Pinnacle Systems, Inc. NSD-TR-01 User manual

Safety Mat System
Installation
and
Operation Manual

Rev. 2.3

NSD Safety Mat System
Installation and Operation Manual
Pinnacle Systems, Inc.
3715 Swenson Avenue
St. Charles, IL 60174
P/N: 28-045r2.3
Customer Service: 630-443-8542 (CST)
(Please have Model #, Serial #, and Software Rev # Available)
Sales and Marketing: 800-569-7697 (EST)
www.pinnaclesystems.com •[email protected] •[email protected]

Proper Use and Limitations
The NSD Safety Mat System is critical for operator
safety. Repairs should only be made by factory
authorized personnel. The manufacturer cannot be
held responsible for your repair attempts or the unit’s
subsequent safe operation.
As the NSD Safety Mat System is a single function
device, that of sensing an unauthorized intrusion into
a guarded area while simultaneously determining that
it is capable of sensing such an intrusion, any internal
malfunction will manifest itself with a RED condition
shut down. The manufacturer will not supply individual
component parts of any circuit board but will supply the
individual circuit board complete.
The information disclosed herein includes proprietary
rights of the manufacturer. Neither this document nor
the information disclosed herein shall be reproduced
or transferred to other documents, used or disclosed
to others for manufacturing purposes, or for any other
purposes, except as specifically authorized in writing
by the manufacturer. If this manual is supplied in
connection with the sale or delivery of manufacturer’s
equipment,itisto beused solelyfor maintenance,repair
or installation of such equipment.
Warnings and Warranty
Manufacturer warrants that this product will be free
from defects in material and workmanship for a period
of two years from the date of shipment thereof. Within
the warranty period, manufacturer will repair or replace
suchproductswhich arereturned withshipping charges
prepaid and which will be disclosed as defective upon
examination by the manufacturer. This warranty will not
apply to any product which will have been subject to
misuse, negligence, accident, restriction, and use not
inaccordancewith manufacturer’sinstructionsorwhich
willhavebeenalteredorrepairedby person’sother than
theauthorizedagent oremployees of themanufacturer.
Disclaimer
The provisions of the “Warranty” paragraph above are
the sole obligations of the manufacturer and exclude
all other warranties of merchantability, expressed or
implied. Further, there are no warranties which extend
beyond the above warranty.
Limitation of Liability
In the event of any claim for breach of any obligations
of manufacturer under any order, whether expressed
or implied, and particularly in the event of any claim
of a breach of the warranty or warranties contained in
the paragraph “Warranty” or of any other warranties,
expressedor impliedwhichmight,despitetheparagraph
entitled “Disclaimer,” be determined to be incorporated
inanyorder, thecompany shallunderno circumstances
be liable for any consequential or special damages,
either in law or in equity, or for losses or expenses or
claims for the same arising from the use of, or inability
touse, theproductsofthemanufacturerforany purpose
whatsoever.
The manufacturer has designed this equipment to
the very highest performance and safety standards
known to the current technological state of the art.
However, the installation, usage, suitability, and fitness
of our equipment for any purpose, known or unknown,
is interdependent upon the performance of other
equipment not manufactured, installed, secured or
maintainedbythe manufacturer. Wecannot anddonot
acceptresponsibility forany overallsystem performance
when factors, such as these, are beyond our control.
WARNING: The entire machine safety system
mustbe testedatthestartofeveryshift. Machine
testing should include: (1) proper machine
operation and stopping capability; and (2)
verification of proper installation and settings of
all point of operation guards and devices before
the operation is released for production.

- I-
Table of Contents
Overview
Circuit Description...................................................................................................................................................1
Specifications..........................................................................................................................................................2
Dimensions
1. NSD-TR-01 (Metal Box) Controller..............................................................................................................3
2. NSD-DR-01 (Basic DIN-rail) and NSD-DR-04 (DIN-rail with diagnostics) Controllers ...............................3
Installation and Operation
Mat Installation........................................................................................................................................................4
Controller Installations
NSD-TR-01 (Metal Box) Controller...................................................................................................................4
NSD-DR-01 (Basic DIN-rail) Controller ...........................................................................................................5
NSD-DR-04 (DIN-rail with diagnostics) Controller............................................................................................5
Operation
1. Stop Circuit (application) .............................................................................................................................6
2. Manual/Automatic Reset .............................................................................................................................6
3. External Relay Checking.............................................................................................................................6
Wiring Diagrams
1. NSD-TR-01 (Metal Box) Controller..............................................................................................................7
1. NSD-TR-01 (Metal Box) Controller - Older boards PRIOR to Rev 10.........................................................8
2. NSD-DR-01 (Basic DIN-rail) Controller .......................................................................................................9
3. NSD-DR-04 (DIN-rail with diagnostics) Controller.....................................................................................10
NSD-DR-04 (DIN-rail with Diagnostics) Accessible Connections.........................................................................11
NSD-DR-04 (DIN-rail with Diagnostics) Board Connector Layout........................................................................12
Appendix A: Troubleshooting
NSD-TR-01 (Metal Box) and NSD-DR-01 (Basic DIN-rail) Controllers.............................................................AA-1
NSD-DR-04 (DIN-rail Controller with diagnostics)............................................................................................AA-1
DeviceNet (for NSD-DR-04 only)......................................................................................................................AA-3
Appendix B: Saftey Guidelines for Management
Operational Safety............................................................................................................................................AB-1
Safety Enforcement ..........................................................................................................................................AB-2
Supervisor Training...........................................................................................................................................AB-2
Operator Training..............................................................................................................................................AB-2

