MAYSER SG-RST 153 User manual

Control unit SG-RST 153
Original instructions
1004931 SG-RST 153 AC 230 V AC/DC 12 to 24 V
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.
Version 0.3
EN | Operating instructions

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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 2019
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/EU (RoHS)
•2014/30/EU (EMC)

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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
Installation 8
Testing 10
Connection examples 10
Commissioning 11
Testing 11
Pressure-sensitive protection device actuated 12
Correlations 12
Decommissioning 12
Recommissioning 12
Maintenance and cleaning 13
Maintenance 13
Cleaning 13
Troubleshooting and remedies 13
Replacement parts 14
Disposal 14
Technical data 14

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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.
About this manual
Dimensions in drawings Unless otherwise indicated, all dimensions are stated in millimetres (mm).

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Safety
Without a test signal, the control unit corresponds only to category 1.
The control unit is designed only for safety edges with an 8k2 monitoring resistor.
Safety mats and safety bumpers may not be connected.
The performance level PL is dependent on the output of the connected load. PL d can
also be achieved in some cases. We will be glad to assist you.
Intended use
The control unit is designed for signal processing of a pressure-sensitive protective
device. It evaluates the output signals of sensors with monitoring resistor 8k2. The
integrated output signal switching device (OSSD) transmits the evaluated safety sig-
nals directly to the downstream control.
The product complies with ISO13849-1:2015 Category2 PLc. So that the safety
classification is retained, the downstream control must be of the same or a higher
category.
Safety
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.
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.

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Safety
Terminals X1 to X2 are not potential-free.
ÄDo not modify the control unit
Never manipulate or make changes to the control unit.
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).
ÄObserve degree of protection
Only use the control unit in rooms with a minimum degree of protection of IP54
(e.g. switch cabinet).
To prevent irreparable damage to the product, the following safety instructions ap-
ply.

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Parts supplied
Connections: Terminals:
Switching channel 1 14, 13
Test signal T1, T2
Sensor X1, X2
Supply voltage AC/DC 12-24 V A1, A2
Supply voltage AC 230 V PE, N, L1
Parts supplied
1× Control unit
Enclosure with electronics module,
1× PG9 cable screw connection and
2× PG11 cable screw connection.
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

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Operation
•red LED „FAULT“:
Cable break
•yellow LED „SENSOR“:
Sensor actuated or testing
•green LED „POWER“:
Supply voltage connected
The control unit can be operated with AC/DC 12 to 24 V or AC 230 V. If supply volt-
age is connected, the green “POWER” LED lights up. The control unit now monitors
the connected sensor, which must be equipped with an 8k2 monitoring resistor. In
sensors that are not actuated, relay K1 energizes and switching channel 1 is closed. If
the sensor is actuated, relay K1 de-energizes, the yellow “SENSOR” LED lights up, and
switching channel 1 is opened. In case of a cable break, relay K1 de-energizes, the red
“FAULT” LED lights up, and switching channel 1 is opened.
Prior to any dangerous movement the safety function of the sensor must be moni-
tored via an external test signal from the machine control.
Without a test signal, the control unit corresponds only to category 1.
Automatic reset
1. Mount the sensor in the desired position using screws with a diameter of 4 mm.
To do so, remove the enclosure cover.
Operation
The control unit operates without a reset function. If the sensor is released after actu-
ation, relay K1 energizes again with a delay of tw. (see reactivation time twin chapter
Technical data)
LED indicators
Installation
For your safety, the generally accepted 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.

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Installation
Machine control
Test device
3. Wire the sensors, relay contacts and supply voltage to the cable terminals.

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Installation
Testing
ÄSet jumper JP1 according to the applied test signal.
Voltage for
test signal
Type
test signal
Position of
jumper JP1
Reaction of switch-
ing channel 1
Machine
control
Connection examples
Connection examples 1

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Commissioning
1. Make sure no sensors are activated.
-only green LED „POWER“ is on
-Switching channel 1 is closed
2. Activate the sensor
-yellow LED „SENSOR“ is on
-Switching channel 1 is open
3. Have the machine control initiate a test signal.
-yellow LED „SENSOR“ is on
-Switching channel 1 is open
6. Disconnect the sensor
-red LED „FAULT“ is on
-Switching channel 1 is open
Flowchart
open
closed
inactive
active
actuated
not actuated
Switching
channel 1
Test signal
Sensor
Commissioning
1. Reinstall the enclosure cover.
2. Connect the supply voltage.
Testing

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Commissioning
LEDs Outputs Meaning
Power
green
Sensor
yellow
Fault
red 13, 14 LED o: LED on:
open No supply voltage
closed Control unit ready for operation
open Sensor actuated or test active
open Fault at sensor
(Cable break)
Correlations
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.
Pressure-sensitive protection device actuated
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.
Recommissioning
Decommissioning
ÄRecommission the pressure-sensitive protection device as specified in the chapter
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.

