MAYSER SG-EFS 104/4L User manual

Original instructions
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.
Control unit SG-EFS 104/4L
1004128 SG-EFS 104/4L AC/DC 24V
Version 2
EN | Operating instructions

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 2/19
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.
UL certification
The design type of the product complies with the basic requirements
of UL certification:
•UL508
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)

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 3/19
Table of contents
Table of contents
About these instructions......................................................................................................................................................4
Safety..........................................................................................................................................................................................5
Intended use .........................................................................................................................................................................5
Safety instructions................................................................................................................................................................5
Residual dangers ..................................................................................................................................................................6
Parts supplied ..........................................................................................................................................................................7
Storage ......................................................................................................................................................................................7
Product overview....................................................................................................................................................................7
Connections...........................................................................................................................................................................7
LED information....................................................................................................................................................................8
Function ....................................................................................................................................................................................8
Reset........................................................................................................................................................................................9
Automatic reset........................................................................................................................................................9
Controlled reset and manual reset......................................................................................................................9
Installation................................................................................................................................................................................9
Reset..................................................................................................................................................................................... 11
Automatic reset..................................................................................................................................................... 11
Controlled reset.....................................................................................................................................................11
Manual reset ..........................................................................................................................................................11
Signal output......................................................................................................................................................................11
Connection examples ......................................................................................................................................................12
Commissioning......................................................................................................................................................................13
Testing the function..........................................................................................................................................................13
Automatic reset..................................................................................................................................................... 13
Controlled reset and manual reset...................................................................................................................14
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
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 2023

090323 v3.12-RiA Operating instructions SG-EFS 104/4L 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).

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 5/19
Safety
The control unit is designed for processing the signals of a pressure-sensitive
protection device (PSPD). It evaluates the output signals of BK-type sensors. The
integrated output signal switching devices (OSSDs) transmit the evaluated safety
signals directly to the downstream control.
The product complies with ISO13849-1:2015 category3 PLe. To prevent any re-
duction in the safety classification, the downstream control must be of the same
category or higher.
Intended use
ÄDo not open the control unit
Never open, tamper with or alter the control unit.
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
To avoid electrical injuries, disconnect electrical systems from the power sup-
ply and secure them to prevent them being switched back. Do this before you
start working on them.
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.

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 6/19
Safety
Terminals Y11, Y12 and Y21, Y22 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.
Residual dangers
There are no known residual dangers associated with this product.
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).
ÄObserve protection class
Only use the control unit in spaces with a minimum protection class of IP54
(e.g. a switch cabinet).

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 7/19
Parts supplied
Connections: Terminals:
Supply voltage A1, A2
BK-type sensor Y11, Y12
Y21, Y22
OSSD 1 13, 14
OSSD 2 23, 24
OSSD 3 33, 34
Signal output 41, 42
Bridge for automatic reset S1, S2
Manual reset button S1, S2
Parts supplied
1× control unit
Enclosure with electronics module and terminal cover.
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

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 8/19
Function
Terminology: ON state,
OFF state according to
ISO13856
•Light-green “Power” LED:
supply voltage connected
•Green “Channel 1” LED:
relay K1 picked up
•Green “Channel 2” LED:
relay K2 picked up
The signal output (terminals 41, 42) works the opposite way round to OSSDs 1, 2
and 3.
The single-fault-safe electronics module has dual channels (redundant design).
Each channel controls a force-guided relay and additionally monitors the relay of
the other channel. The relays control OSSD1 (terminals 13, 14), OSSD2 (terminals
23, 24) and OSSD3 (terminals 33, 34). The electronic system monitors the con-
nected BK-type sensors.
The control unit is operated with a voltage of 24VAC/DC. When the supply volt-
age is connected, the light-green “Power” LED lights up.
When the sensor is not activated, and after a reset, OSSDs 1, 2 and 3 are in the ON
state and the signal output is open. The green “Channel1” and “Channel2” LEDs
light up.
If the sensor is activated, then OSSDs 1, 2 and 3 are in the OFF state; the signal
output is closed. The green “Channel1” and “Channel2” LEDs go out.
In the event of a cable break on the sensor, OSSDs 1, 2 and 3 are in the OFF state;
the signal output is closed. The green “Channel1” and “Channel2” LEDs go out.
Function
Sensor activated
Ready for operation
Sensor cable break
Signal output
LED information