6
Overview
NSD Safety Mat System
Overview
The NSD Safety Mat System contains two independent
control circuits which allow for shut down due to any
single failure in one of the control circuits. The N.O.
output circuit is controlled by two captivated contact
relaysinseries whichareboth monitored. Ifthecontact
in one relay should stick closed (i.e., contact weld) the
other relay will shut down and an LED will indicate the
fault,evenif thecontacton thebadrelay opensbackup
you must reset the power to clear the fault. The relay
contactmonitoring providesa highdegreeofusersafety.
Circuit Description
The NSD-TR-01 (metal box) and NSD-DR-01 (basic
DIN-rail) are alike in that they use discrete logic circuits
to detect the mat. The NSD-DR-04 (DIN-rail with
diagnostics)is diverseredundant microprocessordriven
and has a built-in diagnostics display. A low voltage
(24VAC) signal is sent out to the safety mat(s) through
twowires.Thevoltagepassesthroughthematandback
into the NSD control unit through two more wires. Two
specialoptically-isolateddiverseredundantcircuits look
atthesignalscomingback fromthe mat(s)detectingthe
presence of proper positive and negative voltage (AC)
levels and output their signals to redundant missing
pulse detectors. If the voltage coming back is too high
or low, the missing pulse detectors will drop out and
de-energize the relay circuit. If the voltage coming back
is not AC (missing either positive or negative peaks),
then the signal going to the missing pulse detector will
disappear which will, in turn, drop out and de-energize
the relay circuit.
Redundant relay position detectors watch for a relay
contactstuckin thewrongposition.Thecircuits willlock
out the reset feature of the NSD control unit if a relay
contact is closed when it should be open.
Each relay has its own driver circuit to complete the
redundancy of the circuits.
The output relays will de-energize if the voltage coming
from the mat(s) is either too high or low (12VAC to
36VAC) or is not AC (i.e., DC), including the following
reasons:
1. When you step on the mat, you are shorting
out the 24VAC signal going back into the NSD
control unit to OV, so the relays de-energize.
2. If you cut any wire going to or coming from
the mat(s), the signal going back into the NSD
control unit is OV, so the relays de-energize.
3. If any wire going to or coming from the mat(s)
is cut and/or shorted to any other mat wire, the
signal going back into the NSD control unit is
OV, so the relays de-energize.
4. If any wire going to or coming from the mat(s)
is cut and/or shorted to an outside AC power
source (i.e., 120VAC) the signal going back
intotheNSD controlunit willexceedthe 24VAC
signal level and the relays will de-energize.
5. If any wire going to or coming from the mat(s)
is cut and/or shorted to an outside DC power
source(i.e.,24VDC), thesignalgoing backinto
the NSD control unit will not be an AC signal
and the relays will de-energize.
6. If,whenyoustep onthemat,eithersafety output
relay is stuck in the closed position, the NSD
control unit will automatically shut down the
other relay and lock out and further attempts
to reset the unit until the power is reset.
1

