Omron MC3 Series User manual

. . . . .
Mat Controller
MC3 Series
Installation and Operating Manual
© OSTI 0715 PN99307-0010 Rev.E

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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
1
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA 4©OSTI 0715 PN99307-0010 Rev. E
Original Instructions
1 I MPORTANT SAFETY MESSAGE 1
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
2
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 2
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).

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DESCRIPTION OF CONTROLS
Output Relays
OMRON SCIENTIFIC TECHNOLOGIES INC.
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Original Instructions
3 D ESCRIPTION OF C ONTROLS 3
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
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 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
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OMRON SCIENTIFIC TECHNOLOGIES INC.
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Original Instructions
4 O PERATING M ODE 4
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
!
5
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.

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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
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OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA 10 ©OSTI 0715 PN99307-0010 Rev. E
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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INSTALLATION
Output Wiring
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA 11 ©OSTI 0715 PN99307-0010 Rev. E
Original Instructions
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. OUTPUT WIRING
!
WARNING! To use this product for a Category 3 system, both safety outputs
must be connected to the safety system.Configuring a safety system with
only one safety output may result in serious injuries due to output control
fault and a failure of the machine to stop.
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.

MACHINE CONTROL CONNECTIONS
Two Normally Open Preferred Connection Method
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Original Instructions
6 M ACHINE C ONTROL
C ONNECTIONS 6
6.1. TWO NORMALLY OPEN PREFERRED CONNECTION
METHOD
The following connection scheme uses both of the normally open output relay
contacts to control the machine. This is the Omron STI recommended wiring
method.
In the machine control circuit, locate the two machine primary control elements
(MPCE1 & MPCE2). These are defined as “The electrically powered element
that directly controls the normal operation of a machine in such a way that it is
the last element (in time) to function when machine operation is to be initiated or
arrested.” IEC 61496-1
The method to arrest hazardous machine motion will vary depending on the type
of machine. Control methods include hydraulic, pneumatic, clutch and
mechanical braking systems. For example, an MPCE may consist of relays,
contactors, solenoids or electromechanical valves. If relays, the MPCE must use
force-guided contact type relays.

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MACHI N E C ONTROLC ONNE C TION S
Two Normally Open Preferred Connection Method
OMRON SCIENTIFIC TECHNOLOGIES INC.
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Original Instructions
Figure 6-1 Two Normally Open Preferred Connection

MACHINE CONTROL CONNECTIONS
Suggested PLC Connection
6
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA 14 ©OSTI 0715 PN99307-0010 Rev. E
Original Instructions
6.2. SUGGESTED PLC CONNECTION
The wiring from the MC3 controller to the machine control must be control
reliable as explained in ANSI B11.19-2010 section 6.1 or OSHA
1910.217(b)(13). Normally, PLCs are not designed to be control reliable and thus
safety devices, such as safety mat systems, must not depend on a PLC to stop a
guarded machine.
Figure 6-2 shows a connection diagram which provides for an extra set of
contacts on each MPCE to be used as a signal input to a PLC. Note that in this
diagram, the PLC is not wired directly to the MC3 controller and thus removes
the PLC from the safety mat controller stop signal circuit.
Always contact the manufacturers of the PLC and the guarded machine before
using a PLC in conjunction with an operator safety control.
The PLC control system design, wiring, installation and programming are the sole
responsibility of the employer.

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MACHI N E C ONTROLC ONNE C TION S
Suggested PLC Connection
OMRON SCIENTIFIC TECHNOLOGIES INC.
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Original Instructions
Figure 6-2 Suggested PLC Connection
!WARNING! To prevent severe injury to the operator or other personnel, DO
NOT operate this presence sensing safety device (mat and controller
system) unless it is properly installed, tested and inspected in accordance
with all OSHA, ANSI, government, industry and company safety regulations.
The guarded machine must be capable of stopping motion anywhere in it
stroke or cycle. Do not use this safety device on a full revolution clutch
machine.

TEST PROCEDURE
Performing Test Procedure
7
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Original Instructions
7 T EST P ROCEDURE 7
7.1. PERFORMING TEST PROCEDURE
The test procedure given in Appendix A must be performed by a qualified person
at installation and after any maintenance, adjustment, or modification to the
presence sensing mats, the MC3 controller or the machine and machine control
circuitry. Testing ensures that the mats, MC3 controller, machine and machine
control circuitry work properly to stop the machine. Failure to test properly could
result in serious injury to personnel.

