MAYSER SG-RSV 205 User manual

Operating instructions
Original instructions
Innovative by tradition.
Mayser GmbH & Co. KG
Örlinger Strasse 1–3
89073 Ulm
GERMANY
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Website: www.mayser.com
Control unit SG-RSV 205
1002378 SG-RSV 205/2 18–32V=
Semiconductor outputs
Version 2

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Copyright
The reproduction, distribution and utilisation of this document as well as the communication of its contents with-
out 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 2013
Table of contents
About these operating instructions.......................................................................................................................... 3
Intended use.................................................................................................................................................................. 4
Safety instructions ....................................................................................................................................................... 4
Parts supplied................................................................................................................................................................ 5
Transport and storage ................................................................................................................................................. 5
Packaging and transport ......................................................................................................................................................5
Storage.......................................................................................................................................................................................5
Product overview ......................................................................................................................................................... 6
Connections..............................................................................................................................................................................6
Function, installation and commissioning............................................................................................................... 6
Function.....................................................................................................................................................................................6
Flowchart.......................................................................................................................................................................6
Installation................................................................................................................................................................................7
Commissioning........................................................................................................................................................................8
Testing the function...................................................................................................................................................8
Recommissioning....................................................................................................................................................................9
Automatic reset...........................................................................................................................................................9
Connection example..............................................................................................................................................................9
Maintenance and cleaning ....................................................................................................................................... 10
Maintenance ......................................................................................................................................................................... 10
Cleaning.................................................................................................................................................................................. 10
Troubleshooting and remedies................................................................................................................................ 10
Replacement parts .............................................................................................................................................................. 11
Disposal ........................................................................................................................................................................ 11
Conformity................................................................................................................................................................... 11
Technical data.............................................................................................................................................................. 12

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About these operating instructions
These operating instructions are part of the product.
Mayser Polymer Electric accepts no responsibility or warranty claims for damage and
consequential damage due to failure to observe the operating instructions.
ÄRead the operating instructions carefully before use.
ÄKeep the operating instructions somewhere safe so you can refer to them
throughout the product’s entire service life.
ÄPass the operating instructions on to every subsequent owner or user of the
product.
ÄAdd any supplement received from the manufacturer to the operating instruc-
tions.
These operating instructions are only valid for the products specified on the title
page.
Validity
The target group of these operating instructions are operators and trained specialist
personnel who are familiar with installation and commissioning.
Target group
ÄIn addition to the operating instructions, observe the following documents:
- Drawing of the sensor system (optional)
- Wiring diagram (optional)
- Installation instructions for the sensors used
Other applicable
documents
Symbol Meaning
Ä... Action with one step or with more than one step where
the order is not relevant.
1. ...
2. ...
3. ...
Action with more than one step where the order is rel-
evant.
• ...
- ...
Bullets first level
Bullets second level
(see Installation) Cross-reference
Symbols used

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Safety instructions
ÄDo not open control unit
Never open, tamper with or attempt to modify the control unit.
ÄCheck supply voltage
Check the supply voltage. It must correspond to the connecting voltage USspeci-
fied on the type plate.
ÄObserve protection class
Only use the control unit in spaces with a minimum protection class of IP54 (e.g.
a switch cabinet).
ÄEnsure sucient clearance
When installing the product in a switch cabinet, ensure sucient clearance from
heat sources (at least 2cm).
Intended use
The control unit conforms to ISO13849-1:2006 category 1 PL c. To prevent any re-
duction in the safety classification, the downstream control must be of the same cat-
egory or higher.
The control unit is designed for processing the signals of a pressure-sensitive protec-
tion device (PSPD). It evaluates the output signals of sensors with a 1k2 monitoring
resistor. The integrated output signal switching devices (OSSD) transmit the evaluat-
ed safety signals directly to the downstream machine controls.
ÄObserve correct terminal assignment
Observe the correct terminal assignment when connecting the supply voltage.
Symbol Meaning
DANGER Immediate danger leading to death or serious injury.
CAUTION Possible danger which may lead to minor injury or damage
to property.
Information on easier and safer working practices.
Danger symbols and
information