3
Specifications
NSD Safety Mat System
2
NSD-TR-01
Controller
(Metal Box)
NSD-DR-01
Controller
(Basic DIN-rail)
NSD-DR-04
Controller
(DIN-rail with Diagnostics)
Enclosure: NEMA 12, 13, IP 54 NEMA 1, IP 32 NEMA 1, IP 32
Input Power: 120VAC +/- 10% @ 3 watts
50-60 Hz fused 24VDC +/- 20% @ 7 watts 24VDC +/- 20% @ 7 watts
Category/Type: 4 4 4
Relay Style: Monitored force-guided captive
contact safety relays Monitored force-guided captive contact safety relays Monitored force-guided captive contact safety relays
Relay Configuration: 2 N.O. Safety Relays (closed
when circuit activated)
1 Aux Output N.O. or N.C
2 N.O. Safety Relays (closed
when circuit activated)
1 Aux Output N.O. or N.C
2 N.O. Safety Relays (closed
when circuit activated)
1 Aux Output N.O. or N.C.
1 Fault Relay N.O.
Safety Relay Rating: 4A @ 220VAC 4A @ 220VAC 4A @ 220VAC
Reset Provisions: Manual or Automatic Manual or Automatic Manual or Automatic
Controller Response
Time: 15 msec. 15 msec. 19 msec per mat input used
Self-Checking
Intervals: Every 20 msec. Every 20 msec. Every 20 msec.
Number of Isolated
Zones: 1 to 13 (customer specified) 1 per controller 1 per controller
Maximum Number of
Mats: 20 20 4 with homerun wiring
20 with daisy chain wiring
External Reset
Provision: Green push button Green push button Green push button
Indicators:
Internal (on board): Yellow LED = +5VDC power
supply
Red LED = Normally dim,
brighter when mat is stepped
on. Cut wire detected when
not lit.
Green LED = Relay contact
detected closed when it should
have been open when not lit.
Must reset power to clear.
Green LED(s) = next to
each relay (3)
Red LED = +12V
Yellow LED = +5V
Green LED = -5V
Red LED = +12VDC
Green LED = +20VDC
Yellow LED = +5VDC
Green LEDs = one for each
relay (4 total)
External: Red LED = 1 or both relays are
de-energized.
Green LED = All relays are
energized.
Red LED = 1 or both relays are
de-energized.
Green LED = All relays are
energized.
Yellow LEDs = 2 to show on/off
mat.
Yellow LED = relay fault if it
turns off.
Red LED = 1 or both relays are
de-energized.
Green LED = All relays are
energized.
Yellow LEDs = 1 for each mat
status — (4 total)
Diagnostic Message
Display: N/A N/A Built-in
DeviceNet: N/A N/A Add suffix DN to Model #. See
next page for additional
information.
Warranty: 2 years 2 years 2 years

4
Specifications
NSD Safety Mat System
Dimensions
NSD-TR-01 (Metal Box Controller)
Board (NSD-TR-B1): 5” x 7” plate with 4 holes 4-1/4” x 6-1/4” on center.
127mm x 177.8mm with 4 holes 107.95mm x 158.75mm on
center
Box (NSD-TR-01): 8”h x 6”w x 3.5”d (4” x 8-3/4” holes), NEMA 12, 13
203.mm x 152.4mm x 88.9mm (101.6mm x 222.25mm holes)
(NSD-TR-02): 12”h x 10”w x 5”d (8” x 12-3/4” holes), NEMA12, 13
304.8mm x 254mm x 127mm (203.2mm x 323.85mm holes)
(NSD-TR-03/04): 16”h x 14”w x 6”d (13” x 16-3/4” holes), NEMA 12, 13
406.4mm x 355.6mm x 152.4mm (330.2mm x 425.45mm holes)
(NSD-TR-05/up): Call for sizes available.
NSD-DR-01 and NSD-DR-04 (both DIN-rail Controller models)
Mounting: 35mm DIN-rail mountable or mounting screws on corners of enclosure requiring
3

4
Installation and Operation
NSD Safety Mat System
WARNING: The entire machine safety system
mustbe testedatthestartofeveryshift. Machine
testing should include: (1) proper machine
operation and stopping capability; and (2)
verification of proper installation and settings of
all point of operation guards and devices before
the operation is released for production.
Mat Installation
The NSD mat system has been designed to promote
individual mat “homerun” wiring back to the mat
controller. This is suggested for easing installation
and diagnostics for maintenance troubleshooting. This
will also eliminate cumbersome “daisy chain” wiring
practices of mat systems. It also eliminates numerous
wiringconnectionpoints buriedunder theperimetertrim
which are time intensive to troubleshoot.
1) Sweep the floor area where the safety mat is to
be installed. The floor should be flat and free
of foreign material.
2) Locate the safety mat in the desired location.
For future reference, install the mat with the
label side up.
3) Slide the black wire raceway component under
the mat edge (Part #M002). Refer to Figure 1
below for proper component positioning.
NOTE: The wire raceway component must be
installed whenever the surface perimeter trim
component is used.
4) Route the wire/plug assembly on the raceway
toward the mat controller location.
5) Lay the aluminum perimeter trim piece around
the mat assembly. Determine where the mat
wiring will exit the trim and notch the trim and
wire raceway for the wire to exit the assembly.
6) If surface metal raceway is used to route the
wiring (Part #M005 or M006) from the mat
assembly across the floor toward the mat
controller, it should be aligned with the notch
in the perimeter trim and anchored to the floor.
Route wires accordingly and snap cover plate
over the wires.
7) Slide the perimeter trim over the wire raceway
component and align over the mat edge. Drill
the perimeter trim and floor for securing the
perimetertrim tothe floorwithanchoringscrews
and floor anchors.
8) Ifamultiple matassembly istobe installed,use
the aluminum active coupler component (Part
#M003) to connect mats end to end or side to
side. Refer to Figure 1 below.
Controller Installation
NSD-TR-01 (Metal Box) Controller
IMPORTANT: The NSD-TR-01 Controller
provides both N.O. and N.C. output circuits, but
only Terminals 5-6 (N.O.) are safety monitored
and should be used in series with your stop
circuit. Terminals 7-8-9 are NOT monitored; this
output should only be used as an auxiliary signal
line.
Figure 1: Cross Section View of Mat Assembly Active Edging
0.67”
3.025”
0.62”

