schmersal CSS 30S, CSS 300 Operating Instructions Manual

CSS 30S CSS 300
Operating instructions Safety sensor
EN
1
1. About this document
This operating instructions manual provides all the information you need for the mounting, set-up and commissioning to ensure the safe operation and disassembly of the safety switchgear. The operating instructions must be available in a legible condition and a complete version in the vicinity of the device.
1.2 Target group: authorised qualified personnel
All operations described in this operating instructions manual must be carried out by trained specialist personnel, authorised by the plant operator only.
Please make sure that you have read and understood these operating instructions and that you know all applicable legislations regarding occupational safety and accident prevention prior to installation and putting the component into operation.
The machine builder must carefully select the harmonised standards to be complied with as well as other technical specifications for the selection, mounting and integration of the components.
1.3 Explanation of the symbols used
Information, hint, note:
This symbol is used for identifying useful additional information.
Caution: Failure to comply with this warning notice could lead to failures or malfunctions. Warning: Failure to comply with this warning notice could lead to physical injury and/or damage to the machine.
1.4 Appropriate use
The products described in these operating instructions are developed to execute safety-related functions as part of an entire plant or machine. It is the responsibility of the manufacturer of a machine or plant to ensure the correct functionality of the entire machine or plant.
The safety switchgear must be exclusively used in accordance with the versions listed below or for the applications authorised by the manufacturer. Detailed information regarding the range of applications can be found in the chapter "Product description".
1.5 General safety instructions
The user must observe the safety instructions in this operating instructions manual, the country-specific installation standards as well as all prevailing safety regulations and accident prevention rules.
Further technical information can be found in the Schmersal catalogues or in the online catalogue on the Internet: www.schmersal.net.
The information contained in this operating instructions manual is provided without liability and is subject to technical modifications.
There are no residual risks, provided that the safety instructions as well as the instructions regarding mounting, commissioning, operation and maintenance are observed.
Content
1 About this document
1.1 Function ..............................................1
1.2 Target group: authorised qualied personnel..................1
1.3 Explanation of the symbols used ...........................1
1.4 Appropriate use ........................................1
1.5 General safety instructions ...............................1
1.6 Warning about misuse ...................................2
1.7 Exclusion of liability .....................................2
2 Product description
2.1 Ordering code .........................................2
2.2 Special versions........................................2
2.3 Comprehensive quality insurance to 2006/42/EC ..............2
2.4 Destination and use .....................................2
2.5 Technical data .........................................2
2.6 Safety classication .....................................3
3 Mounting
3.1 General mounting instructions .............................3
3.2 Dimensions ...........................................3
3.3 Adjustment ............................................3
3.4 Switching distance ......................................3
4 Electrical connection
4.1 General information for electrical connection..................4
4.2 Series-wiring ..........................................4
5 Set-up and maintenance
5.1 Functional testing.......................................4
5.2 Maintenance ..........................................4
6 Diagnostic functions
6.1 Operating principle of the diagnostic LED's ...................4
6.2 Operating principle of the electronic diagnostic output ..........5
6.3 Safety-sensors with serial diagnostic function .................5
7 Disassembly and disposal
7.1 Disassembly...........................................6
7.2 Disposal ..............................................6
8 Appendix
8.1 Wiring examples .......................................7
9 EU Declaration of conformity
x.000 / 11.2016 / v.A. - 101204658-EN / F / 2016-11-17 / AE-Nr. 6758
EN
Operating instructions. . . . . . . . . . . . .pages 1 to 8
Original
2
Operating instructions Safety sensor
CSS 30S CSS 300
EN
1.6 Warning about misuse
In case of improper use or manipulation of the safety switch­gear, personal hazards or damages to machinery or plant components cannot be excluded when safety switchgear is used. The relevant requirements of the standard ISO 14119 must be observed.
1.7 Exclusion of liability
We shall accept no liability for damages and malfunctions resulting from defective mounting or failure to comply with this operating instructions manual. The manufacturer shall accept no liability for damages resulting from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary repairs, conversions and modifications to the device are strictly forbidden; the manufacturer shall accept no liability for damages resulting from such invasive work, arbitrary repairs, conversions and/or modifications to the device.
2. Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
CSS 11-➀-➁-M-ST No. Option Description
30NO Stainless steel enclosure 300 Thermoplastic enclosure
D With diagnostic output SD with serial diagnostic function
Actuator
CST 30S-1 M30-Stainless steel threaded pipe
2.2 Special versions
For special versions, which are not listed in the order code below 2.1, these specifications apply accordingly, provided that they correspond to the standard version.
2.3 Comprehensive quality insurance to 2006/42/EC
Schmersal is a certified company to appendix X of the Machinery Directive. As a result, Schmersal is entitled to autonomously conduct the conformity assessment procedure for the products listed in Appendix IV of the MD without involving a notified body. The prototype test certificates are available upon request or can be downloaded from the Internet at www.schmersal.com.
2.4 Destination and use
This non-contact, electronic safety sensor is designed for application in safety circuits and is used for monitoring the position of movable safety guards. In this application, the safety sensor monitors the position of hinged, sliding or removable safety guards by means of the coded electronic actuator.
The safety switchgears are classified according to ISO 14119 as type 4 interlocking devices.
The safety sensor CSS 300 is suitable for concealed installation behind stainless steel.
The diagnostic output of the safety sensor alternatively can be used as a conventional output or as a “serial output“ with input and output channel. The serial connections of the individual sensors are wired in series together with other devices and connected to a Field Bus Gateway.
Mode of operation of the safety outputs
The opening of a safety guard, i.e. the actuator is removed out of the active zone of the sensor, will immediately disable the safety outputs of the sensor (also refer to Switching distance of the safety sensor).
Any error that does not immediately affect the functioning of the safety sensor (e.g. too high the ambient temperature, interference potential at a safety output, cross-wire short) will lead to a delayed shut-down. The safety outputs are disabled after 30 minutes if the error is not rectified.
This signal combination, diagnostic output disabled and safety channels still enabled, can be used to stop the production process in a controlled manner. After fault rectification, the error message is reset by opening and re-closing the corresponding safety guard. The safety outputs enable and allow a restart.
Series-wiring
Max. 31 sensors can be wired in series. A 200 m long sensor chain can be set up. Wiring examples for series-wiring, refer to appendix
The user must evaluate and design the safety chain in accordance with the relevant standards and the required safety level. If multiple safety sensors are involved in the same safety function, the PFH values of the individual components must be added.
The entire concept of the control system, in which the safety component is integrated, must be validated to the relevant standards.
2.5 Technical data
Standards: IEC 60947-5-3, ISO 13849-1, IEC 61508 Housing:
- CSS 30S: stainless steel, 1.4404 to EN 10088
- CSS 300: thermoplastic enclosure Operating principle: inductive Coding level according to ISO 14119: low
Switching distances to IEC 60947-5-3:
Rated operating distance Sn: 11 mm Assured switching distance sao: 8 mm Assured switch-off distance sar: 15 mm Hysteresis: < 2 mm Repeat accuracy: < 1 mm Switching frequency f: 3 Hz Connection: M12 connector, 8 pole Series-wiring: max. 31 devices Fuse (Circuit breaker): external, 2 A Cable length: max. 200 m
Ambient conditions:
Ambient temperature Tu:
- CSS 30S: –25 °C … +65 °C
- CSS 300: –25 °C … +60 °C Storage and transport temperature: −25 °C … +85 °C Resistance to vibration: 10 … 55 Hz, amplitude 1 mm Resistance to shock: 30 g / 11 ms Protection class:
- CSS 30S: IP69K, to DIN 40050-9;
IP65, IP67 to IEC 60529
- CSS 300: IP65, IP67 to IEC 60529
EMC rating: according to EN 61000-6-2 Electromagnetic interference: according to EN 61000-6-4
Electrical data:
Rated operating voltage Ue: 24 VDC −15% / +10%
(stabilised PELV to IEC 60204-1)
Rated operating current Ie: 0.6 A No-load current lo: max. 0.1 A; in average: 50 mA Protection class: II Overvoltage category: III Degree of pollution: 3
3
CSS 30S CSS 300
Operating instructions Safety sensor
EN
Rated impulse withstand voltage U
imp
: 0.8 kV Rated insulation voltage Ui: 32 V Response time: < 60 ms Duration of risk: < 60 ms
Safety outputs Y1/Y2: NO function, dual-channel,
p-type, short-circuit proof
Rated operating voltage Ue1: 24 VDC (-15% / +10%) Voltage drop: Ue < 1 V Leakage current lr: < 0.5 mA Related operating current le1: max. 0.25 A Minimum operating current Im: 0.5 mA Utilisation category: DC-12, DC-13 Required rated short-circuit current: 100 A
Diagnostic output: short-circuit proof, p-type
Rated operating voltage Ue2: 24 VDC (-15% / +10%) Voltage drop: Ue < 5 V Related operating current le2: max. 0.05 A Utilisation category: DC-12, DC-13
Serial diagnostic
Operating current: 150 mA, short-circuit proof Wiring capacitance for serial diagnostics: max. 50 nF
2.6 Safety classification
Standards: ISO 13849-1, IEC 61508 PL: e Control Category: 4 PFH: 3.6 x 10-9 / h PFD: 3.95 x 10
-5
SIL: suitable for SIL 3 applications Service life: 20 years
3. Mounting
3.1 General mounting instructions
During fitting of the actuator and the sensor, the requirements of ISO 14119, especially paragraph 7 must be observed!
