schmersal EX-CSS 180 User manual

EX-CSS 180
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, labelled with the caution or warning symbol above,
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 Purpose ..............................................2
2.4 Technical data .........................................2
2.5 Safety classication .....................................3
3 Mounting
3.1 General mounting instructions .............................3
3.2 Dimensions ...........................................3
3.3 Switching distance ......................................4
3.4 Adjustment............................................4
4 Rear side Electrical connection
4.1 General information for electrical connection..................4
4.2 Connection example ....................................4
4.3 Series wiring ..........................................4
4.4 Wiring example ........................................5
4.5 Note on the total length of a safety sensor chain...............5
5 Set-up and maintenance
5.1 Functional testing.......................................6
5.2 Maintenance ..........................................6
6 Diagnostic functions
6.1 Operating principle of the diagnostic LED's ...................6
6.2 Operating principle of the electronic diagnostic output ..........6
7 Disassembly and disposal
7.1 Disassembly...........................................6
7.2 Disposal ..............................................6
8 EU Declaration of conformity
x.000 / 11.2017 / v.A. - 101189309-EN / E / 2017-11-08 / AE-Nr. 8356
EN Operating instructions. . . . . . . . . . . . .pages 1 to 8
Original

2
Operating instructions
Safety sensor EX-CSS 180
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. 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:
EX-CSS 8-180-2P+D-M-L-3G/D
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 Purpose
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 closed
position of hinged, sliding or removable safety guards by means of the
coded electronic CST 180-1 or CST 180-2 actuators.
The components can be used in explosion-endangered areas of Zone
2 and 22 equipment category 3 GD. The installation and maintenance
requirements to the standard series EN 60079 must be met.
Conditions for safe operation
Due to their specific impact energy, the components must be fitted
with a protection against mechanical stresses. The specific ambient
temperature range must be observed. The user must provide for a
protection against the permanent influence of UV rays.
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 safety sensor, will immediately disable the safety
outputs (also refer to Switching distance of the safety sensor).
Faults which no longer guarantee the functioning of the safety sensor
(internal fault,) will also disable the safety outputs immediately. Any
error that does not immediately affect the safe functioning of the safety
sensor (e.g. the ambient temperature too high, interference potential
at a safety output, cross-wire short) will lead to a delayed shut-down.
In this situation, the diagnostic output will be switched off after approx.
10 seconds. The safety outputs are disabled when the fault is active
for 1 minute. Signal combination, diagnostic output disabled and
safety outputs still enabled, can be used to shut down the machine in
a controlled manner. After fault rectification, the error message is reset
by opening and re-closing the corresponding safety guard. The safety
outputs will switch, thus enabling the machine. For the release, the chain
of sensors must be permanently actuated.
A cross-wire short at the safety outputs of a sensor chain will
load the sensor from the place where the fault is located up
to the end of the chain. The fault therefore can be signalled
by multiple sensors. Starting from the safety-monitoring
module, the cross-wire short is located before the first sensor
signalling the fault.
Series wiring
Max. 16 sensors can be wired in series.
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.
2.4 Technical data
Equipment category: L II 3GD
Ex protection: Ex nA IIC T6 Gc X
Ex tc IIIC T70°C Dc X
Standards: IEC 60947-5-3, IEC 61508,
EN 60079-0, EN 60079-15, EN 60079-31
Enclosure: glass-fibre reinforced thermoplastic
Operating principle: inductive
Actuator: CST 180-1, CST 180-2
Series-wiring: max. 16 components
Connection: Cable
Cable section: 7 × 0.25 mm²
Switching distances to IEC 60947-5-3:
Rated switching distance Sn:8 mm
Assured switching distance sao: 7 mm
Assured switch-off distance sar: 10 mm
Hysteresis: ≤ 0.7 mm
Repeat accuracy R: ≤ 0.2 mm
Cable length: max. 200 m (cable length and
cable section alter the voltage drop
depending on the output current)
Ambient conditions:
Ambient temperature: –20 °C … +40 °C
Storage and transport temperature: −25 °C … +85 °C
Protection class: IP65 / IP67
Resistance to vibration: 10…55 Hz, Amplitude 1 mm
Resistance to shock: 30 g / 11 ms
Switching frequency f: 3 Hz
Response time: < 30 ms
Duration of risk: ≤ 30 ms
Electrical data:
Rated operating voltage Ue: 24 VDC −15% / +10%
PELV (to IEC 60204-1)
Rated operating current Ie: 1 A
Minimum operating current Im:0.5 mA
Required rated short-circuit current: 100 A
Rated insulation voltage Ui:32 V
Rated impulse withstand voltage Uimp:800 V
No-load current Io:0.05 A
Leakage current Ir: ≤ 0.5 mA
Protection class: II
Overvoltage category: III
Degree of pollution: 3
EMC rating: according to EN 61000-6-2
Electromagnetic interference: to EN 61000-6-4
Safety inputs X1/X2:
Rated operating voltage Ue: 24 VDC -15% / +10%
PELV (to IEC 60204-1)
Rated operating current Ie: 1 A

