Product group: 02

Component
Evaluation device group:
05

General Spare
Parts List 5.2
group:
Service information SI 120207 Page: 1 of 3

Application
Safety-related part (SRP) as replacement.
The intended use, mounting position and connections
are identical to those of the component to be replaced.
The contact-free safety switch consists of:
- Evaluation device
- Reading head
- transponder
This item of service information deals only with the evaluation device.

Safety instructions
Safety switches have personal protection functions. Incorrect installation or manipulations may result
in lethal injury.
Check that the protective device is working properly, particularly
- after each instance of starting up
- after each instance of replacing a component
- after a lengthy idle period
- Safety switches must not be bypassed (contacts overridden), turned away, removed or made
ineffective in any other way.
The reading head and transponder must not be used as a mechanical limit stop.

Preparation
When replacing this SRP, several connection lines must be disconnected and then reconnected.
Before undoing the clips, take note of the wire colours on the evaluation device, and take a photo of
the connections for safety's sake.
An incorrect connection can lead to the safety function malfunctioning, and in some cases, to the
component being damaged beyond repair.

Assembly
- Disconnect the connecting lines on the evaluation device.
- Detach the evaluation device from the top-hat section rail.
- Fit the new evaluation device.
- Observe the maximum tightening torque for the fastenings, i.e. 0.6 to 0.8 Nm.
- Connect the evaluation device to the electric supply (connector/cable).

Starting up
LED indicators:

LED Colour Meaning

STATE green Status indicator (multifunction indicator that uses

flashing modes)

OUT Yellow Safety circuit closed

Putzmeister Concrete Pumps GmbH • Postfach 2152 • D-72629 Aichtal, Germany • Tel. +49 (0)7127 599-0 • Fax +49 (0)7127 599-520
No. SI 120207 Replaces: Authored by: Buck/Hoffmann/Neumann Date of issue: 29.06.12
 Product group: 02
Component
Evaluation device group:
05

General Spare
Parts List 5.2
group:
Service information SI 120207 Page: 2 of 3

LED Colour Meaning

DIA red - Operating error or

- external fault (fault in the feedback loop) or
- invalid learning process or
- internal device fault or
- TST input activated

Learning process:
During starting up, the evaluation device parameters are set by the machine operator by means of a
learning process (number of reading heads connected, transponder assigned to the reading heads,
with or without automatic start, with or without feedback loop). During this process, the reading heads
are activated. These configuration parameters are stored in the non-volatile memory of the evaluation
device.

Important!
The following conditions must be met during the learning process:
- There must be no change in status, e.g. a protection door opening, another protection door
closing, or a signal change on the terminals for the Start button and feedback loop.
- The supply voltage must not be switched off.
If these conditions are not met, the evaluation device changes to "safe error status" (diagnosis LED
lights up) and indicates this operating error by means of 3 short flashing pulses on the STATE-LED,
each of which are repeated after 1 second. The learning process must be repeated.
The number of learning processes is unlimited. The evaluation device can be reconfigured as often as
desired.
Without a new learning process, transponders cannot be swapped round.
A transponder that has not been taught-in will not be detected by the reading head concerned.
Even if just one new transponder is to be taught-in, a completely new learning process must be carried
out as per the "Setting up" section.
Do not adjust the DIP switch during operation.

To start a learning process, the following processes must be carried out by the machine operator in
the prescribed sequence:
1. Prepare for the learning process
- Switch off the UB supply voltage
- Fit a jumper between terminals J1 and J2
2. Apply the DIP switch configuration of the old evaluation device.
3. Set the required configuration on the machine
- Close all doors that are to be monitored (each transponder must be located in the activation
area of the reading head concerned)
- In "Manual start" operation mode: connect terminal S to  4 V (or press and hold the Start
button)
4. Start the learning process
- Switch on the supply voltage
- Wait for the self-test to finish (STATE-LED pulses for approx. 10 seconds at 15 Hz)
- The learning process begins (STATE-LED flashes at approx. 1 Hz)

Putzmeister Concrete Pumps GmbH • Postfach 2152 • D-72629 Aichtal, Germany • Tel. +49 (0)7127 599-0 • Fax +49 (0)7127 599-520
No. SI 120207 Replaces: Authored by: Buck/Hoffmann/Neumann Date of issue: 29.06.12
 Product group: 02
Component
Evaluation device group:
05

General Spare
Parts List 5.2
group:
Service information SI 120207 Page: 3 of 3

- Wait for the learning process to be acknowledged (STATE-LED goes out after approx. 10
seconds)
5. Complete the learning process
- Remove the jumper between J1 and J2
- For "Manual start" operation mode: connect the Start button to terminal S
- Press the reset button or interrupt the supply voltage for at least 10 seconds
- Wait for the self-test to finish (STATE-LED pulses for approx. 10 seconds at 15 Hz)
6. Check that all protective devices are functioning properly

Function check
Warning!
Lethal injury caused by errors during installation and function checking.
Ensure that no-one is in the danger zone before carrying out function checks.
Observe the applicable accident prevention regulations.
The safety function must be fully checked after installation and any error. Proceed as follows:
- Switch on the supply voltage.
The safety switch carries out a self-test.
The green LED STATE flashes up to 3 times. Then the LED STATE lights up permanently. The
LEDs OUT and ERROR do not light up.
- All protective devices close.
The machine must not start up by itself.
The green LED STATE and yellow LED OUT light up permanently.
- Enable operation in the control system.
- Open the protective device.
The machine must switch off, and must not be able to be started while the protective device is
open.
The green LED STATE lights up permanently, the LEDs OUT and ERROR do not light up.

After the learning process is complete, the safety function must be tested in accordance with company
standard 5050.

Putzmeister Concrete Pumps GmbH • Postfach 2152 • D-72629 Aichtal, Germany • Tel. +49 (0)7127 599-0 • Fax +49 (0)7127 599-520
No. SI 120207 Replaces: Authored by: Buck/Hoffmann/Neumann Date of issue: 29.06.12