The sensor enclosure must not be used as an end stop. The component can be mounted in any position. The active surface of the safety sensor and the actuator have to be opposite. The safety sensor must only be
used within the assured switching distances ≤ sao and ≥ sar.
The safety sensor and the corresponding actuator can be fixed using the supplied M30 nuts (A/F 36). The max. tightening torque is 30 Nm (CSS 30S) or 400 Ncm (CSS 300).
A concealed mounting is possible, however this reduces the switching distance. The reduction will be lower, when the sensor and the actuator protrudes a few mm.
The actuator has a slot in the active front surface. In confined spaces, this slot can be used to fix the actuator by means of a screwdriver.
Safety sensor and actuator must be permanently fitted to the safety guards and protected against displacement by suitable measures (tamperproof screws, gluing, drilling of the screw heads).
To avoid any interference inherent to this kind of system and any reduction of the switching distances, please observe the following guidelines:
• Minimum distance between two sensors: CSS 30S: 50 mm CSS 300: 100 mm
• The presence of metal chips in the vicinity of the sensor is liable to modify the switching distance
• Keep away from metal chips
3.2 Dimensions
All measurements in mm.
Safety sensor
M30 x 1,5
78,5
99,5
88,5
6
5
Ø28
LED
M12x1
36
Actuator
24,5
M30x1,5
5
36
3.3 Adjustment
The LED of the safety sensor can be used as an adjustment tool. The yellow flashing LED of a sensor signals that an adjustment of the switching distance is required. Reduce the distance between the sensor and the actuator, until the LED of the safety sensor is continuously lit yellow.
The correct functionality of both safety channels must be checked by means of the connected safety-monitoring module.
3.4 Switching distance
The graphs show the switch-on and switch-off points of the sensor due to the approach of the actuator. The maximum misalignment of the actuator with regard to the sensor centre is 9 mm. A concealed mounting of the sensor and the actuator will reduce the switching distance. (see “Mounting” part)
S
V
4
Operating instructions Safety sensor
CSS 30S CSS 300
EN
Typical response range of the sensor
-5-10 5
5
10
10
0
0
S
S
ar
S
on
S
ao
S
off
V [mm]
S [mm]
Key
S Switching distance X Axial misalignment S
on
Switch-on distance
S
off
Switch-off distance
S
h
Hysteresis range Sh = S
off
– S
on
S
ao
Assured switch-on distance to IEC 60947-5-3
S
ar
Assured switch-off distance to IEC 60947-5-3
4. Electrical connection
4.1 General information for electrical connection
The electrical connection may only be carried out by authorised personnel in a de-energised condition.
The power supply for the safety sensors must provide protection against permanent over-voltage. Under fault conditions, the voltage must not exceed 60 V.
The safety outputs can be integrated into the safety circuit of the control system. For applications of PL e / control category 4 to ISO 13849-1, the safety outputs of the safety sensor or sensor of the chain must be wired to a safety monitoring module of the same control category.
