Omron MC3 Series Bedienungsanleitung

. . . . .

Mat Controller

MC3 Series

Installation and Operating Manual

Original Instructions

OMRON Scientiﬁc Technologies Inc.

Manufacturing and Sales Ofﬁce

6550 Dumbarton Circle

Fremont CA 94555-3605 USA

1 / 888 / 510-4357

Tel: 510/608-3400

Fax: 510/744-1442

www.sti.com

. . . . .

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

3©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

MC-3 Mat Controller

Table of Contents

Section 1—Important safety message . . . . . . . . . . . . . . . . . . . . . . page 4

Section 2—Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6

Section 3—Description of Controls . . . . . . . . . . . . . . . . . . . . . . . .page 6

Section 4—Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 7

Section 5—Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 8

Section 6—Machine Control Connections . . . . . . . . . . . . . . . . . .page 11

Section 7—Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 15

Section 8—Trouble-shooting Faults . . . . . . . . . . . . . . . . . . . . . . .page 15

Section 9—Speciﬁcations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 16

Section 10—Warranty and Additional Information . . . . . . . . . . .page 18

Section Appendix A —

Section Appendix B —Declaration of Conformity Information. ..page 21

Test Procedure . . . . . . . . . . . . . . . . . . . . . .page 20

I M P O R T A N T S A F E T Y M E S S A GE

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

1 I

MPORTANTSAFETY MESSAGE

A presence sensing mat and controller are general purpose presence sensing

devices designed to guard personnel working around moving machinery. The

use of this type of guarding system is regulated by government safety agencies.

Whether a speciﬁc machine application and presence sensing mat and

controller installation complies with government regulations depends upon

several items, including: the proper application, installation, maintenance and

operation of the presence sensing mat and controller. These items are the sole

responsibility of the purchaser, installer and employer.

The employer is also responsible for the selection and training of the personnel

necessary to properly install, operate and maintain the machine and its

safeguarding systems. For example, the presence sensing mat and controller

should be installed, checked out and maintained only by a qualiﬁed person,

deﬁned as “a person who, by possession of a recognized degree in applicable

ﬁeld or certiﬁcate of professional standing, or who by extensive knowledge,

training, and experience, has successfully demonstrated the ability to solve

problems relating to the subject matter and work.” (ASME B30.2-2001)

The machine operator must notify management if the machine, tooling or

safety devices are not operating properly. Never use the machine if it or the

safety equipment is not is proper working order.

The following additional requirements must be met before using a safety mat

and controller system:

• The machine on which the presence sensing mat and controller are installed

must be capable of stopping motion anywhere in its cycle or stroke. Never use a

presence sensing mat and controller on a power press with a full-revolution

clutch.

• Do not use a presence sensing mat and controller:

– on any device with inconsistent stopping time or inadequate control

devices or mechanisms.

– where the environment, such as corrosive chemicals, may degrade the

performance of the mat and/or controller.

– to initiate machine motion.

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

. . . . .

I M P O R T A N T S A F E T Y M E S S A GE

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

• When a presence sensing mat and controller are used as a safety device, the

employer has the responsibility to ensure that all applicable federal, state, and

local requirements, rules, codes and regulations are satisﬁed.

• All safety related machine control circuit elements, including pneumatic,

electric or hydraulic controls, must be control reliable as deﬁned by ANSI

B11.19-2003, 6.1 which states in part:

— prevent initiation of hazardous machine motion (or situation) until the

failure is corrected or until the control system is manually reset: or

— initiate an immediate stop command and prevent re-initiation of hazardous

machine motion (or situation) until the failure is corrected or until the

control system is manually reset; or

— prevent re-initiation of hazardous machine motion (or situation) at the next

normal stop command until the failure is corrected or until the control

system is manually reset.

• All other machinery or equipment must meet OSHA standard 1910.212 for

general machine guarding plus any other applicable regulations, codes and

standards.

• Additional guarding such as safety light curtains or mechanical guards may be

required if the presence sensing mat and controller do not protect all areas of

entry to the point of operation hazard.

• All brakes and stopping mechanisms must be inspected regularly to ensure

proper working order. If the stopping mechanisms are not working properly, the

machine may not stop safely even though the presence sensing mat and

controller are functioning properly.

• The Omron STI Test Procedure must be performed at installation and after any

maintenance, modiﬁcation or adjustment is performed on the machine controls

or on the presence sensing mat and controller. The Test Procedure is presented

in this manual.