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 9/19
Installation
If the machine controls send a reset command or 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.
Installation
For your own safety, you must also adhere to the following familiar rules during
installation:
•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.
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.
Controlled reset and manual reset

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 10/19
Function
(UL: use 60/75°C copper wire only)
ÄTighten the screws of the cable terminals to a torque of between 0.5 and
0.6Nm.
(UL: overtorquing may cause enclosure breakage.)
The two contact surfaces of the sensor act as bridges between connections Y11
and Y12 and connections Y21 and Y22 respectively. This is the only way to ensure
proper monitoring of the sensor and detection of a cable break.
ÄPay careful attention to paths that are supposed to have single-colour wiring
from end to end, e.g. red wires at both Y21 and Y22.
ÄAlways connect multiple sensors in series:
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, OSSDs and supply voltage to the cable terminals.
Sensor
Sensor 1 Sensor 2

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 11/19
Function
Cable Sensor Y21 Y11 Y12 Y22
2× 2-core SM8, SL WH BN BN WH
2× 2-core SM, SP, SL, SB RD BK BK RD
2× 2-core SM11 BU BN BN BU
1× 4-core SM, SB BU BK BN WH
Colour coding:
BK Black
BU Blue
BN Brown
RD Red
WH White
Integrate the circuits for enabling the machine
ÄConnect the NC contacts of the external contactors to the reset button at ca-
ble terminals S1 and S2, ensuring they are connected in series (see Connection
examples).
The signal output is a voltage-free relay contact (NC contact). Its operation is in-
verted compared to OSSDs 1, 2 and 3.
ÄWire the load between cable terminals 41 and 42.
Automatic reset
ÄInsert a bridge between cable terminals S1 and S2.
A bridge must be inserted to trigger an automatic reset (without the reset func-
tion).
Manual reset
In order for a manual reset to be performed (with the reset function) a button
must be connected.
ÄWire up a button between cable terminals S1 and S2.
Reset
Controlled reset
Signal output
In order for a controlled reset to be performed via the machine controls (with the
reset function), a NO contact of the controls must be connected.
ÄConnect the wiring for the NO contact of the machine controls between cable
terminals S1 and S2.
Caution Automatic reset due to jammed/sticking reset button
If the protective device stops being actuated, the OSSDs automatically switch
from the OFF state to the ON state. Risk of injury or property damage due to
unexpected restart.
ÄIt is essential to use a high-quality button.
ÄTest the function of the button regularly (at least once a month).

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 12/19
Function
Q1
Q1 Q2
Q2
M
Q2
Q3
M
Q2
SG-EFS 104/4L
F2
13
14
23
24
Q1
OSSD 1 OSSD 2 OSSD 3
Q1
F3
Q2
Q3
33
34
Q2
F4
Q3
Machine controls
Connection examples
Connection example 1
Connection example 3
Connection example 2
Automatic reset
Contact multiplication

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 13/19
Commissioning
3. Disconnect the sensor.
-The green “Channel1” and “Channel2” LEDs go out
-OSSDs 1, 2 and 3 are in the OFF state
-The signal output is closed
1. Make sure no sensors are activated.
-The green “Power”, “Channel1” and “Channel2” LEDs light up
-OSSDs 1, 2 and 3 are in the ON state
-The signal output is open
2. Activate the sensor.
-The green “Channel1” and “Channel2” LEDs go out
-OSSDs 1, 2 and 3 are in the OFF state
-The signal output is closed
Commissioning
ÄConnect the supply voltage.
Connection example 4
Manual reset
Contact multiplication
Automatic reset
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.

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 14/19
Commissioning
2. Trigger a reset command via the machine controls or press the reset button.
-The green “Power”, “Channel 1” and “Channel 2” LEDs light up
-OSSDs 1, 2 and 3 are in the ON state
-The signal output is open
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
Controlled reset and manual reset
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.
1. Make sure no sensors are activated.
-The green “Power” LED lights up
-OSSDs 1, 2 and 3 are in the OFF state
-The signal output is closed
3. Activate the sensor.
-The green “Channel1” and “Channel2” LEDs go out
-OSSDs 1, 2 and 3 are in the OFF state
-The signal output is closed
4. Repeat step 2.
5. Disconnect the sensor.
-The green “Channel1” and “Channel2” LEDs go out
-OSSDs 1, 2 and 3 are in the OFF state
-The signal output is closed

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 15/19
Maintenance and cleaning
LEDs Outputs Meaning
Power
light green
Channel 1
green
Channel 2
green
13, 14
23, 24
33, 34
41, 42 LED o: LED on:
OFF OFF No supply voltage
OFF ON Supply voltage connected; sensor not acti-
vated; no reset signal
ON OFF Control unit ready for operation
OFF ON Sensor activated or fault on sensor (cable
break)
OFF ON Incorrect supply voltage or faulty control
unit
OFF ON Incorrect supply voltage or faulty control
unit
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.