5
Installation and Operation
NSD Safety Mat System
1) Mount the NSD-TR-01 (metal box) where you
can get access to it without having to step on
the mat.
2) Attach 120VAC to Terminals L1 and N2 and
Earth ground to GND.
3) Wirematto terminals1-2-3-4 (1=blue,2=white,
3=black,4=brownfor a single 4-wire lead mat
and 1=black, 2=red, 3=red, 4=black for a two-
dual lead mat.) If your mat has two zip cords
(twowiresineachcord), thenone zipcord goes
to Terminals 1-2 and the other toTerminals 3-4
(it does not matter which zip cord).
4) Wire Terminals 5-6 into your STOP circuit.
Terminals 5-6 come from two N.O. contacts in
series for safety (see “important” note above).
5) Unit is setup for Manual Reset if you have the
Green button on the case.
AutomaticReset: disconnect allfour wiresfrom
Terminals 14-15-16-17.
Remote Manual Reset: Place one pole of any
D.P.N.C. button between Terminals 14-15 and
the other pole between Terminals 16-17.
6) You can use Terminals 7-8-9 for non-safety
indicatingor monitoring(i.e., strobelights,PLC).
7) External 24VDC Red Zone light goes to
Terminals 11-12; 24VDC Green Zone goes to
Terminals 12-13; Terminal 12 is 24VDC out.
NSD-DR-01 (Basic DIN-rail Controller)
IMPORTANT: You must use both Terminals 7-8
and 9-10 in your Stop circuit. If you have one
Stopcircuit, youmust jumperTerminal8 to9, then
use Terminal 7 and 10 in your Stop circuit. Do
not use Terminals 11-12-13 for safety circuits.
1) MounttheNSD-DR-01(basicDIN-railController)
inside an enclosure since all the wiring
terminates on the outside of the controller box.
2) Attach 24VDC to Terminals 1-2 and Earth
ground to Terminal on the right side of the DIN-
rail controller box.
3) WiremattoTerminals 3-4-5-6(1=blue, 2=white,
3=black,4=brownfor a single 4-wire lead mat
and 1=black, 2=red, 3=red, 4=black for a two-
dual lead mat.)
4) Wire your Stop circuit to Terminals 7 and 10.
Place jumper between Terminals 8 and 9 (see
“important” note above).
5) Unitcomessetupinmanualmodewitha jumper
between Terminals 2 and 16 (use the built-in
“zone reset” button to clear the zone).
Automatic Reset: Remove jumper wire from
between Terminals 2 and 16.
RemoteReset: Wirea N.C.pushbutton inplace
of the jumper wire.
6) You can useTerminals 11-12-13 for non-safety
indicatingor monitoring(i.e., strobelights,PLC).
7) You can install remote red and green lights
(Terminals 14-15). These terminals go to GND
when active.
NSD-DR-04 (DIN-rail Controller with diagnostics)
IMPORTANT: You must use both Terminals 4-5
and6-7in yourStopcircuit. Do notuseTermnals
8-9-10-11-12 for safety circuits.
1) Mount the NSD-DR-04 (DIN-rail controller with
diagnostics) inside an enclosure since all the
wiringterminates onthe outsideof thecontroller
box.
2) Select the number of mats (1-4) you want to
hook up. Open the DIN-rail box and select
the proper jumper settings (see NSD-DR-04
Jumper Settings, Page 12).
3) SelectAutomaticorManual Zoneresetting (see
Jumper Settings, Page 12).
4) Select External relay checking (see Jumper
Settings, Page 12).
5) Attach24VDCtoTerminals1-2andEarthground
to Terminal 3 of Power/Output connector.
6) Wire mat to terminals 1-2-3-4 of each mat
connector (1=blue, 2=white, 3=white, 4=brown
for a single 4-wire lead mat and 1=black,
2=red, 3=red, 4=black for a single two-dual
lead mat.)
7) Wire your Stop circuit to Terminals 4 and 7.
Placejumperbetween 5and6 (see “important”
note above).
8) You can use Terminals 8-9-10-11-12 for non-
safety indicating or monitoring (i.e., strobe
lights, PLC).
NOTE: Canadian market wiring is black, red, red, black with 18-guage wiring size.

