unit directly in the control circuit or that two channels
continue to be used in the downstream control.
ÄDo not interconnect control units
Do not combine control units by interconnecting them.
ÄFit spark absorbers
When connecting inductive loads, fit spark absorbers (RC circuits) to the con-
sumer.
ÄCheck supply voltage
Check the supply voltage. It must correspond to the connecting voltage US
specified on the type plate.
ÄObserve correct terminal assignment
Observe the correct terminal assignment when connecting the supply volt-
age.
ÄProtect relay contacts
Risk of contact welding: provide the relay contacts with external fuse protec-
tion.
ÄDo not overload control unit
Ensure that the specified switching current is not exceeded.
ÄDo not exceed maximum number of sensors
Do not connect more sensors to the control unit than the maximum number
specified in the sensor installation instructions.
ÄEnsure sucient clearance
When installing the product in a switch cabinet, ensure sucient clearance
from heat sources (at least 2cm).
ÄProtect against strong electromagnetic pulses
Protect the control unit from excessive incoming electromagnetic radiation.
Strong electromagnetic pulses are capable of triggering a safe OFF on the
control unit.
ÄObserve protection class
Only use the control unit in spaces with a minimum protection class of IP54
(e.g. a switch cabinet).

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Parts supplied
Terminals: Connections:
A1, A2 Supply voltage
Sensor input:
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 Manual reset button
Parts supplied
1× Control unit
Enclosure with electronics module and plug-in connectors.
1× Operating Instructions
1× Declaration of Conformity
ÄUpon receipt, immediately check the parts supplied to ensure they are com-
plete and in good condition.
Product overview
Connections
ÄStore control units in a dry place inside the original packaging.
ÄObserve the storage temperature in accordance with the technical data.
Storage
Residual dangers
There are no known residual dangers associated with this product.

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Function
Terminology: ON state,
OFF state according to
ISO13856
•Green “Power” LED:
supply voltage connected
•Green “Sensor” LED:
sensor not activated
•Green “Output” LED:
control unit ready for operation
•Red “Fault” LED:
cable break
The single-fault-safe electronics module has dual channels (redundant design).
Each channel controls a force-guided relay (OSSD 1 and 2), with each one also
responsible for monitoring the other. The electronic system monitors the electrical
resistance of the sensor with a defined closed-circuit current.
If the sensor is actuated, OSSDs 1 and 2 switch from the ON state to the OFF state.
The green “Sensor” and “Output” LEDs go out, the M1 signal output is set to LOW
and the M2 signal output is set to HIGH. The signal circuit is in the ON state.
The control unit is operated with a voltage of 24VAC/DC. When the supply volt-
age is connected, the green “Power” LED is lit up.
When the sensor is not activated, and after a reset, OSSDs 1 and 2 are in the ON
state. The green “Sensor” and “Output” LEDs are lit up and the M1 and M2 signal
outputs are set to HIGH. The signal circuit is in the OFF state.
In the event of a cable break on the sensor, OSSDs 1 and 2 are in the OFF state.
The red “Fault” LED lights up. The green “Sensor” and “Output” LEDs go out and
the M1 and M2 signal outputs are set to LOW. The signal circuit is in the ON state.
The signal circuit works the opposite way round to OSSDs 1 and 2.
Function
LED information
Ready for operation
Sensor activated
Signal circuit
Sensor cable break

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Installation
If the reset button is pressed, the OSSDs switch from the OFF state to the ON state
after a delaytw.
Automatic reset
Reset
The control unit works without a reset function. If the protective device stops be-
ing actuated, the output signal switching device of the control unit automatically
switches from the OFF state to the ON state after a delaytw. Without an additional
starting lockout, the machine would start up again immediately.
Manual reset
The control unit works with a reset function. If the protective device stops being
actuated, the output signal switching devices of the control unit remain in the
OFF state. This prevents the machine from restarting. Only a “Reset” command will
change the state from OFF to ON.
For your own safety, you must also adhere to the following rules during installa-
tion:
•Disconnect from the power supply all devices and live parts that are located in
the immediate vicinity.
•Secure them to prevent them being switched back on.
•Check that they are de-energised.
1. Fix the control unit in any position on a 35°mm mounting rail acc. to
IEC60715.
Installation

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Installation
A bridge must be inserted to trigger an automatic reset (without the reset func-
tion). The unit is supplied with a bridge already connected between cable termi-
nals S1 and S2.
ÄCheck whether the bridge is connected between cable terminals S1 and S2.
In order for a manual reset to be performed (with the reset function), a button
must be connected between cable terminals S1 and S3. The control unit reacts
when the button changes from “activated” to “not activated”, i.e. if the button
sticks, no reset function is initiated.
ÄRemove the bridge between cable terminals S1 and S2.
ÄWire up a button between cable terminals S1 and S3.
Caution Impaired operation due to overheating
If the control unit overheats as a result of external heat, operation of the pro-
tective device may be impaired or it may fail completely.
ÄIt is absolutely essential to ensure sucient clearance from heat sources
(at least 2cm).
2. Wire the sensors, relay contacts and supply voltage to the cable terminals.
Reset
Automatic reset
Manual reset