3
EX-CSS 180
Operating instructions
Safety sensor
EN
Safety outputs: p-type, short-circuit proof
Rated operating current Ie1:max. 0,5 A
depending on the ambient temperature
Utilisation category: DC-12 Ue/Ie24 VDC / 0.5 A
DC-13 Ue/Ie24 VDC / 0.5 A
Voltage drop: 0.5 V
Diagnostic output: short-circuit proof, p-type
Rated operating voltage Ue2:max. 4 V below Ue
Rated operating current Ie2:max. 0.05 A
Utilisation category: DC-12 Ue/Ie24 VDC / 0.05 A
DC-13 Ue/Ie24 VDC / 0.05 A
External fuse rating: fuse:
1.0 A at output current ≤ 200 mA
1.6 A at output current > 200 mA
2.5 Safety classification
Standards: ISO 13849-1, IEC 61508
PL: e
Control Category: 4
PFH value: 2.5 x 10-9 / h
SIL: suitable for SIL 3 applications
Service life: 20 years
3. Mounting
3.1 General mounting instructions
Fitting is only authorised in a de-energised condition
The component can be mounted in any position. The only condition
is that, the active surface of the safety sensor and the actuator are
opposite. The distance between both surfaces must be smaller than
7 mm when the safety guard is closed. The safe switching distance sar
must be observed.
The sensor enclosure must not be used as an end stop. 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 M18 nuts (A/F 24). The max. tightening torque of
the supplied screws is 500 Ncm. Alternatively, the H18 fixing clamp
(accessory) can be used for the fixation of the safety sensor.
A concealed mounting is possible, however this reduces the switching
distance. The reduction will be lower, when the sensor protrudes a
few mm.
The CST 180-1 actuator has two fixing holes displaced by 90°.
The max. tightening torque of the supplied screws is 100 Ncm.
The CST 180-2 actuator is screwed into a prepared tapped hole
M 18 × 1. Use the slot to the front.
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:
• The presence of metal chips in the vicinity of the sensor is liable to
modify the switching distance
• Keep away from metal chips
• Minimum distance between two sensors: 100 mm
Please observe the recommendations regarding maximum
impact energy, actuating speed and tightening torque in the
technical data.
Please observe the relevant requirements of the standards
ISO 12100, EN 953 and ISO 14119.
3.2 Dimensions
All measurements in mm.
Safety sensor
24
LED
98
4
154
M 18x1
CST 180-1 actuator
25 24,4
15,2
M18 x 1
33,5
46
15
Ø 5,6Ø 5,1
Ø 9
CST 180-2 actuator
25
¤16,6
M18x1
H 18 clamp
15
M5
8
30
Ø 18
33
46
17

4
Operating instructions
Safety sensor EX-CSS 180
EN
3.3 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 7 mm. A concealed
mounting of the sensor and the actuator will reduce the switching
distance.
S
V
Key
S = switching distance
V = axial misalignment
-5-6-7-8 5678
5
0
[mm] 0-1-2-3-4 1 234
8
10
SSar
SOFF SON
Sao
S [mm]
V [mm]
Typical response range of the EX-CSS 180 sensor
sON switching point
soff switch-off point
Shhysteresis range
sH = sOFF – sON
Sao Assured switching distance
Sar Assured switch-off distance
3.4 Adjustment
The LED in the end cap of the safety sensor can be used as adjustment
tool. The yellow flashing LED of a sensor signals if an adjustment of the
switching distance is required. Reduce the distance between the sensor
and the actuator, until the LED in the end cap of the safety sensor is
continuously lit yellow. In this position, a reliable switching position
of the sensor is obtained. (also refer to "Operating Principle of the
Diagnostic Outputs").
The proper functionality must always be checked by means of the
connected safety-monitoring module.
4. Rear side 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. supply units according to IEC 60204-1 is
recommended.
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 safety sensors with NC
function.
The safety-monitoring module must tolerate internal functional tests of
the sensors with cyclic switch-off of the sensor outputs for max. 2 ms.
The safety-monitoring module must not be equipped with a cross-wire
detection function. Short-circuit recognition by the evaluation is not
necessary.
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.
4.2 Connection example
Sensor with safety inputs and safety outputs in one pre-wired cable:
The series-wiring of multiple safety sensors is realised by wiring in the
control cabinet or in on-site junction boxes.
Colour Connection example
BN (brown) A1 Ue
BU (blue) A2 GND
VT (violet) X1 Safety input 1
WH (white) X2 Safety input 2
BK (black) Y1 Safety output 1
RD (red) Y2 Safety output 2
GY (grey) Diagnostic output
WH
VT GY
BK
RD
BN
BU
4.3 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.

