schmersal BNS 300-01ZG User manual

BNS 300
Operating instructions
Safety sensor
EN 1
1. About this document
1.1 Function
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 Destination and use .....................................2
2.4 Technical data .........................................2
2.5 Safety classication .....................................2
3 Mounting
3.1 General mounting instructions .............................3
3.2 Dimensions ...........................................3
3.3 Axial misalignment......................................4
3.4 Adjustment............................................4
4 Electrical connection
4.1 General information for electrical connection..................4
4.2 Contact variants........................................4
4.3 Connector plug.........................................4
5 Set-up and maintenance
5.1 Functional testing.......................................4
5.2 Maintenance ..........................................4
6 Disassembly and disposal
6.1 Disassembly...........................................4
6.2 Disposal ..............................................4
7 EU Declaration of conformity
x.000 / 04.2016 / v.A. - 101119995-EN / N/ 2016-04-20 / AE-Nr. 6009
EN Operating instructions. . . . . . . . . . . . .pages 1 to 6
Original

2
Operating instructions
Safety sensor BNS 300
EN
1.6 Warning about misuse
In case of improper use or manipulation of the safety switch-
gear, 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 result-
ing from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary re-
pairs, 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:
BNS 300-01ZG-
➀
-
➁
No. Option Description
➀
connecting cable
ST integrated connector
➁
2211 increased switching distance
2230 supplementary signalling output
2334 increased switching distance and
supplementary signalling output
2246 Ue42 VAC
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 Destination and use
The safety sensor is designed for application in safety circuits and is
used for monitoring the position of movable safety guards to ISO 14119
and IEC 60947-5-3. To actuate the safety sensors, only the BPS 300,
BPS 303 or BPS 303 SS actuators can be used, conventional magnets
are not suitable.
The safety switchgears are classified according to
ISO 14119 as type 4 switching devices.
The safety switches are used for applications, in which the hazardous
situation is terminated without delay when the safety guard is opened.
Only the entire system consisting of the safety sensor (BNS 300 with
integrated safety-monitoring module) and the actuator (BPS 300/
BPS 303 or BPS 303 SS) meets the requirements of the standard
IEC 60947-5-3.
The user must evaluate and design the safety chain in
accordance with the relevant standards and the required
safety level.
The entire concept of the control system, in which the
safety component is integrated, must be validated to the
relevant standards.
2.4 Technical data
Standards: IEC 60947-5-3, BG-GS-ET-14
Enclosure: glass-fibre reinforced thermoplastic
Tightening torque: max. 300 Ncm, A/F 36
Protection class: IP67 to IEC 60529
Degree of pollution: 3
Termination: cable Boflex 4 x 0.75 mm²,
connector M12 x 1, 4-pole;
- ordering suffix -2230: cable YSLYÖ-0 5 x 0.75 mm²
Operating principle: magnetic
Actuator: BPS 300, BPS 303, BPS 303 SS, coded
Coding level according to ISO 14119: low
Switching distances:
- Assured switching distance sao:5 mm,
8 mm (ordering suffix -2211/-2334)
- Assured switch-off distance sar:15 mm,
18 mm (ordering suffix -2211/-2334)
Operating voltage: 24 VDC +10 %/–15 %
ordering suffix -2246: 42 VAC
Operating current: 30 mA
Rated impulse withstand voltage Uimp:4 kV
Rated insulation voltage Ui:250 VAC / 30 VDC
Required short-circuit current: 100 A
Output: 1 enabling path
Switching voltage: max. 250 VAC
Load current: max. 3 A
Switching capacity: max. 750 VA
Max. fuse rating: 3 A gG D-fuse to IEC 60269-1
Supplementary signalling contact: max. 100 mA
Ambient temperature: −25 °C ... +55 °C
Storage and transport temperature: −25 °C ... +70 °C
Max. switching frequency: 5 Hz
Resistance to shock: 30 g / 11 ms
Resistance to vibration: 10 ... 55 Hz, amplitude 1 mm
EMC rating: according to EN 61000-6-2
2.5 Safety classification
Standards: ISO 13849-1
Intended structure:
- 1-channel usage: useable to cat.1 / PL c
for max. 5 million of switching cycles / year for
sensor and for MTTFd ≥ 40 years for safety contact
B10d value for safety contact:
- at 100% contact load: 400,000
- at 80% contact load: 1,000,000
- at 60% contact load: 2,500,000
- at 40% contact load: 7,500,000
- at 20% contact load: 20,000,000
Service life: 20 years
MT
TF
Bdxx
hs/h3600
d
10d op op
op
n
0,1 x nop tcycle
(Determined values can vary depending on the application-specific
parameters hop, dop and tcycle as well as the load.)