6
Installation and Operation
NSD Safety Mat System
9) You can install remote red and green lights
(Terminals 7 and 8 of I/O connector). These
terminals go to GND when active.
10) Remote Zone reset connects to Terminal 3 of
I/O connector.
11) Ifyou needtouse externalrelays,then connect
externalrelays toTerminals1-2ofI/Oconnector
(see below for explanation).
Operation
If you have manual reset (standard), you must push the
RESET button to reset the NSD controller.
If you have automatic reset, the NSD Controller will go
GREEN when you step off the mat. Automatic reset
should not be used in applications where there is no
barrier past the mat.
Stop Circuit (application)
Anyone stepping on the mat(s) will automatically shut
themachineoff. Thiscircuit allowsformultiple numbers
of mats to be wired in series to protect a very large
area around dangerous equipment with only one NSD
Controller.
Manual/Automatic Reset
NSD-TR-01 (Metal Box): If nothing is attached to
Terminals 14-15-16-17, then the NSD Controller will
automatically reset itself. If you have a pushbutton,
simplyremove allfourofthesewires fromtheir terminals.
If a 2 pole N.C. push-button contact is placed across
Terminals 14-15 and the second pole is placed across
Terminals 16-17, then you must use the push-button to
manually reset the NSD Controller unit.
NSD-DR-01 (Basic DIN-rail): If you select manual, you
will have to go to the control box and press the zone
resetbutton eachandeverytimeyoustepon anymat(s).
This requires a jumper wire between Terminals 2 and
16. To remote the zone reset, place a N.C. button in
place of the jumper wire.
If you select automatic, the zone will clear itself when
you have stepped off the mat(s). Remove the jumper
wire from between Terminals 2 and 16.
NSD-DR-04 (DIN-rail with diagnostics): If you select
manual,youwill have togoto the controlboxand press
the zone reset button each and every time you step on
any mat(s). Place jumper across JP3 to activate this
feature.
To remote the zone reset, place a N.O. button between
Terminal 3 of the Input/Outputs connector and Terminal
2 of the Power Connector.
If you select automatic, the zone will clear itself when
youhave steppedoffthe mat(s). Removejumperacross
JP3 to activate this feature.
Note: This setting changes all mats. You cannot
change some mats to manual and others to
automatic.
External Relay Checking
NSD-DR-04 (DIN-rail with diagnostics): This option is
selected when you have to switch a large load. This
feature allows the NSD to monitor your external relays.
This system requires that you use two force-guided
relays for the external switching and that the secondary
pole of each relay (N.C.) be tied in series back to the
NSD control external relay input terminals for each
particular zone. Place jumper across JP4 EXT to
activate this feature (see Page 10 for wiring diagram).

7
Installation and Operation
NSD Safety Mat System
7.0"
6.25"
5.0"
4.25"
4 mounting holes (#8
screws)
120vac
power Earth Ground
Mat #1
Mat #2
2 Independent
Safety Outputs
A&B:
Wire each in
series with each
STOP circuit in
a DUAL STOP
system.
NOTE:
These are N.O.
Held Closed
outputs
Replacement
Safety Relay
32-101
NC-C-NO Aux Output:
for status only
Replacement
relay 32-001
Push “Clear” button to Reset
mat control.
Mat Control will Auto-Reset
is both N.C. contacts are
disconnected.
GRN
RED
External Status
Indicators
24vdc
Indicators on
door are LED’s
with internal
resistors set for
24vdc
Connect either of the 2 wire pairs
to Terminal#1 & #2, and the other
pair to Terminal#3 & #4 (as
shown)
NSD Mat Wiring:
Style “X” or “E”
1 Black, 2 Red, 3 Black, 4 Red
Or Style “W” or “P”
1 Blue, 2 White, 3 Black, 4 Brown
White Steel
mounting plate
is used to
support the PCB
Power ON
AB
Wiring Diagrams
NSD-TR-01 (Metal Box Controller)
NOTE: If you daisy chain mats, the blue/white is one
pair and should go to Terminals #1 and #2. The black/
brown is the other and should go to the blue/white pair
of the second mat, and so on. The black/brown pair of
the last mat goes back to Terminals #3 and #4.
If the mat has two lamp cords, then either pair can go
to Terminals #1 and #2 and so on.
Relay Fault LED’s D14,D18
(ON=good, OFF=Relay stuck on FAULT)
On Mat LED’s D10,D12
(ON=ON mat, OFF=OFF mat)
NOTE: Canadian market wiring is black, red, red,
black with 18-guage wiring size.

