Omron MC3 Series User manual

. . . . .
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: [phone]
Fax: [phone]
www.sti.com
© OSTI 0411 PN99307-0010 Rev. D

. . . . .
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA
Tel: [phone] 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
1
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA
Tel: [phone] in USA and Canada
4
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: [phone] in USA and Canada
5
• 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
2
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA
Tel: [phone] in USA and Canada
6
2 I
NTRODUCTION
2
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 OF C ONTROLS
3
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: [phone] in USA and Canada
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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 M ODE 4
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
5
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA
Tel: [phone] in USA and Canada
8
5 I NSTALLATION 5
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: [phone] in USA and Canada
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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
5
OMRON SCIENTIFIC TECHNOLOGIES INC.
Fremont CA USA
Tel: [phone] in USA and Canada
10
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.
!
©OSTI 0411 PN99307-0010 Rev. D
Original Instructions