STI MC4 Series User manual

Call: 1/800/221-7060 U.S.A. and Canada
Telephone: [phone], Fax [phone]
Multi-Mat Manager
1
R
Mat Controller
MC4 Series
Installation and Operating Manual
P/N 99554-0010 Rev. A © Oct 1999 STI
Scientific Technologies Inc.
Optical Sensor Division
Manufacturing and Sales Office
6550 Dumbarton Circle,
Fremont, CA 94555-3611
Phone [phone]
Fax [phone]
http://www.sti.com
European Sales Office
Bötzinger Straße 29
79111 Freiburg, Germany
Phone [phone]
Fax [phone]

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Mat Controller MC4 Manual Rev.A
1
SCIENTIFICTECHNOLOGIES INC.
Call: 1/888/510-4357 in USA and Canada
Mat Controller MC4
Table of Contents
Section 1— Important Safety Message . . . . . . . . . . . . . page 2
Section 2—
Introduction . . . . . . . . . . . . . . . . . . . . . . . . page 4
Section 3—
Description of Controls . . . . . . . . . . . . . . . . page 5
Section 4—
Operating Mode . . . . . . . . . . . . . . . . . . . . . . page 6
Section 5—
Installation . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Section 6—
Machine Control Connections . . . . . . . . . page 11
Section 7—
Test Procedure . . . . . . . . . . . . . . . . . . . . . . page 15
Section 8—
Trouble-shooting Faults . . . . . . . . . . . . . . page 16
Section 9—
Specifications . . . . . . . . . . . . . . . . . . . . . . page 17
Section 10—
Warranty and Additional Information . . page 20
Section Appendix A—
— Test Procedure . . . . . . . . . . . page 22

Mat Controller MC4 Manual Rev.A 2
IMPORTANT SAFETY MESSAGE
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1 I MPORTANT S AFETY M ESSAGE 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. Please contact STI in California, USA at
510-608-3400 for additional assistance.
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, check out and
maintained only by a qualified person, as
“a person or persons who, by
possession of a recognized degree or certificate of professional training
or who, by extensive knowledge, training and experience, has
successfully demonstrated the ability to solve problems relating to the
subject matter and work.”
(ANSI B30.2-1983)
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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I
MPORTANT
S
AFETY
M
ESSAGE
Mat Controller MC4 Manual Rev.A
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– 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 B11.19-1990, 5.5, which states in part
“...the
device, system or interface shall be designed, constructed and
installed such that a single component failure within the
device, interface or system shall not prevent normal stopping
action from taking place, but shall prevent a successive
machine cycle...”
• 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 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.

Mat Controller MC4 Manual Rev.A 4
INTRODUCTION
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• The user must follow all procedures in this manual for proper operation
of the MC4 controller.
The enforcement of these requirements is beyond STI’s control. The
employer has the sole responsibility to follow the preceding
requirementsandanyprocedures,conditionsandrequirementsspecific
to your machinery.
2 I NTRODUCTION 2
Presence sensing mats combined with an MC4 safety mat controller
improve productivity while providing access guarding. Less downtime
occurs because it is not necessary to set up or remove mechanical safety
barriers during operation and maintenance.
Presence sensing mats and the MC4 controller are used where
perimeter access guarding is required, such as around robots,
manufacturing work cells, food processing equipment and automated
assembly equipment.
The MC4 controller is designed to meet the applicable sections of ANSI
B11.19-1990, OSHA 1910.212 and EN1760-1:1997. CE standards are
met only when used in conjunction with STI UM series presence
sensing safety mats.
The MC4 controller is designed to work in conjunction with four-wire
(could be up to six) normally open safety mat (such as the STI UM series
safety mats).

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D
ESCRIPTION OF
C
ONTROLS
Output Relays
Mat Controller MC4 Manual Rev.A
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3 D ESCRIPTION OF C ONTROLS 3
Figure 3-1 MC4 Mat Controller
3.1. O UTPUT R ELAYS
The safety-rated outputs of the MC4 controller are referred to as
OutputSignalSwitching 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 NO1 and NO2. Two normally closed OSSD are provided
across terminals NC1 and NC2.
3.2. I NDICATORS
• 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.
• 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.
AC IN
NEUT
NO 1 NO 2 NC 1 NC 2
Relay Output
T2A
250V
F3
SHIELD
START 2
+24 VDC IN
24 V RET
START 1
LED 1
LED 2
LED 3
Clear
Run
Stop
Reset
JMP 2
JMP 3
JMP 1
K2 K1
Terminal Connections for Safety Mats Terminal Connections for Safety Mats
1BLK
1BLU 2BLK 2BLU 3BLK
3BLU
4BLK
4BLU
5BLK 5BLU 6BLK 6BLU
1BRN
1WHT
2BRN
2WHT
3BRN
3WHT 4BRN 4WHT
5BRN
5WHT
6BRN
6WHT
AC Version Only