8
Installation and Operation
NSD Safety Mat System
Wiring Diagrams
NSD-TR-01 (Metal Box Controller) - Diagram below is for older boards PRIOR to Rev 10.
NOTE: If you daisy chain mats, the blue/white is one
pair and should go to Terminals #1 and #2. The black/
brown is the other and should go to the blue/white pair
of the second mat, and so on. The black/brown pair of
the last mat goes back to Terminals #3 and #4.
If the mat has two lamp cords, then either pair can go
to Terminals #1 and #2 and so on. NOTE: Canadian market wiring is black, red, red,
black with 18-guage wiring size.
7.0"
6.25"
5.0"
4.25"
4 mounting holes (#8
screws)
120vac
power Earth Ground
Mat #1
Mat #2
Safety Output:
Wire in series
with STOP
circuit.
This is a N.O.
Held Closed
output
NC C NO
Aux Output: for
status only
Test
Power ON
Push “Clear” button to Reset
mat control.
Mat Control will Auto-Reset
is both N.C. contacts are
disconnected.
GRN
RED
External Status
Indicators
24vdc
Indicators on
door are LED’s
with internal
resistors set for
24vdc
Connect either of the 2 wire pairs
to Terminal#1 & #2, and the other
pair to Terminal#3 & #4 (as
shown)
NSD Mat Wiring:
Style “X” or “E”
1 Black, 2 Red, 3 Black, 4 Red
Or Style “W” or “P”
1 Blue, 2 White, 3 Black, 4 Brown
White Steel
mounting plate
is used to
support the PCB
Relay Fault LED’s D14,D18
(ON=good, OFF=Relay stuck on FAULT)
On Mat LED’s D10,D12
(ON=ON mat, OFF=OFF mat)

9
Installation and Operation
NSD Safety Mat System
NSD-DR-01 (Basic DIN-rail Controller)
Red Grn
Optional Remote 24vdc
Status indicator lights
LED indictors:
STOP: Safety Relays OFF (OPEN)
RUN: Safety Relays ON (CLOSED)
MAT STATUS: OFF = ON Mat
Fault When Off: OFF = Relay Fault
NOTE:
Mat Wiring for Mat Styles “W” and “P” are
shown above (Blue, White, Black, Brown)
Mat Wiring for Mat Styles “X” and “E” are
Black, Red, Red, Black
(and are wired in that order)
Canadian market wiring is black, red, red,
black with 18 gauge wiring size.
NOTE:
Safety Relay outputs are N.O. (Held Closed)
and are wired into your STOP circuit(s).
Aux Relay should only be used for indicator
lights.
Manual Relay Latching Reset:
Wire Terminal #2 to #16 and use the Green ZONE
RESET button to reset
Optional Remote Latching Relay Reset:
Use a N.C. push button wired as shown above

10
Installation and Operation
NSD Safety Mat System
NSD-DR-04 (DIN-rail Controller with diagnostics)
NOTE: Terminal #6 (INPUT/OUTPUT PLUG) is internally connected to Terminal #1 (POWER/OUTPUT)
plug. This allows Terminal #6 to provide +24v to the lights for the RSD (Remote Status Display).
REMOTE STATUS DISPLAY
Green: Terminal #8 (INPUT/OUTPUT)
Red: Terminal #7 (INPUT/OUTPUT)
Black: Terminal #1 (POWER/OUTPUT)
White/Black: Terminal #3 (INPUT/OUTPUT) / Terminal #2 (POWER/OUTPUT)
12cond cable: J1 (on left side of diagnostics display)
External Relay Checking (optional usage)
NOTE: Canadian market wiring is black, red, red, black with 18-guage wiring size.

