Omron MC3 Series User manual

. . . . .

Mat Controller

MC3 Series

Installation and Operating Manual

. . . . .

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA 3©OSTI 0715 PN99307-0010 Rev. E

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 7

Section 4—Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8

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

Section 6—Machine Control Connections . . . . . . . . . . . . . . . . . . . page 12

Section 7—Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16

Section 8—Trouble-shooting Faults . . . . . . . . . . . . . . . . . . . . . . . . page 17

Section 9—Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18

Section 10—Warranty and Additional Information . . . . . . . . . . . . page 20

Section Appendix A —Test Procedure . . . . . . . . . . . . . . . . . . . . . . page 22

Section Appendix B —Declaration of Conformity information . . . page 23

IMPORTANT SAFETY MESSAGE

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA 4©OSTI 0715 PN99307-0010 Rev. E

Original Instructions

1 I

MPORTANT

SAFETY

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 presence sensing mat(s) and controller are a part of a Safety Related Control

System. The purchaser and installer must determine if the category and

performance level (PL) of the mat and controller are appropriate for the

application, according to ISO 13849-1 The installer shall determine the PL for the

application.

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:

. . . . .

IMPORTANT SAFETY MESSAGE

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA 5©OSTI 0715 PN99307-0010 Rev. E

Original Instructions

– 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.

• 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 B11.19-2010,

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, after any

maintenance, modification or adjustment is performed on the machine controls or

on the presence sensing mat and controller and at regular periodic intervals. 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.

INTRODUCTION

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA 6©OSTI 0715 PN99307-0010 Rev. E

Original Instructions

• 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.

2 I

NTRODUCTION

Presence sensing mats and the MC3 controller 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-

2010, OSHA 1910.212 and EN ISO 13856-1:2013. CE standards are met only

when used in conjunction with STI UM and UMQ series presence sensing safety

mats.

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).

. . . . .

DESCRIPTION OF CONTROLS

Output Relays

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA 7©OSTI 0715 PN99307-0010 Rev. E

Original Instructions

3 D

ESCRIPTION

ONTROLS

3.1. OUTPUT RELAYS

The safety-rated outputs of the MC3 controller are referred to as Output Signal

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

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.

No User Serviceable Parts Inside

24 VDC

2.2 VA

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 under Terminal Block

Automatic Start – Install 3 Jumpers

Figure 3-1 MC3 Mat Controller

3.2. INDICATORS

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. MAT INPUTS

Four terminal positions (M11-Blk, M12-Brn, M21-Blu, M22-Wht) 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.

OPERATING MODE

Automatic Restart

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA 8©OSTI 0715 PN99307-0010 Rev. E

Original Instructions

4 O

PERATING

ODE

4.1. AUTOMATIC RESTART

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. START/RESTART INTERLOCK

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.

5 I

NSTALLATION

WARNING! 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.

WARNING! The MC3 is a Category 3, PLd device. Verify these ratings are

appropriate for the application.

. . . . .

INSTALLATION

Mounting

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA 9©OSTI 0715 PN99307-0010 Rev. E

Original Instructions

5.1. MOUNTING

5.1.1 MODE SELECT

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.

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. INPUT WIRING

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”)

INSTALLATION

Input Wiring

OMRON SCIENTIFIC TECHNOLOGIES INC.

Original Instructions

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 SAFETY MAT

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:

M12

M11

M21

M22

MAT 1 MAT 2 MAT 3

BROWNWHITE

BLACK

Splice wires together

inside PVC trim

BLUE

BROWN

BLACK

WHITE

BLUE

BROWN

BLACK

WHITE

BLUE

WHITE

BLUE

Splice wires together

inside PVC trim

Figure 5-1 Hookup Drawing

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 EARTH CONSIDERATIONS

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.

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