5
EX-CSS 180
Operating instructions
Safety sensor
EN
4.4 Wiring example
Series-wiring of 4 safety sensors EX-CSS 8-180-2P+D+M-L-3G/D with common connecting cable for the inputs and outputs
The series-wiring of multiple sensors is realised by wiring in the control cabinet or in on-site junction boxes. A sensor of this type can also be used
as individual component or as first sensor of a chain. In these both cases, the positive operating voltage is supplied in both safety inputs.
24 V
0V
GY
BN
BU
WH
VT
BK
RD
0V
WH
VT
0V
GY
BK
RD
0V
WH
VT
0V
BN
BU
BN
BU
BN
BU
GY
BK
RD
GY
BK
RD
WH
VT
Safety-monitoring
module
CST-180-1 CST-180-1 CST-180-1 CST-180-1
EX-CSS 180 EX-CSS 180 EX-CSS 180 EX-CSS 180
4.5 Note on the total length of a safety sensor chain
Typical resistance of the different sensor connecting cables (20°C):
0,50 mm²: ca. 36 Ω / km
0,34 mm²: ca. 52 Ω / km
0,25 mm²: ca. 71 Ω / km
The resistance of the safety outputs / sensor used is load-dependent:
• 300 mΩ at 1 A current load, i.e. max. load of the safety outputs is
2 x 500 mA
• 30 mΩ at 100 mA current load, i.e. 2x 50 mA load when a safety-
monitoring module is connected.
• Power consumption of a safety sensor approx. 30 mA
• Diagnostic output of a safety sensor max. 50 mA
An approx. 200 m long sensor chain with 6 sensors, 0.5 mm² cable
section and at 20 °C, features approx. 2 V voltage drop when the total
current load of the safety outputs is 100 mA. If junction boxes are used
for longer cable lengths, the conductor sections between the junction
boxes should be designed so that the connected load causes a low as
possible voltage drop on the connection cables.
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.
For very long sensor chains, it can be useful supplying the
voltage at the beginning of the chain. In that case, the supply
of the safety sensors and that of the safety channels can be
protected individually e.g. by 1A gG each.

6
Operating instructions
Safety sensor EX-CSS 180
EN
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. The installation is executed according to the instructions
2. The connection is executed correctly
3. The safety component is not damaged
4. The system is free of dirt and soiling (in particular metal chips)
5. Check cable entry and connections in a de-energised condition
5.2 Maintenance
In the case of correct installation and adequate use, the safety-
monitoring module 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
3. Check the cable for damage
4. Check cable entry and connections in a de-energised condition
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. 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 lateral surfaces of the sensor.
The green LED indicates that the safety sensor is ready for operation.
The sensor is not actuated. When the safety sensor is actuated by the
CST 180 actuator, the indication switches from green to yellow. The
safety outputs of the safety sensor are enabled. If the actuator is near
the limit of the sensor's switching distance, the yellow LED will flash.
The safety outputs remain enabled. The sensor can be readjusted
before the safety outputs are disabled, thus stopping the machine.
Errors in the coding of the actuator, at the outputs of the sensor or in
the sensor are signalled by the red LED. After a short analysis of the
active fault, signalled by the red permanent signal, the defined error is
indicated by flash pulses. The safety outputs are enabled in a delayed
manner, when the fault is active for 1 minute.
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
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 closed condition of the safety guard, i.e. the sensor is actuated,
is indicated through a positive signal. If the sensor is operating near
the limit of its switching distance, e.g. due to the sagging of the safety
guard, the sensor will emit a 2 Hz cyclic signal before the safety outputs
are disabled. An active fault will disable the diagnostic output after a
short analysis.
Table: diagnostic information
Sensor status LED Diagnostic
output
Safety outputs
not actuated green 0 V 0 V
actuated yellow Ue2 Ue
Actuated in limit
area
flashes
yellow
2 Hz pulsed Ue
Fault:
1 ... 5 pulses
flashes red 10 s delayed
Ue2 0 V
1 min delayed
Ue 0 V
Error red 10 s delayed
Ue2 0 V
undelayed
Ue 0 V
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
EN
EX-CSS180-D-EN
EX-CSS 180
Operating instructions
Safety sensor
8. EU Declaration of conformity
Name of the component: EX-CSS 180
L II 3G Ex nA IIC T6 Gc X
L II 3D Ex tc IIIC T70°C Dc X
Type: See ordering code
Description of the component: Non-contact safety sensor
Relevant Directives: Machinery Directive
EMC-Directive
Explosion Protection Directive (ATEX)
RoHS-Directive
2006/42/EC
2014/30/EU
2014/34/EU
2011/65/EU
Applied standards: DIN EN 60947-5-3:2014,
EN 60079-0:2012 + A11:2013,
EN 60079-15:2010,
EN 60079-31:2014
Notied body, which approved the full
quality assurance system, referred to in
Appendix IV, 2014/34/EU:
TÜV Rheinland Industrie Service GmbH
Am Grauen Stein
51105 Köln
ID n°: 0035
Person authorised for the compilation
of the technical documentation:
Oliver Wacker
Möddinghofe 30
42279 Wuppertal
Place and date of issue: Wuppertal, May 2, 2017
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