11
Installation and Operation
NSD Safety Mat System
NSD-DR-04 (DIN-rail Controller with diagnostics)
Accessible Connections
NOTE: Canadian market wiring is black, red, red, black with 18-guage wiring size.
J1 Diagnostics display plug (used by remote status display option)
The Plug is located under the top cover on the left side of the controller
External:
POWER/OUTPUT PLUG
Terminal No. Usage
1,2,3 +POS, -NEG, EARTH GROUND (24VDC ONLY)
4,5 Safety relay N.O. output (dry contact) (held closed when GREEN)
6,7 Safety relay N.O. output (dry contact) (held closed when GREEN)
8,9,10 Auxiliary relay N.C., COM, N.O.
11,12 Fault relay N.O. (open when faulted)
INPUT / OUTPUT PLUG
Terminal No. Usage
1,2 +pos, -neg External relay checking (option)
24vdc applied across these terminals when external relay is de-energized
3 Remote external zone reset (Ground to reset zone)
4,5 Auxiliary inputs (Ground to activate feature)
6 +24vdc input (Common for terminals 3,4,5) (jumper from term #1 Power/Output)
7 Optional remote RED “STOP” indicator output (Grounded when RED)
8 Optional remote GREEN “RUN” indicator output (Grounded when GREEN)
MAT 1,2,3,4 INPUT
Terminal No. Usage
1,2 20VDC output to mat (1=blue, 2=white)
voltage between 1 & 2 alternates
(1=black, 2=red for single two-dual lead mats)
3,4 Return from mat (3=black, 4=brown)
(3=red, 4=black for single two-dual lead mats)
DEVICENET PLUG (DB-9 female)
Terminal No. Usage
2,7 CANL, CANH (twisted pair data lines)
3,6 Ground

12
Installation and Operation
NSD Safety Mat System
NSD-DR-04 (DIN-rail Controller with Diagnostics)
Jumper Settings
1= jumper install
Number of Mats:
JP2 JP1
0 0 1 mat
1 0 2 mats
0 1 3 mats
1 1 4 mats
JP3
1= Manual relay reseting
0= Automatic relay reseting
JP4
1= External relay checking enabled
0= Disabled
JP5
Not used at this time
JP6
Not used at this time
NSD-DR-04 (DIN-rail Controller with diagnostics)
Board Connector Layout
J2,J26 MAT INPUT #1 thru #4 JP1,2 NUMBER OF MATS SELECTION
J1 DIAGNOSTICS DISPLAY (remote) JP3 MANUAL
J120 POWER/OUTPUT JP4-6 EXT, AUX1, AUX2
D13,14 Safety relay output on (closed) D3 +12v supply
D16 Auxiliary relay output on D1 +5v supply
D15 Fault relay output on (closed) D23 +20v supply

AA - 1
Appendix “A”
Troubleshooting
NSD-TR-01 (Metal Box) and
NSD-DR-01 (Basic DIN-rail) Controllers
PROBLEM: No indicators are lit
Cause(s): 1) Incorrect line voltage OR no line
voltage.
2) Incorrectly wired.
3) Blown fuse.
4) Bad regulator.
Cure: Check fuse, then make sure you
have line voltage present at the
correct terminals and that its within
specifications. If it all checks out, then
the control board must be replaced.
PROBLEM: NSD control will not go green when
reset, relay fault LED is off
Cause(s): 1) Noise on the power line caused a
glitch in the NSD control.
2) Relay contact stayed closed when
user stepped on mat.
3) One of the redundant control
circuits is faulty.
Cure: Remove power to unit for 30 seconds,
applypowerand hitthe RESETbutton.
This should reset the circuits and the
NSD control should come back up.
Check the relays for signs of contact
pitting. Also, it’s possible that large
voltage spikes on the power line could
havecaused aglitchintheNSDcontrol
and it shut down. If the unit continues
havethisproblem, installMOV’sonthe
power terminals of any nearby motors,
or solenoids. These devices cause
noise on the power line and the MOV’s
can usually cure this.
PROBLEM: NSD control will not go green when
reset, wire fault LED is off
Cause(s): 1) Wires from mat have not been
installed correctly.
2) One or more of the four wires going
out to the mat has been cut.
Cure(s): 1) See wiring diagram page for mat
wire colors and terminals.
2) Repair or replace cut wires.
PROBLEM: NSD control will not go green when
reset, all internal indicators are on
Cause(s): 1) Object on mat is keeping control
RED.
2) Short in either the mat or external
wires going to the mat.
3) You forgot to press the RESET
button to reset the mat.
Cure: Removethe matwiresfrom thecontrol
unitand useanOHMmetertocheckfor
a short between the wires or between
each pair of wires on the mat. If there
is a short, check for physical signs of
damage to the wiring or the mat. The
matwill requirereplacementiftheshort
is not in the wiring.
NSD-DR-04
(DIN-rail Controller with diagnostics)
PROBLEM: Mat wiring fault
Cause(s): 1) Low voltage on input that should
be ground.
2) High voltage on input that should
be ground.
Cure: Badwiring,badcomparator,orbadmat.
PROBLEM: Circuit fault
Cause(s): 1) Voltage to mat below low setpoint.
2) Voltage tomat belowhigh setpoint.
3) One of the redundant circuits
indicates ON mat, the other
indicates OFF mat.
4) One of the redundant circuits
indicates OFF mat, the other
indicates ON mat.
5) High voltage on input that should
be ground.
Cure: Badwiring,badcomparator,orbadmat.
PROBLEM: Zone # out of sequence
Cause: The master and slave processors
disagree on which sequence they are
on.
Cure: An external electrical noise could be
causing one of the processors to loose
sequence.