Requirements for the connected safety-monitoring module
• Dual-channel safety input, suitable for p-type sensors with NO function
The sensors cyclically switch off the safety output to test them. The
switch-off times of 250 μs – 1500 μs must be tolerated by the safety­monitoring module. The switch-off time of 250μs of the safety sensor is
additionally extended depending on the cable length and the capacity
of the cable used. Typically a switch off time of 500 μs with 100 m of
connection cable is reached. A cross-wire short detection is therefore not required as part of the evaluation.
Information for the selection of suitable safety-monitoring modules can be found in the Schmersal catalogues or in the online catalogue on the Internet: www.schmersal.net.
If the safety sensor is connected to electronic safety-monitoring modules, we recommend that you set a discrepancy time of min. 100 ms. The safety inputs of the safety-monitoring module must be able to blank a test impulse of approx. 1 ms. The safety-monitoring module does not need to have a cross-wire short monitoring function, if necessary, the cross-wire short monitoring function must be disabled.
4.2 Series-wiring
A 200 m long sensor chain can be set up. Please note that voltage losses could occur (due to cable length, cable section, voltage drop/ sensor)! For longer cable lengths, the section of the connecting cables must be taken as large as possible.
Wiring examples for series-wiring, refer to appendix
Protection is not required when pilot wires are laid. The cables however must be separated from the supply and energy cables. The max. fuse rate for a sensor chain depends on the section of the connecting cable of the sensor.
When wiring SD devices, please observe the voltage drop on the cables and the current carrying capacity of the individual components.
5. Set-up and maintenance
5.1 Functional testing
The safety function of the safety components must be tested. The following conditions must be previously checked and met:
1. Fitting of the sensor and the actuator
2. Fitting and integrity of the power cable
3. The system is free of dirt and soiling (in particular metal chips)
After the safety sensor is wired, open and close the safety guard to check whether the enabling signal is given.
5.2 Maintenance
In the case of correct installation and adequate use, the safety sensor features maintenance-free functionality. A regular visual inspection and functional test, including the following steps, is recommended:
1. Check the fitting and integrity of the safety sensor, the actuator and the cable
2. Remove possible metal chips
Measures must be taken to protect against manipulation or against the bypassing of safety device, for example, using an extra actuator.
Damaged or defective components must be replaced.
6. Diagnostic functions
6.1 Operating principle of the diagnostic LED's
The safety sensor indicates the operating condition and faults by means of three-colour LED's located in the connection area.
The green LED indicates that the safety sensor is ready for operation. The supply voltage is on. The yellow LED always signals the presence of an actuator within range. If the actuator is operating near the limit of the hysteresis range of the safety sensor, the LED is flashing. The flashing can be used to prematurely detect variations in the clearance between the sensor and the actuator (e.g. sagging of a safety guard). The sensor must be adjusted before the distance to the actuator increases and before the safety outputs are disabled, thus stopping the machine. Either red or green illuminates in a two colour LED. If an error is detected, the red LED will be activated.
Flash codes red diagnostic LED
LED indication (red) Error cause
1 flash pulse Error output Y1 2 flash pulses Error output Y2 3 flash pulses Cross-wire Y1/Y2 4 flash pulses ambient temperature too high 5 flash pulses Wrong or defective actuator Continuous red Internal error
5
CSS 30S CSS 300
Operating instructions Safety sensor
EN
6.2 Operating principle of the electronic diagnostic output
The short-circuit proof diagnostic output can be used for central visualisation or control functions, e.g. in a PLC. The electronic diagnostic output signals faults before the safety outputs are disabled, thus enabling a controlled shutdown.
The diagnostic output is not a safety-related output!
The diagnostic output can also be used to detect clearance variations between the sensor and the actuator in the same way as the yellow LED. An active fault causes the diagnostic output to be disabled. The safety outputs are disabled after max. 30 minutes if the fault is not rectified. The signal combination, diagnostic output disabled and safety channels still enabled, can be used to stop the production process in a controlled manner.
Error
A fault has occurred, which causes the safety outputs to be disabled. The fault is reset, when the cause is eliminated and bit 7 of the request byte changes from 1 to 0 or the safety guard is opened. Faults at the safety outputs are only deleted upon the next release, as the fault rectification cannot be detected sooner.