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Installation
Signal outputs with US DC
Signal outputs M1 and M2 are semiconductor outputs and are short-circuit-proof.
In the HIGH state, a voltage of 18 to 22VDC is applied, depending on the load
and supply voltage.
Cable terminal A2 forms the second connection to the signal outputs.
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
Signal outputs M1 and M2 are semiconductor outputs and are short-circuit-proof.
In the HIGH state, a voltage of 20 to 29VDC is applied, depending on the load
and supply voltage.
Cable terminal S1 forms the second connection to the signal outputs. To prevent
damage to the device, never use cable terminal A2 in conjunction 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.
Connection examples
Signal outputs
Connection example 1

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Installation
Connection example 2
Connection example 3
Connection example 4
Manual reset
Contact multiplication
Automatic reset
Contact multiplication
Machine controls

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Commissioning
1. Make sure no sensors are activated.
-Green “Power”, “Sensor” and “Output” LEDs light up
-OSSDs 1 and 2 are closed
-Signal circuit open
-Signal outputs M1 and M2 are set to HIGH
2. Activate the sensor.
-Green “Sensor” and “Output” LEDs go out
-OSSDs 1 and 2 are open
-Signal circuit closed
-Signal output M1 is set to LOW and M2 is set to HIGH
3. Repeat step 1.
4. Disconnect the sensor.
-Green “Sensor” and “Output” LEDs go out
-Red “Fault” LED lights up
-OSSDs 1 and 2 are open
-Signal circuit closed
-Signal outputs M1 and M2 are set to LOW
5. Repeat step 1.
1. Make sure no sensors are activated.
-Green “Power” and “Sensor” LEDs light up
-OSSDs 1 and 2 are open
-Signal circuit closed
-Signal outputs M1 and M2 are set to HIGH
Manual reset
Commissioning
1. Make sure the plug connections are firmly attached.
2. Connect the supply voltage.
Automatic reset
WARNING Danger of injury from electric shock
ÄNever unplug plug-in connectors while live.
Testing the function
Once the functional test has been successfully completed, the protective device is
ready for operation.
If the functional test could not be completed correctly, see Troubleshooting and
remedies.

081222 v2.11-RiA Operating instructions SG-EFS 104/2W Page 14/19
Commissioning
2. Activate the reset button.
-Green “Power”, “Sensor” and “Output” LEDs light up
-OSSDs 1 and 2 are closed
-Signal circuit open
-Signal outputs M1 and M2 are set to HIGH
3. Activate the sensor (the described state is only visible while the sensor is being
activated).
-Green “Sensor” and “Output” LEDs go out
-OSSDs 1 and 2 are open
-Signal circuit closed
-Signal output M1 is set to LOW, M2 is set to HIGH
4. Repeat steps 1 and 2.
5. Disconnect the sensor.
-Green “Sensor” and “Output” LEDs go out
-Red “Fault” LED lights up
-OSSDs 1 and 2 are open
-Signal circuit closed
-Signal outputs M1 and M2 are set to LOW
6. Repeat steps 1 and 2.
Throughout the entire time the protective device remains activated, the OSSDs
stay in the OFF state.
If the protective device stops being activated, various states are possible for the
OSSDs. This depends on which reset type is selected (see Function, Reset).
Protective device activated
Once the functional test has been successfully completed, the protective device is
ready for operation.
If the functional test could not be completed correctly, see Troubleshooting and
remedies.

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Maintenance and cleaning
LEDs Outputs Meaning
Power
green
Sensor
green
Output
green
Fault
red
13, 14
23, 24 41, 42 M1 M2 LED o: LED on:
Open Closed LOW LOW No supply voltage
Open Closed HIGH HIGH Supply voltage connected; sensor not
activated; no reset signal
Closed Open HIGH HIGH Control unit ready for operation
Open Closed LOW HIGH Sensor activated
Open Closed LOW LOW Fault on sensor (cable break)
Correlations
Recommissioning
Decommissioning
ÄCarry out the commissioning process (see Commissioning).
ÄDisconnect the protective device and secure it to prevent unintentional recon-
nection.
ÄAttach a clear notice to the protective device stating that it is temporarily or
permanently out of service.
Cleaning
ÄClean the outside of the enclosure with a dry cloth.
Maintenance and cleaning
Maintenance
The control unit is maintenance-free.
ÄRepeat the functional test monthly.