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Maintenance and cleaning
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
yellow LED „SENSOR“
lights continuously
Incorrect monitoring resistor on sensor ÄConnect sensor with monitoring resis-
tor 8k2
If monitoring resistor is correct: sensor is
faulty
ÄReplace sensor
Jumper JP1 is missing or is set incorrectly 1. Check jumper JP1 (see chapter Testing)
2. Set jumper JP1 correctly
Test signal is applied constantly ÄCheck test signal
red LED „FAULT“ is on No sensor connected ÄConnect sensor
Sensor connected incorrectly ÄCheck terminal assignment
Incorrect monitoring resistor on sensor ÄConnect sensor with monitoring resis-
tor 8k2
Cable break ÄReplace sensor
Cleaning
Maintenance and cleaning
Maintenance
The control unit is maintenance-free.
ÄRepeat the operational test monthly.
Troubleshooting and remedies
Prerequisite: the control unit is connected to the supply voltage and sensor. No sen-
sor is activated.
ÄClean the outside of the enclosure with conventional cleaning products.
ÄAfter cleaning, remove any remaining moisture.
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.

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Replacement parts
SG-RST 153 AC/DC 12 to 24 V AC 230 V
Testing basis EN12978, ISO13849-1, ISO13856-2
Supply voltage US
Nominal voltage
Voltage tolerance
Nominal current
Nominal frequency
External protection
Short circuit current (max.)
Power consumption
AC/DC 12 to 24V
-10% to +25%
35 to50 mA
48 to 62Hz
–
2 A
< 1.5VA / < 1.5 W
AC 230V
-10 % to +10%
12mA
48 to 62Hz
250 mA slow-acting
–
< 3.0VA
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.
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 enlist the services of a disposal company, the company will need the
aforementioned list of materials.
-Materials should be recycled or disposed of in an eco-friendly manner.
Technical data
Type plate A type plate for identification of the control unit is axed to the enclosure cover.

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Technical data
SG-RST 153 AC/DC 12 to 24 V AC 230 V
Times
Reaction time ta
Re-start time tw
< 5ms
< 50ms
< 5ms
< 50ms
Safety classifications
ISO13856: Reset function
ISO13849-1:2015
MTTFD
DCavg
B10D (Load: DC 24V / 2A)
nop (Estimate)
CCF
IEC 60664-1: Creep distance and air
gap
IEC 61140:2001+A1:2004
without
Category 2 PL c
33a
90%
18× 105
52560/a
Requirements fulfilled
soiling degree 2, overvoltage catego-
ry III / 250V, basic insulation
Protection class II
without
Category 2 PL c
33a
90%
18× 105
52560/a
Requirements fulfilled
soiling degree 2, overvoltage catego-
ry III / 250V, basic insulation
Protection class II
Inputs
Sensor
Monitoring resistor
Short-circuit resistance
Line resistance
Line length (max.)
Switching thresholds
Sensor activated
Cable break
X1, X2
8k2 Ohm
≤ 400 Ohm
≤ 10Ohm
100m
< 4 kOhm
> 12 kOhm
X1, X2
8k2 Ohm
≤ 400Ohm
≤ 10 Ohm
100m
< 4 kOhm
> 12kOhm
Outputs
Switching channel 1 (NO contact)
EN60947-5-1: Utilization catego-
ry
Switching voltage (max.)
Switching current (max.)
Switching capacity (max.)
Switching operations, mechanical
Switching operations, electrical
Contact fuse protection external
13, 14
AC-12: 250V / 2A
DC-12: 24V / 2A
AC 250V DC 24V
2A 2A
500VA 48W
> 4× 106
> 4× 105(DC 250V / 2A)
3.15A quick-acting
13, 14
AC-12: 250V / 2A
DC-12: 24V / 2A
AC 250V DC 24V
2A 2A
500VA 48W
> 4× 106
> 4× 105(DC 250V / 2A)
3.15A quick-acting
Mechanical operating conditions
Cable terminals
Solid wire
Strand with sheath
IEC60529: Degree of protection
max. humidity (23°C)
Operating temperature
Storage temperature
Impact resistance in operation
Impact resistance transport
Dimensions (B × H × T)
Weight
1× 2.5mm2or 2× 1.5mm2
1× 1.5mm2or 2× 1.5mm2
IP65
95%
-30°C to +55°C
-30°C to +55°C
2.5g
10g
120 × 107 × 55mm
315g
1× 2.5mm2or 2× 1.5mm2
1× 1.5 mm2or 2× 1.5mm2
IP65
95%
-30°C to +55°C
-30°C to +55°C
2.5g
10g
120 × 107 × 55mm
315g