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:

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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.
Fremont CA USA 7©OSTI 0715 PN99307-0010 Rev. E
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
4
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA 8©OSTI 0715 PN99307-0010 Rev. E
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
5
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.