AA - 2
Appendix “A”
Troubleshooting
PROBLEM:Zone 1 relay off, should be on
Cause(s): Relayfoundinthewrongstate;circuitry
failure or relay failure.
Cure: Call for assistance.
PROBLEM:External relay contact welded/cut
Cause: External relay check input remained
open (0 volts) while the zone was de-
energized.
Cure: Whenthe zoneis de-energized(RED),
your external relay must close within
1/4 second.
PROBLEM:External relay contact short
Cause: External relay check input remained
closed(voltageapplied) whilethe zone
was energized.
Cure: When the zone is energized, the
secondary pole of your external relay
(N.C.)mustopen upwithin 1/4second.
PROBLEM:Mat # out of sequence
Cause: The master and slave processors
disagree on which sequence they are
on.
Cure: Couldhaveanelectrical noiseproblem
causing one of the processors to loose
sequence.
PROBLEM:Ram failure
Cause: Microprocessor failed the internal
memory test.
Cure: Call for assistance.
PROBLEM:Power failure
Cause: Circuitry failure; brown out.
Cure: Call for assistance.
PROBLEM:Watchdog failure
Cause: Watchdog circuitry failure.
Cure: Call for assistance.
PROBLEM:Serial data corrupted
Cause: Electrical noise getting into the control
box causing one of the computer to
reset.
Cure: Place MOV’s across the coil of any
device (outside this control) switched
on/off by the relay outputs of this
controller.
PROBLEM:Serial data transmission incomplete
Cause: Electrical noise getting into the control
box causing one of the computer to
reset.
Cure: Place MOV’s across the coil of any
device (outside this control) switched
on/off by the relay outputs of this
controller.
PROBLEM:Master relay on, Slave relay off
Cause(s): The master processor disagrees with
the slave.
Cure: Call for assistance.
PROBLEM:Slave relay on, Master relay off
Cause: Theslaveprocessordisagreeswiththe
master.
Cure: Call for assistance.

AA - 3
Appendix “A”
Troubleshooting
DeviceNet
Applicable for the DIN-rail (with diagnostics) only
Vendor ID code = 0459
Diagnostics Display
“OK U”
Devicenet unconnected (may be unplugged from
network)
“OK C”
Devicenet connected but not allocated (passed
duplicated mac id check)
“OK A”
Devicenet allocated (in service)
“OK F”
Devicenet faulted out (mat controller will work, but
not devicenet)
User adjustable MAC_ID
(default = 63)
If the NSD controller finds a duplicate MAC_ID,
it will go off-line and display the current MAC_ID
on the diagnostics display. Use the Fault Reset
buttontodecrement theMAC_ID toanew (unused)
value. Hold the button in for 2 sec to program it
permanently.
The NSD controller will now check for duplicate
MAC_ID’s using the new ID.
Network adjustable BAUD_RATE
(default = 125Kb/s)
If your network runs at different baud rate, you can
adjusttheNSDcontrollerusing standardDeviceNet
set commands. The NSD controller supports 125,
250,and500Kb/s rates.After you changetheBaud
rate, you must cycle power to NSD to re-enable
Devicenet.
Network settable CONNECTION
(default= offline)
The NSD controller will allow EXPLICIT and BIT_
STROBE connections only
Network adjustable EPR_RATE timer
(default= 10sec for explicit connection, none for
bit-strobe)
The EPR (Extendend packet rate) timer is set in
250msec increments. A value of less than 250 will
keep the connection forever.
Bit_Strobe Return Values: (4 bytes returned)
BYTE 0: Status Code
Value Definition
0 Off all mat
1 On at least one mat
5 Waiting for Fault Reset button to be
pushed
6 Fault reset button held down
10-19 Mat fault codes
21-26 Relay fault codes
27-32 External relay fault codes
34 Ram failure
35 Power on reset
36 Clock / watchdog failure
37 Data exchange with Slave computer
corrupted
38 Data exchange with Slave not
completed
Byte 1: Zone Status
Definition:
0=relays off / contacts open;
1=relays on / contacts closed
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Zone Zone Zone
#3 #2 #1
Byte 2: Mat Status
Definition: 0=on mat;1=off mat
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Mat Mat Mat Mat Mat Mat Mat Mat
#8 #7 #6 #5 #4 #3 #2 #1
Byte 3: Options Enabled
Definition: 0=disabled, 1=enabled
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Re- Re- Re- Aux Aux Mute- Ext. Manual
served served served #2 #1 out Relay Reset
Ckg.