• Do not perform any test or repairs other than those outlined in this manual. All

electrical wiring must be installed in accordance with local electrical codes and

regulations.

• The user must follow all procedures in this manual for proper operation of the

MC3 controller.

The enforcement of these requirements is beyond Omron STI’s control. The

employer has the sole responsibility to follow the preceding requirements and

any procedures, conditions and requirements speciﬁc to your machinery.

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

I NTRODUCTION

Output Relays

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

2 I

NTRODUCTION

Presence sensing mats and the MC3controller are used where perimeter access

guarding is required, such as around robots, manufacturing work cells, food

processing equipment and automated assembly equipment.

The MC3 controller is designed to meet the applicable sections of ANSI B11.19-

2003, OSHA1910.212, EN1760-1:1997 and ISO13856-1:2001. CE standards are met

only when used in conjunction with OMRON STI UM and UMQ series presence

The MC3 controller is designed to work in conjunction with a four-wire,

normally open safety mat (such as the Omron STI UM and UMQ series safety mats).

3 D

ESCRIPTION

ONTROLS

3 . 1 . O U T P U T R E L AY S

The safety-rated outputs of the MC3controller are referred to as Output Signal

Switching Devices. (OSSD). When the mat surface is activated by suf cient

weight, the OSSD will respond by going to an OFF state. Two-normally open

OSSD are provided across terminal 13/14 and 23/24. Two normally closed

OSSD are provided across terminals 31/32 and 41/42.

Figure 3-1 MC3 Mat Controller

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

No User Serviceable Parts Inside

24 VDC

2.2 VA

13 14 23 24 31 32

Outputs

250 VAC 6 A 1500 VA Max

41 42

MC3 Mat Controller

M11

Blk

M12

Brn

M21

Blu

M22

Wht

X2X1

Y1Y2

–

Mat Clear

Stop Run

Start Mat

Start/Restart Interlock – Remove 3 Jumpers

Mode Select Jumpers Located underTerminal Block

Automatic Start – Install 3 Jumpers

sensing safety mats.

. . . . .

OPERATING MODE

Indicators

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

3.2. IN D I C A T O R S

RUN: Will be lit when the OSSD relays are in the MACHINE RUN state.

STOP: Will be lit when the OSSD relays are in the MACHINE STOP state.

MAT CLEAR: A diagnostic indicator. Shows that the mat is properly wired, that

it is clear, and that it is possible to energize the relays.

3.3. MA T IN P U T S

Four terminal positions (M11-Blk, M12-Brn, M21-Blu, M22-Wh) are provided

for input of a four-wire safety mat or a series of four-wire safety mats. See

details in Section 5.2.—Input Wiring.

4 O

PERATING

ODE

4.1. AU T O M A T I C RE S T A R T

The MC3 controller will energize relays whenever the mat is clear, and de-

energize whenever it has been stepped upon. During both power up and normal

operation, an ON-delay of approximately 1/10 to 2/10 second is normal. The

RUN indicator will follow the MAT CLEAR light.

4.2. ST A R T /RE S T A R T IN T E R L O C K

The MC3 controller will interlock in de-energized state both upon application

of power and also whenever the mat is stepped upon. Requires a manual reset

operation to cause the system to energize relays. The MAT CLEAR light will

indicate that it is possible to activate the start switch and enter into the

MACHINE RUN state. The controller attempts to enter the RUN STATE upon

the release of the start switch. Press and hold the start switch for more than

0.15 seconds. The safety mat area must be clear at the time the start switch is

pressed and released.

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

INSTALLATION

Mounting

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

5 I

NSTALLATION

WARNING! Read this manual completely before installing the MC3

controller. The MC3 controller should only be installed, checked out, tested

and maintained by a qualiﬁed person (as described in the Important Safety

Message at the beginning of this manual). It is important that the user be

familiar with the installation requirements, safe mounting distance, controls

and features of the MC3 controller before using the guarding system.

5.1. MOUNTING

5.1.1 MODESELECT

The installer must select whether the MC3 controller will operate in

AUTOMATIC START or START/RESTART INTERLOCK mode. To make the

selection, remove the terminal block on the input side of the controller box.

Behind this terminal block are three yellow jumpers.

With all three jumpers installed, the controller is conﬁgured for AUTOMATIC

START operation. This is the factory setting.

