schmersal EX-CSS 8-16 User manual

1
EX-CSS 8-16
Operating instructions
Safety sensor
EN
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
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 Purpose ..............................................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 ......................................4
4 Rear side Electrical connection
4.1 General information for electrical connection..................4
4.2 Series wiring ..........................................4
4.3 Note on the total length of a safety sensor chain...............5
5 Set-up and maintenance
5.1 Functional testing.......................................5
5.2 Maintenance ..........................................5
6 Diagnostic functions
6.1 Operating principle of the diagnostic LED's ...................5
6.2 Operating principle of the electronic diagnostic output ..........5
7 Disassembly and disposal
7.1 Disassembly...........................................5
7.2 Disposal ..............................................5
8 Appendix
8.1 Wiring example ........................................6
9 EU Declaration of conformity
x.000 / 11.2017 / v.A. - 103003017-EN / B / 2017-11-08 / AE-Nr. 8356
EN Operating instructions. . . . . . . . . . . . .pages 1 to 8
Original

2
Operating instructions
Safety sensor EX-CSS 8-16
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 EN 1088 must be observed.
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
These mounting instructions apply to the following types:
EX-CSS 8-16-2P+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 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 EC
prototype test certificates are available upon request or can be
downloaded from the Internet at www.schmersal.com.
2.4 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 position of
hinged, sliding or removable safety guards by means of the coded
electronic CST 16-1 actuator.
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 or the removal of the actuator 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 functionality 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. This 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.
2.5 Technical data
Equipment category: L II 3GD
Ex protection: EX nA IIB T6 Gc X
EX tc IIIC T80°C Dc X
Standards: IEC 60947-5-3, EN ISO 13849-1, IEC 61508,
EN 60079-0, EN 60079-15, EN 60079-31
Enclosure: glass-fibre reinforced thermoplastic,
self-extinguishing
Max. impact energy: 4 J
Operating principle: inductive
Actuator: CST 16-1
Switching distances to IEC 60947-5-3:
Rated operating distance Sn:8 mm
assured switching distance sao:6 mm
assured switch-off distance sar:11 mm
Hysteresis: max: 1.0 mm
Repeat accuracy R: < 0.5 mm
Switching frequency f: 3 Hz
Series-wiring: max. 16 components
Cable length max. 200 m (cable length and cable section alter the
voltage drop depending on the output current)
Termination: cable or cable with M12 connector plug
Connecting cable: PVC / LIYY/
UL style Y-UL 2464 / 2 m
Cable section: depending on the version:
4 × 0.5 mm2, 5 × 0.34 mm2, 7 × 0.25 mm2
Ambient conditions:
Ambient temperature Tu:- 20°C…+50°C at max.
output current ≤ 500 mA /output
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: IP65 / IP67

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EX-CSS 8-16
Operating instructions
Safety sensor
EN
Electrical data:
Rated operating voltage Ue: 24 VDC −15% / +10%
(stabilised PELV to IEC 60204-1)
Rated operating current Ie: 1.1 A
Required rated short-circuit current: 100 A
External fuse rating:fuse:
- ≤ 200 A at output current 1.0 mA
- > 200 A at output current 1.6 mA
Rated insulation voltage Ui:32 V
Rated impulse withstand voltage Uimp:800 V
No-load current Io:0.05 A
Response time: ≤ 30 ms
Duration of risk: ≤ 30 ms
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 le:1 A
Safety outputs Y1/Y2: NO function, p-type, short-circuit proof
Voltage drop: 0.5 V
Rated operating voltage Ue1:min. Ue −0.5 V
Leakage current Ir: ≤ 0.5 mA
Rated operating current Ie1:max. 0.5 A depending on
the ambient temperature
Minimum operating current Im:0.5 mA
Utilisation category : DC-12 Ue/Ie24 VDC / 0.5 A;
DC-13 Ue/Ie24 VDC / 0.5 A
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
2.6 Safety classification
Standards: EN ISO 13849-1, IEC 615083
PL: e
Control Category: 4
PFH value: 2.5 × 10-9/h
SIL: suitable for SIL 3 applications
Service life: 20 years
3. Mounting
3.1 General mounting instructions
During fitting, the requirements of EN 1088 must be
observed.
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 marking of the safety sensor simultaneously identifies
the active face. 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.
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 the center lines of two sensors: 100 mm
When used at ambient temperatures < −10 °C, the
connecting cables must be hardwired.
3.2 Dimensions
All measurements in mm.
Safety sensor and actuator
¤ 5,5
55
40
60
39,5
20
9
93
7
37
26
11
17
17
40
27,5
18
15
3.3 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 that an adjustment of the
switching distance is required. Reduce the distance between the sensor
and the actuator, until the of the LED in the end cap 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.