3
BNS 300
Operating instructions
Safety sensor
EN
3. Mounting
3.1 General mounting instructions
During fitting, the requirements of ISO 14119 must
be observed.
• Fitting is only authorised in a de-energised condition
• Do not use the sensor and the actuator as a mechanical backstop
• Any mounting position, provided that the active surfaces are opposite
• Screw both nuts in the provided mounting holes to fix the safety
sensor (max. tightening torque 300 Ncm)
• Do not install the safety sensor and the actuator in strong magnetic
fields
• If possible, do not install the safety sensor and the actuator on
ferromagnetic material.
• Do not subject the safety sensor and actuator to extreme vibrations
and shocks.
• Keep away from metal chips
• The mounting distance between two sensors should always be at
least 50 mm.
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).
3.2 Dimensions
All measurements in mm.
Safety sensor with cable
1000
M 30 x 1.5
6
78
36
Safety sensor with connector
LED
70
M30x1,5
5
83,6
12
M12x1
36
Actuator
BPS 300
with plastic enclosure
2
30
15
90°
14
ø 2
ø 4,5
BPS 303
for food-processing industry, with plastic enclosure
15
2
14
ø 2
ø 37
ø 30
BPS 303 SS
for food-processing industry, with metal enclosure
2
1,5
13,8
15 M4
ø 30
ø 37
Actuator BPS 303 and BPS 303 SS
The actuators are primarily provided for use in the food-processing
industry and therefore are not labelled.
The actuators are fixed by means of the supplied tamper-proof screws.
The mounting hole must have a diameter of 4.5 mm. Next to the
mounting hole, a second mounting hole must be provided. This hole is
used for the fixture of the displacement protection dowel.
Position of the dowel: refer to the image below.

4
Operating instructions
Safety sensor BNS 300
EN
3.3 Axial misalignment
A horizontal and vertical misalignment of the safety sensor and the
actuator is tolerated. The possible misalignment depends on the
distance of the active surfaces of the sensor and the actuator. The
sensor remains active within the tolerance range.
The specified switching distances refer to opposedly mounted safety
sensors and actuators.
1
0
1
2
3
4
5
2
2,5
3
3
3
6
8
10
10
Assured switching distance: sao = 5 mm,
8 mm (ordering suffix -2211, -2334)
Assured switch-off distance: sar = 15 mm,
18 mm (ordering suffix -2211,
-2334)
3.4 Adjustment
If the central marking of the actuator is within the represented base
position area, the authorisation signal is given.
Recommended Adjustment
Align the safety sensor and actuator at a distance
of 0.5 x sao .
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 safety sensors must be wired in accordance with the wire colours
or the pin configuration.
4.2 Contact variants
The contact position shows the actuated sensor function when the
safety guard is closed. The LED is illuminated when the guard is
closed. Inductive loads (e.g. contactors, relays, etc.) are to be provided
with suitable interference suppression circuitry.
BNS 300-01ZG
BNS 300-01ZG-2211
BNS 300-01ZG-2271
BNS 300-01ZG-2246 (42 VAC)
BNS 300-01ZG-2230
BNS 300-01ZG-2334
BN
BK
BK
BU
24 VDC
30 mA
L+
L-
24 VDC
100 mA
30 mA
1
2
3
4
5
L+
A
L-
BNS 300-01ZG-ST
24 VDC
30 mA
3
1
2
4
4.3 Connector plug
Integrated connector M12, 4-pole
3
2
1
4
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)
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:
• Check the fitting of the sensor and the actuator
• Remove possible metal chips
• Check the cable for damage.
Adequate measures must be taken to ensure protection
against tampering either to prevent tampering of the safety
guard, for instance by means of replacement actuators.
Damaged or defective components must be replaced.
6. Disassembly and disposal
6.1 Disassembly
The safety switchgear must be disassembled in a de-energised
condition only.
6.2 Disposal
The safety switchgear must be disposed of in an appropriate manner
in accordance with the national prescriptions and legislations.

5
EN
BNS300-C-EN
BNS 300
Operating instructions
Safety sensor
7. EU Declaration of conformity
Name of the component: BNS 300
Type: See ordering code
Description of the component: Safety sensor with integrated safety-monitoring module
Relevant Directives: Machinery Directive
EMC-Directive
RoHS-Directive
2006/42/EC
2014/30/EU
2011/65/EU
Applied standards: DIN EN 60947-5-3:2005,
DIN EN ISO 13849-1:2008,
DIN EN ISO 13849-2:2008
Notied body, which approved
the full quality assurance system,
referred to in Appendix X, 2006/42/EC:
TÜV Rheinland Industrie Service GmbH
Alboinstr. 56, 12103 Berlin
ID n°: 0035
Person authorized for the compilation
of the technical documentation:
Oliver Wacker
Möddinghofe 30
42279 Wuppertal
Place and date of issue: Wuppertal, April 20, 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.
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: [email protected]
Internet: http://www.schmersal.com