To conﬁgure for START/RESTART INTERLOCK operation, all three jumpers

must be removed.

WARNING! Perimeter Guarding Special Requirements: Perimeter guarding

refers to installations where the presence sensing mats are positioned

around the outside perimeter of the machine, robot or area to be guarded.

This could leave sufﬁcient space for an operator to stand between the mats

and the machine.

For perimeter guarding installations, the guarded machine or robot must be

wired such that any interruption of the sensing area will cause an immediate

stop of the hazardous motion. The machine or robot must only be restarted

by actuation of a start switch. This start switch must be located outside the

area of hazardous motion and positioned such that the hazardous area may

be observed by the start switch operator.

Unexpected or automatic restart of the machine or robot may cause severe

injury or death to the operator or other personnel.

Always contact the machine manufacturer for advice and assistance on the

proper connection of any safety device.

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

. . . . .

INSTALLATION

Input Wiring

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

5.1.2 ENCLOSURE

The MC3 controller is designed to be installed inside a machine control cabinet

which has an environmental rating of at least IP54.

5.2. INPUTWI R I N G

5.2.1 POWER

A 24VDC power source is required. Connect PLUS to terminal block Y1 position

and MINUS (0, Return) to terminal block Y2 position. (Note: see separate

discussion of “earth”)

5.2.2 START

Used only in START/RESTART INTERLOCK mode. If AUTOMATIC START mode

is used, no connection is required. If required, customer-supplied remote start

switch with a single set of normally open contacts is used.

Two optional wiring conﬁgurations are acceptable:

— Connect the remote start switch between terminals X1 and X2.

— Connect one terminal of the remote start switch to +24VDC (must share a

common return with MC3 power supply), and the second terminal to X2.

5.2.3 SAFETYMAT

An Omron STI 4-wire mat is expected. For an Omron STI Universal safety mat

the blue and black conductors are connected to the bottom electrode plate. The

brown and white conductors are connected to the top electrode plate. For a

single mat installation, black is connected to M11 and blue to M21. The brown

conductor is connected to M12 and white conductor is connected to M22.

Multiple mats must be connected to the controller in series. To wire an STI UM

series multiple mat system in series, follow the wiring as shown in the drawing

below:

Figure 5-1 Hookup Drawing

M12

M11

M21

M22

2TAM1TAM MAT 3

BROWNWHITE

BLACKBLUE

BROWN

BLACK

WHITE

BLUE

BROWN

BLACK

WHITE

BLUE

WHITE

BLUE

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

INSTALLATION

Output Wiring

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA

Tel: 1/888/510-4357 in USA and Canada

WARNING! Connecting mats in parallel will appear to work, but it is an

UNSAFE installation. In this conﬁguration, it is possible for one or more

mats to be disconnected or have an open wire and the controller will not

detect that these mats are non-functioning.

5.2.4 EARTHCONSIDERATIONS

Normally, earthing of the house system is not a consideration. Presence

sensing mats are sealed - any wiring to them should not be in contact with

earth. Likewise, the mat controller operates between +24VDC and it’s return, so

the selection of an earth scheme is not signiﬁcant.

However, there are abnormal conditions that could cause current ﬂow due to

house earth. This is related to the fact that mats lie on the ﬂoor, and are

typically in close proximity to true “earth”. Under certain conditions (e.g.

wetting of the mat cable connectors), it is possible that one of the plates of the

mat might become referenced to earth.

Note: If the entire connector becomes immersed, this is the equivalent of the

mat being shorted, and the system will simply indicate so, i.e. the mat clear

indicator will not be able to light.

One of the mat plates is electrically connected through the mat controller to

the 24VDC return. (minus, Y2). If the plus side of the 24VDC power supply is

earthed, and the minus side of the mat is also earthed, ground current will

attempt to ﬂow through the mat controller. This will cause the primary power

fuse to blow. However, the fuse is a self-mending type, and will continue to re-

make and blow again.

5.3. OU T PUTWI R I N G

Two safety outputs must be connected to, and operate, the two MPCE of the

guarded machine. One to each. The product offers two normally closed and two

normally open FSD (ﬁnal switching device) outputs for this purpose. Customer

shall wire by normal methods. External over-current protection must be

provided by the user.

The remaining two connections may be used for indicator/communications

purposes as desired.

Original Instructions

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