Error warning
A fault has occurred, which causes the safety outputs to be disabled after 30 minutes. The safety outputs initially remain enabled. This enables the shutdown of the process in a controlled manner. An error warning is deleted when the cause of error is eliminated.
Table 1: Examples of the diagnostic function of the safety-sensor with conventional diagnostic output
System condition Duo LED
green red
LED
yellow
Diagnostic
output
Safety
outputs
Y1, Y2
Note
Supply voltage on, not actuated On Off Off 0 V 0 V Voltage on, no evaluation of the voltage quality Actuated On Off On 24 V 24 V The yellow LED always signals the presence of an
actuator within range
Actuated in limit area On Off Flashes 24 V
pulsed
24 V The sensor must be adjusted before the distance to
the actuator increases and before the safety outputs are disabled, thus stopping the machine
Actuator, error warning Off Flashes On 0 V 24 V The safety outputs are disabled after 30 minutes
if the error is not rectified. Actuated, fault Off Flashes On 0 V 0 V Refer to table with flash codes Actuated, internal fault Off On On 0 V 0 V ---
6.3 Safety-sensors with serial diagnostic function
Safety sensors with serial diagnostic cable have a serial input and output cable instead of the conventional diagnostic output. If safety sensors are wired in series, the safety channels as well as the inputs and outputs of the diagnostic channels are wired in series.
Max. 31 sensors can be wired in series. For the evaluation of the serial diagnostics line either the PROFIBUS-Gateway SD-I-DP-V0-2 or the Universal-Gateway SD-I-U-… are used. This serial diagnostic interface is integrated as a slave in an existing field bus system. In this way, the diagnostic signals can be evaluated by means of a PLC. The necessary documentation for the integration of the SD-Gateway is available for download at www.schmersal.com.
Accessories SD interface
For ease of wiring and series-wiring of SD devices, considerable accessories are available. Detailed information is available on the Internet, www.schmersal.net.
The response data and the diagnostic data are automatically and permanently written in the assigned input byte of the PLC for each safety sensor in the series-wired chain. The request data for each safety sensor are transmitted to the device through an output byte of the PLC. In the event of a communication error between the field bus Gateway and the safety sensor, the switching condition of the safety output of the safety sensor is maintained.
6
Operating instructions Safety sensor
CSS 30S CSS 300
EN
Table 2: Function of the visual diagnostic LED`s, the serial status signals and the safety outputs by means of an example
System condition Duo-LED LED Safety
outputs
Response byte Bit-Nr.
green red yellow Y1, Y2 7 6 5 4 3 2 1 0
Supply voltage on, not actuated On Off Off 0 V 0 0 0 0 0 0 0 0 Actuated, safety outputs enabled On Off On 24 V 0 0 0 1 0 0 1 1 Actuated in limit area On Off Flashes 24 V 0 0 1 1 0 0 1 1 Actuator, error warning Off Flashes On 24 V 0 1 0 1 0 0 1 1 Actuated, fault Off Flashes On 0 V 1 0 0 1 0 0 1 0
The shown bit order of the diagnostic byte is an example. A different combination of the operational conditions will lead to a change of the bit order.
Table 3: I/O data and diagnostic data
Communication directions: Request byte: from the PLC to the local safety sensor
Response byte: from the local safety sensor to the PLC Warning/error byte: from the local safety sensor to the PLC
Bit n° Request byte Response byte Diagnostic error warning Diagnostic error
Bit 0: --- Safety output activated Error output Y1 Error output Y1 Bit 1: --- Actuator detected Error output Y2 Error output Y2 Bit 2: --- --- Cross-wire Y1/Y2 Cross-wire Y1/Y2 Bit 3: --- --- Temperature too high Temperature too high Bit 4: --- Input condition X1 and X2 --- incorrect or defective actuator Bit 5: --- Actuated in limit area Internal device error Internal device error Bit 6: --- Error warning Communication error between the field
bus Gateway and the safety switch
---
Bit 7: Error reset Error (enabling path switched off) --- ---
The described condition is reached, when Bit = 1
7. Disassembly and disposal
7.1 Disassembly
The safety switchgear must be disassembled in a de-energised condition only.
7.2 Disposal
The safety switchgear must be disposed of in an appropriate manner in accordance with the national prescriptions and legislations.