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 16/19
Troubleshooting and remedies
Fault indication Possible cause Remedy
Light-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
The green “Channel 1”
and “Channel 2” LEDs do
not light up
Manual reset: reset button not activated ÄPress reset button
Manual reset: connection to button in-
terrupted
ÄCheck connection to button
Manual reset: button jammed/sticking ÄReplace buttons on S1 and S2
Automatic reset: bridge missing ÄConnect bridge between S1 and S2
Sensor faulty or connection to sensor
interrupted
1. Disconnect sensor
2. Bridge connections Y11, Y12 and
Y21, Y22
3. Press reset button
4. If LEDs light up: replace sensor
Control unit faulty ÄReplace control unit
Only one green channel
LED lights up:“Channel
1” or “Channel 2”
Incorrect supply voltage ÄCheck supply voltage, compare with
type plate
Control unit faulty ÄReplace control unit
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.

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 17/19
Replacement parts
The devices produced by Mayser are professional electronic tools exclusively in-
tended for commercial use (known as B2B devices). Unlike the B2C (business-
to-consumer)devices mainly used in private households, they must not be dis-
posed 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.

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 18/19
Technical data
SG-EFS 104/4L AC24V DC 24 V
Testing basis EN12978, 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 280mA 86mA
Nominal frequency 50 to 60Hz –
External fuse protection – –
Power consumption < 5VA < 3W
Times
Reaction time ta< 50ms < 30ms
Restart time tw< 500ms < 500ms
Safety classifications
ISO13856: reset function With/without With/without
ISO13849-1:2015 Category 3PLe Category 3PLe
MTTFD100a 100a
DCavg 90% 90%
B10D (load: DC 24V / 2A) 4× 1054× 105
nop (assumption) 52560/a 52560/a
CCF Requirements met Requirements met
IEC 60664-1: creep distance and
air gap
Pollution degree 2, overvoltage
category III / 250V, basic insulation
Pollution degree 2, overvoltage
category III / 250V, basic insulation
Inputs
Sensor Y11, Y12 and Y21, Y22 Y11, Y12 and Y21, Y22
Short-circuit resistance ≤ 400ohms ≤ 400ohms
Line resistance ≤ 10ohms ≤ 10ohms
Line length (max.) 100m 100m
Switching thresholds
Sensor activated < 1k3ohms < 1k3ohms
Cable break – –
Reset S1, S2 S1, S2
Line length (max.) 30m 30m
Outputs
OSSDs 1, 2 and 3 (NO contact) 13, 14 and 23, 24 and 33, 34 13, 14 and 23, 24 and 33, 34
Signal output (NC contact) 41, 42 41, 42
EN60947-5-1: utilisation
category
AC-12: 250V / 5A
DC-12: 30V / 5A
AC-12: 250V / 5A
DC-12: 30V / 5A
Switching voltage (max.) AC 230V DC 24V AC 230V DC 24V
Switching current (max.) 5A 5A 5A 5A
Total current (max.) 13.8A 13.8A 13.8A 13.8A
Switching capacity (max.) 1150VA 120W 1150VA 120W
Switching operations,
mechanical > 1× 107
> 1× 107
Switching operations, electrical > 1× 105(DC 24V / 2A) > 1× 105(DC 24V / 2A)
External contact fuse protection
NO contact 6.3A quick-acting 6.3A quick-acting
NC contact 4A Neozed gL/gG 4A Neozed gL/gG
Technical data

090323 v3.12-RiA Operating instructions SG-EFS 104/4L Page 19/19
Technical data
SG-EFS 104/4L AC24V DC 24 V
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
Tightening torque 0.5 to 0.6Nm 0.5 to 0.6Nm
IEC60529: degree of protection IP20 IP20
Max. humidity (23°C) 95% 95%
Operating temperature −25 to +55°C (UL: up to +40°C) −25 to +55°C (UL: up to +40°C)
Storage temperature −25 to +55°C −25 to +55°C
Impact resistance in operation 2g 2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