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TROUBLE-SHOOTING FAULTS
Performing Test Procedure
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Original Instructions
8 T ROUBLE - SHOOTING F AULTS 8
Symptom
No indicators lit.
Possible Solutions
No power to the controller. Check 24VDC power supply and its connections to
Y1/Y2. Also see earth discussion in Section 5.2.4 “Earth Considerations”.
Symptom
MAT CLEAR indicator cannot be made to light.
Possible Solutions
1. Mat wired improperly. Check connections.
2. Mat wire broken. Replace mat.
3. Mat is shorted. Is there something on the sensing area? Is the surface
deformed?
Symptom
Cannot start in START/RESTART INTERLOCK mode.
1. Check wiring and operation of START switch. Is 24VDC being delivered
when START is depressed and not delivered when it is released?
2. This line is internally fused with a self-mending fuse. Does it blow and reset
repeatedly? If so, see earth discussion Section 5.2.4 “Earth Considerations”.
Symptom
All other conditions
Possible Solutions
Controller is defective. Replace. Call Omron STI for details.
Possible Solutions

SPECIFICATIONS
Mat Controller—MC3
9
OMRON SCIENTIFIC TECHNOLOGIES INC.
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Original Instructions
9 S PECIFICATIONS 9
9.1. MAT CONTROLLER—MC3
9.1.1 GENERAL SPECIFICATIONS
Category: Category 3 safety device
Operating Modes: Automatic Start or Start/Restart Interlock
9.1.2 ELECTRICAL
Power Input: 24 VDC (±15%, < 3W.)
Safety Input: Connections for a four-wire mat system. 20 ohms maximum from
Input M11 to Input M22.
Indicators: Green=Mat Clear; Green=Run; Red=Stop
Reset Function: User-supplied pushbutton or key switch
Safety Outputs: 2 NO and 2 NC outputs. 230VAC, 6A, 1500VA Maximum
(non-fused)
Response time: < 0.030 seconds (STI UM and UMQ series safety mat and
controller combined)
9.1.3 CONSTRUCTION
Case Material: Polycarbonate
IP Rating: IP20
Mounting Type: 35mm DIN rail or screw mount to panel
Shipping Weight: 0.8 pounds (0.32 kg)
9.1.4 ENVIRONMENTAL
Temperature: 0° to +55°C (32° to 131°F)
Shock & Vibration: Per IEC 68000-2-6, 0.15mm displacement, 10 to 55 Hz
Relative Humidity: 95%

. . . . .
SPECIFICATIONS
System Drawings
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA 19 ©OSTI 0715 PN99307-0010 Rev. E
Original Instructions
9.1.5 STANDARDS CONFORMITY
Designed in Accordance with: EN ISO 13856-1:2013,
EN62061:2005+AC:2010+A1:2013, EN ISO 13849-1:2008+AC:2009, IEC
61508, Parts 1-7:2010, EN 50178:1997, EN60204-1:2006+A1:2009+AC:2010,
Machinery Directive 2006/42/EC
9.1.6 APPROVALS
CE, TUV, CSA
9.1.7 CONFORMITIES
PSPD Type 3 , EN ISO 13856-1:2013
Category 3/PL d* (EN ISO 13849-1),
SIL2/SIL2 CL2 (IEC 61508 / EN 62061)
*PL d was calculated using an operation time of 24 hrs per day for 365 days per
year; a cycle time of 1 hr.
9.1.8 SAFETY RELATED PARAMETERS
PFH = 3.97 E-08 1/h
Mission Time = 20 years
MTTFd = 94 years
9.2. SYSTEM DRAWINGS
75 mm
110 mm
35.5 mm
Side View
61.2 mm
38 mm
1.5 mm
Bottom View
55 mm
98 mm
15.25 mm
Figure 9-1 Mat Controller MC3 Dimensional Drawing

WARRANTY AND ADDITIONAL INFORMATION
Omron STI Warranty
10
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10 W ARRANTY AND A DDITIONAL
I NFORMATION 10
10.1. OMRON STI WARRANTY
Omron STI warrants its products to be free from defects of material and
workmanship and will, without charge, replace or repair any equipment found
defective upon inspection at its factory, provided the equipment has been returned,
transportation prepaid, within one year from the date of installation and not to
exceed 18 months from date of factory shipment.
The foregoing warranty is in lieu of and excludes all other warranties not expressly
set forth herein, whether expressed or implied by operation of law or otherwise
including but not limited to any implied warranties of merchantability or fitness for
a particular purpose. No representation or warranty, express or implied, made by
any sales representative, distributor, or other agent or representative of Omron STI
which is not specifically set forth herein shall be binding upon Omron STI. Omron
STI shall not be liable for any incidental or consequential damages, losses or
expenses directly or indirectly arising from the sale, handling, improper application
or use of the goods or from any other cause relating thereto and Omron STI’s
liability hereunder, in any case, is expressly limited to repair or replacement (at
Omron STI’s option) of goods.
Warranty is specifically at the factory or an Omron STI authorized service location.
Any on site service will be provided at the sole expense of the Purchaser at standard
field service rates.
All associated equipment must be protected by properly rated electronic/electrical
protection devices. Omron STI shall not be liable for any damage due to improper
engineering or installation by the purchaser or third parties. Proper installation,
operation and maintenance of the product becomes the responsibility of the user
upon receipt of the product.
10.1.1 PATENTS
Elements of the electronics and optics essential to meet the specifications and
performance standards of Omron STI controls are covered by one or more of the