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Troubleshooting and remedies
Fault indication Possible cause Remedy
Green “Power” LED does
not light up
No or incorrect supply voltage 1. Check supply voltage, compare with
type plate
2. Check terminal assignment
If supply voltage is correctly connected:
control unit is faulty
ÄReplace control unit
Green “Sensor” LED
does not light up
and
signal output M1 is set
to LOW
Incorrect monitoring resistor on the
sensor
ÄConnect sensor to monitoring resis-
tor 1k2 or 8k2
Sensor incorrectly connected ÄCheck terminal assignment
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 “Sensor” LED
lights up
and
green “Output” LED
does not light up
Manual reset: reset button not activated ÄActivate reset button
Manual reset: connection to button in-
terrupted
ÄCheck connection to button
Manual reset: button jammed/sticking ÄReplace buttons on S1 and S3
Automatic reset: bridge missing ÄConnect bridge between S1 and S2
Control unit is faulty ÄReplace control unit
Green “Power”, “Sensor”
and “Output” LEDs light
up
and
switch channel K2 is
open
Control unit is faulty ÄReplace control unit
Red “Fault” LED lights
up
and
signal output M2 is
LOW
Incorrect monitoring resistor on the
sensor
ÄConnect sensor to monitoring resis-
tor 1k2 or 8k2
Sensor incorrectly connected ÄCheck terminal assignment
ÄSensor with 1k2 connected to Y1
and Y2?
ÄSensor with 8k2 connected to Y1
and Y3?
Cable break ÄReplace sensor
Troubleshooting and remedies
Prerequisites:
•The sensor system has passed the latest test (see sensor installation instruc-
tions).
•The control unit is connected to the supply voltage and sensor.
•No sensor is activated.
Still unable to resolve the fault?
ÄContact Mayser-Support: Tel. [phone].
ÄIn the event of enquiries, have the information from the type plate to hand.
Type plate There is a type plate on the side of the control unit for identification purposes.

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Replacement parts
The control units produced by Mayser are professional electronic tools exclusive-
ly intended for commercial use (known as B2B devices). Unlike the B2C (busi-
ness-to-consumer)devices mainly used in private households, they must not be
disposed of at the collection centres of public waste management 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
ÄWhen disposing of the product:
-Ensure compliance with the relevant national disposal regulations and
statutory requirements.
-Ensure that any disposal company you use receives a list of the aforemen-
tioned materials along with the product.
-Ensure that the materials are recycled or disposed of in an environmental-
ly friendly way.
Replacement parts
CAUTION Overall safety at risk
Failure to use original Mayser parts when replacing parts of the product can
impair the function of the protective device.
ÄOnly use original Mayser parts.

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Technical data
SG-EFS 104/2W AC24V DC24V
Testing basis EN12978, EN61000-6-3, ISO13849-1, ISO13856-1, ISO13856-2,
ISO13856-3
Connecting voltage US
Nominal voltage AC 24V DC 24V
Voltage tolerance −10% to +10% −10% to +10%
Nominal current 70mA 60mA
Nominal frequency 50 to 60Hz –
External fuse protection 200mA time-lag 200mA time-lag
Power consumption < 4VA < 3W
Times
Reaction time ta< 15ms < 15ms
Restart 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 (assumption) 52560/a 52560/a
CCF Requirements met Requirements met
IEC60664-1: creep distance and
air gap
Pollution degree 2, overvoltage cat-
egory III / 250V, basic insulation
Pollution degree 2, overvoltage cat-
egory 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ohms ≤ 400ohms ≤ 400ohms ≤ 400ohms
Line resistance ≤ 10ohms ≤ 10ohms ≤ 10ohms ≤ 10ohms
Line length (max.) 100m 100m 100m 100m
Switching thresholds
Sensor activated < 0.6kiloohms < 4kiloohms < 0.6kiloohms < 4kiloohms
Cable break > 1k8ohms > 12kiloohms > 1k8ohms > 12kiloohms
Reset
Automatic S1, S2 S1, S2
Manual S1, S3 S1, S3
Line length (max.) 30m 30m
Technical data

081222 v2.11-RiA Operating instructions SG-EFS 104/2W Page 19/19
Technical data
SG-EFS 104/2W AC24V DC24V
Outputs
OSSDs 1 and 2 (NO contact) 13, 14 and 23, 24 13, 14 and 23, 24
Signal circuit (NC contact) 41, 42 41, 42
Utilisation category AC-12: 250V / 4A AC-12: 250V / 4A
in accordance with
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)
External contact fuse
protection 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
Signal type 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-pin 4× 4-pin
Solid wire 1× 2.5mm2or 2× 1.5mm21× 2.5mm2or 2× 1.5mm2
Wire with sleeve 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 and
UK S.I. 2008 No. 1597:
Emission sound pressure level < 70dB(A) < 70dB(A)
Dimensions (W × H × D) 22.5 × 99 × 114.5mm 22.5 × 99 ×114.5mm
Weight 180g 180g