4
Operating instructions
Safety sensor EX-CSS 8-16
EN
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: refer to on the switching
diagram.
x
S
Key
S Switching distance
X Axial misalignment
Typical response range of the safety sensor
-5-6-7-8 5678
5
0
[mm] 0-1-2-3-4 1 234
8
10
S
Sar
SOFF SON
Sao
S [mm]
x [mm]
11
Key
SON Switch-on distance
SOFF Switch-off distance
SHHysteresis range SH= SOFF-SON
Sao Assured switching distance
Sar Assured switch-off distance
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
EN ISO 13849-1, the safety outputs of the safety sensor or of the
sensor 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 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.
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
4.2 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.

5
EX-CSS 8-16
Operating instructions
Safety sensor
EN
4.3 Note on the total length of a safety sensor chain
The voltage drop of a long sensor chain must be taken into account
when planning the wiring.
Typical resistance of the different sensor connecting cables (20°C):
0.50 mm2: approx. 36 Ω / km
0.34 mm2: approx. 52 Ω / km
0.25 mm2: approx. 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. 2 x 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
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.
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 sensor is wired, please check whether:
1. the enabling signal is given when the safety guard is closed and
2. the machine is switched off when the safety guard is opened.
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.
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 actuator, the indication LED
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 disabled in a delayed
manner, when the fault is active for 1 minute.
Table: flash codes of the 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
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 24 V 24 V
Actuated in
limit area
flashes
yellow
2 Hz pulsed 24 V
Fault:
1- 5 pulses
flashes red 10 s delayed
24 V -> 0 V
1 min delayed
24 V -> 0 V
Error red 10 s delayed
24 V -> 0 V
undelayed
24 V -> 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.

6
Operating instructions
Safety sensor EX-CSS 8-16
EN
8. Appendix
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.
8.1 Wiring example
Series-wiring of safety sensors with common connecting cable for the inputs and outputs
The series-wiring of multiple safety sensors is realised by wiring in the control cabinet or in on-site junction boxes.
24 V
0V
GY
BN
BU
WH
VT
BK
WH
0V
WH
VT
0V
GY
BK
RD
0V
WH
VT
0V
BN
BU
BN
BU
BN
BU
GY
BK
RD
GY
BK
RD
CSS 8-16-2P+D-E-L
CSS 8-16-2P+D-M-L
CST 16-1 CST 16-1
CSS-8-16-2P+D-M-L
CST 16-1
CSS-8-16-2P+D-M-L
CST 16-1
EX-CSS 8-16 EX-CSS 8-16
EX-CSS 8-16 EX-CSS 8-16
BK and RD = safety outputs Y1 and Y2 → safety-monitoring module
If the last safety sensor of the series-wiring is not a terminal or individual device, the positive operating voltage must be wired to both safety inputs.

7
EN
EX-CSS8-16-B-EN
EX-CSS 8-16
Operating instructions
Safety sensor
9. EU Declaration of conformity
Name of the component: EX-CSS 8-16
L II 3G Ex nA IIB T6 Gc X
L II 3D Ex tc IIIC T80°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