7
CSS 30S CSS 300
Operating instructions Safety sensor
EN
8. Appendix
8.1 Wiring examples
The application examples shown are suggestions. They however do not release the user from carefully checking whether the switchgear and its set-up are suitable for the individual application.
Wiring example 1: Series-wiring of the safety sensor with diagnostic output
The voltage is supplied at the safety inputs of the terminal sensor of the chain (considered from the safety-monitoring module). The safety outputs of the first sensor are wired to the safety-monitoring module.
X1
Y1
X2
Y2
24 VDC GND
12356 8
X1
X2
A1
A2
Y1 Y2
12356 8
X1
X2
OUT
A1
A2
4
Y1
4
Y1
7
Y2
7
Y2
OUT
PLC
Safety outputs
Wiring example 2: Series-wiring of the safety sensor with serial diagnostic function
The safety outputs of the first sensor (viewed from the monitoring position) are wired to the safety-monitoring module. The Fieldbus Gateway is connected to the serial diagnostic input of the first sensor.
24 VDC GND
1235468
X1
Y1
X2
SDIN
SDOUT
A1
A2
1235468
X1
Y1
X2
7
Y2
7
Y2
SDIN
SDOUT
A1
A2
X1
Y1
X2
Y2
SD INSD OUT Y1 Y2
SD IN
Safety outputs
Field bus
Gateway
Table 4: Wiring and connectors
Function safety switchgear Pin configuration
of the connector
5
8
4
3
2
1
7
6
Colour codes of the
Schmersal connectors
Possible colour codes
of other
customary connectors
with conventional diagnostic output
with serial diag-
nostic function
IP67 / IP69
to DIN 47100
IP69K (PVC)
to
IEC 60947-5-2: 2007
A1 U
e
1 WH BN BN
X1 Safety input 1 2 BN WH WH A2 GND 3 GN BU BU Y1 Safety output 1 4 YE BK BK
OUT Diagnostic output SD output 5 GY GY GY
X2 Safety input 2 6 PK VT PK Y2 Safety output 2 7 BU RD VT
IN without function SD input 8 RD PK OR
Connecting cables with coupling (female) IP67 / IP69, M12, 8-pole - 8 x 0.23 mm² to DIN 47100
Connecting cables with coupling (female) IP69K, M12, 8-pole - 8 x 0.21 mm²
Cable length Part number Cable length Part number
2.5 m
5.0 m
10.0 m
103011415 103007358 103007359
5.0 m
5.0 m, angled
101210560 101210561
8
EN
CSS30S_CSS300-E-EN
Operating instructions Safety sensor
CSS 30S CSS 300
9. EU Declaration of conformity
Place and date of issue: Wuppertal, November 3, 2016
Authorised signature
Philip Schmersal
Managing Director
EU Declaration of conformity
Original K.A. Schmersal GmbH & Co. KG
Möddinghofe 30 42279 Wuppertal Germany Internet: www.schmersal.com
We hereby certify that the hereafter described components both in their basic design and construction conform to the applicable European Directives.
Name of the component: CSS 30S
CSS 300
Type: See ordering code
Description of the component: Non-contact safety sensor
Relevant Directives: Machinery Directive
EMC-Directive RoHS-Directive
2006/42/EC 2014/30/EU 2011/65/EU
Applied standards: EN 60947-1:2007+ A1:2011,
EN 60947-5-3:2013, ISO 14119:2013, EN ISO 13849-1:2008 + AC:2009, EN 61508 parts 1-7:2010
Notied body for the prototype test: TÜV Rheinland Industrie Service GmbH
Alboinstr. 56, 12103 Berlin ID n°: 0035
EC-prototype test certicate: 01/205/5076.01/14
Person authorised for the compilation of the technical documentation:
Oliver Wacker Möddinghofe 30 42279 Wuppertal
The currently valid declaration of conformity can be downloaded from the internet at www.schmersal.net.
K. A. Schmersal GmbH & Co. KG
Möddinghofe 30, D - 42279 Wuppertal Postfach 24 02 63, D - 42232 Wuppertal
Phone: +49 - (0)2 02 - 64 74 - 0 Telefax: +49 - (0)2 02 - 64 74 - 1 00 E-Mail: info@schmersal.com Internet: http://www.schmersal.com
Loading...