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Parts supplied
1× Control unit
Potted electronics with permanently installed flat connectors.
1× Operating Instructions
1× Declaration of Conformity
Upon receipt, immediately check the parts supplied to ensure they are complete and
in good condition.
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 oper-
ation by decommissioning it.
ÄDo not interconnect control units
Do not combine control units by interconnecting them.
ÄDo not overload control unit
Ensure that the specified switching current is not exceeded.
Terminals Y1, Y2, Y3 and Y4 are not voltage-free.
ÄStore control units in a dry place inside the original packaging.
ÄObserve the storage temperatures given in the technical data.
Storage
The control units are packed in such a way as to ensure a good level of protection.
Several control units are stacked together in one large cardboard box.
The documents are enclosed separately.
Packaging and transport
Transport and storage

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Product overview
Connections
Function, installation and commissioning
Function
Connections: Terminals:
Supply voltage A1, A2
“Activated” output 1, A2
“Fault” output 2, A2
Sensor 1 Y1, Y2
Sensor 2 Y3, Y4
The control unit has two monitoring circuits, which operate two output circuits. The
electronics monitor the electrical resistance of the sensors, which have a defined
closed-circuit current.
The control unit is operated with a voltage of 18 to 32VDC. If the supply voltage is
connected, the control unit is ready for operation.
When the sensors are not activated, the “Activated” output is set to LOW and the
“Fault” output to HIGH.
If a sensor is activated, the “Activated” output switches to HIGH. The “Fault” output
remains set to HIGH.
In the event of a cable break or supply voltage failure, both the “Activated” and the
“Fault” outputs switch to LOW.
The outputs take the form of short-circuit-proof semiconductor outputs.
Flowchart
Operating
state:
Sensor X
activated
“Activated”
output
“Fault”
output
Fault NormalNormalO
No
(1)
(2)
LOW
HIGH
(View from below)

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Installation
DANGER Danger of injury from electric shock!
ÄDisconnect all devices and live parts in the immediate environment from the
power supply and secure them to prevent them from being switched on again
(see relevant operating instructions).
ÄCheck whether all devices and parts are de-energised.
CAUTION Impaired operation due to overheating or incorrect degree of protection
If the control unit overheats or the incorrect degree of protection is selected, opera-
tion of the protection device may be impaired.
ÄWhen installing the product in a switch cabinet, ensure sucient clearance
from heat sources (at least 2cm).
ÄOnly use the control unit in spaces with a minimum protection class of IP54
(e.g. a switch cabinet).
1. Wire the sensors, outputs and supply voltage on the socket plate.
Sensor 1
2. Insert the 7 flat connectors into the relevant sockets. Plug in the control unit
evenly.
Sensor 2

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Testing the function
Commissioning
1. Make sure that the control unit is securely seated.
2. Connect the supply voltage.
2. Activate sensor X.
- “Activated” output is set to HIGH (1)
- “Fault” output is set to HIGH (2)
1. Make sure that everything is connected and no sensor is activated.
- “Activated” output is set to LOW (1)
- “Fault” output is set to HIGH (2)
Danger of injury from electric shock!
ÄNever disconnect terminals while live.
ÄNever unplug plug connections while live.
DANGER
CAUTION Overall safety at risk
Overall safety is aected by the quality and reliability of the interface between the
protection device and the machine.
ÄTake particular care when setting up the interface.
Operation with only one monitoring circuit
It is also possible to operate the control unit with only one monitoring circuit.
ÄTo do this, use a 1k2 resistor to bridge the monitoring circuit that is not re-
quired.
3. Repeat step 1.
4. Disconnect sensor X.
- “Activated” output is set to LOW (1)
- “Fault” output is set to LOW (2)
5. Repeat step 1.

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Connection example
Danger of injury!
ÄNever start your machine as long as the danger remains.
DANGER
Recommissioning
The control unit works without a reset. If the sensor is released after activation, the
“Activated” output returns to “LOW” after a delay tw.
ÄAfter recommissioning, check the unit for proper functioning (see section Com-
missioning).
Automatic reset

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Maintenance and cleaning
Maintenance
Cleaning
The control unit is maintenance-free.
ÄRepeat the functional test monthly.
ÄClean the outside of the enclosure with a dry cloth.
Danger of injury from electric shock!
ÄDisconnect the control unit – as well as all devices and live parts in the imme-
diate environment – from the power supply and secure them to prevent them
from being switched on again (see relevant operating instructions).
ÄCheck whether all devices and parts are de-energised.
DANGER
Troubleshooting and remedies
Error state Possible cause Remedy
“Activated” and “Fault”
outputs both set to LOW
No or incorrect supply voltage 1. Check supply voltage, compare with
type plate
2. Check terminal assignment
Incorrect monitoring resistor in sensor
1 or 2
1. Check non-activated sensor;
resistance = 1k2 ±5%
2. Measured resistance deviates signifi-
cantly
ÄReplace sensor
Cable break 1. Check activated sensor; resistance
< 400ohms
2. Measured resistance deviates signifi-
cantly
ÄReplace sensor
If supply voltage is correctly connected and
sensor is OK: control unit is faulty
ÄReplace control unit
Pre-requisites: the control unit is connected to the supply voltage and sensors; the
sensors are not activated.

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Still unable to resolve the fault?
ÄContact Mayser-Support: Tel. [phone].
Replacement parts
Overall safety at risk
If the sensor and control unit are not replaced using original parts from Mayser, op-
eration of the protection device may be impaired.
ÄOnly use original parts from Mayser.
CAUTION
Disposal
Conformity
The design type of the product complies with the basic requirements of the following
directives:
• 2004/104/EC (EMC)
The Declaration of Conformity can be found in the Downloads area of our website:
www.mayser-sicherheitstechnik.de
The control units produced by Mayser are professional electronic tools exclusively in-
tended for commercial use (known as B2B devices). Unlike the B2C (business-to-con-
sumer)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
Error state Possible cause Remedy
“Activated” and “Fault”
outputs both set to HIGH
Sensor short circuit 1. Check non-activated sensor;
resistance = 1k2 ±5%
2. Measured resistance deviates signifi-
cantly
ÄReplace sensor
Control unit faulty ÄReplace control unit

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Technical data
SG-RSV 205/2 18 to 32VDC
Testing basis ISO13849-1
Connecting voltage US
Voltage tolerance
Nominal current
Nominal frequency
External fuse protection
Power consumption
–
23 to 36mA
–
1A time-lag
< 1.5W (without load)
Times
Reaction time ta
Restart time tw
< 1ms
< 1ms
Safety classifications
EN1760: Reset function
ISO13849-1:2006
MTTFd
DCavg
nop (assumption)
CCF
Without
Category 1 PL c
499 years
–
52,560 per year
–
Control unit inputs
Sensors 1 and 2
Monitoring resistor
Short-circuit resistance
Line resistance
Line length (max.)
Switching thresholds
Sensor activated
Cable break
Y1, Y2 and Y3, Y4
1k2ohms
≤ 400ohms
≤ 100ohms
100m
< 650ohms
> 3.5kiloohms
Control unit outputs
Outputs 1 and 2 (PNP)
HIGH (min.)
LOW (max.)
Switching current (max.)
External contact fuse
protection
1, A2 and 2, A2
US– 1.0V
0.5V
0.4A
1A time-lag
Mechanical operating conditions
Flat connectors
IEC 60529: degree of protection
Max. humidity (23 °C)
Operating temperature
Storage temperature
Vibration fatigue limit
Dimensions (W × H × D)
Weight
6.3 × 0.8mm
IP40
85%, non-condensing
−40 to +80°C
−40 to +80°C
1g in all 3 levels
58 × 41 × 30mm
70g