Mat Controller MC4 Manual Rev.A 6
OPERATING MODE
Mat Inputs
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3.3. M AT I NPUTS
Twenty-four terminal positions (1–6 BLK, 1–6 BLU, 1–6 BRN, 1–6
WHT) are provided for input of up to 6 four-wire safety mat or a series of
four-wire safety mats. See details in Section 5.2.
4 O PERATING M ODE 4
4.1. A UTOMATIC R ESTART
The MC4 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 second is
normal. The RUN indicator will follow the MAT CLEAR light.
4.2. S TART /R ESTART I NTERLOCK
The MC4 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 0.10 seconds. The safety
mat area must be clear at the time the start switch is pressed and
released.

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I
NSTALLATION
Mounting
Mat Controller MC4 Manual Rev.A
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5 I NSTALLATION 5
WARNING! Read this manual completely before installing the
MC4 controller.The MC4 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 MC4 controller before using the guarding system.
5.1. M OUNTING
5.1.1
MODE SELECT
The installer must select whether the MC4 controller will operate
in AUTOMATIC START or START/RESTART INTERLOCK mode. To
make the selection, locate the three yellow jumpers JMP1, 2, and 3
inside the controller box. See
See “Figure 3-1 MC4 Mat Controller”
on page 5
.
WARNING! Do not operate the device with only one or two
jumpers. Use either 3 or more.
With all three jumpers installed, the controller is configured for
AUTOMATIC START operation. This is the factory setting.
Toconfigure 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
▲
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Mat Controller MC4 Manual Rev.A 8
INSTALLATION
Input Wiring
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5
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 MC4 controller is enclosed in a 14 GA steel enclosure rated IP65.
5.2. I NPUT W IRING
5.2.1 POWER
110 to 240 VAC auto selecting, wired to AC IN & NEUT or
24VDC power source is required. Connect PLUS to terminal block
+24VDC position and MINUS (0, Return) to terminal block 24V Return
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
or an optional k.ey switch maybe used.
— Connect the remote start switch between terminals START 1 and START
2.
5.2.3 SAFETY MAT
At least one STI 4-wire mat is expected. For an 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 the black and blue
conductors are connected to 1 BLK and 1 BLU, a jumper is installed
from 2 BLK to 6 BLU. The brown and white conductors are BRN and
WHT. See ˚See “Figure 5-1 Hookup Drawing” on page 9

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I NSTALLATION
Input Wiring
Mat Controller MC4 Manual Rev.A 9
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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
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.
AC IN
NEUT
NO 1 NO 2 NC 1 NC 2
Relay Output
T2A
250V
F3
SHIELD
START 2
+24 VDC IN
24 V RET
START 1
LED 1
LED 2
LED 3
Clear
Run
Stop
Reset
JMP 2
JMP 3
JMP 1
K2 K1
Terminal Connections for Safety Mats Terminal Connections for Safety Mats
1BLK
1BLU 2BLK 2BLU 3BLK
3BLU
4BLK
4BLU
5BLK 5BLU 6BLK 6BLU
1BRN
1WHT
2BRN
2WHT
3BRN
3WHT 4BRN 4WHT
5BRN
5WHT
6BRN
6WHT
MAT 1
MAT 2
Jumper Jumper
Power
Supply
Black
Brown
Blue
White
Black
Brown
Blue
White
Up to 6 mats may be connected to the controller using this method.
As each mat is connected, the jumperis moved to the last unused terminal.
The above example shows 2 mats wired, jumpers would be placed as shown
(3 blk) is jumpered to terminal labeled 6 blue and (3 brn) is jumpered to terminal labeled 6 wht.
When all 6 mats are connected, jumpers are not required.
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Mat Controller MC4 Manual Rev.A 10
INSTALLATION
Output Wiring
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5.2.4 E ARTH 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. 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.
5.3. O UTPUT W IRING
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.

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M ACHINE C ONTROL C ONNECTIONS
Two Normally Open Preferred Connection Method
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6 M ACHINE C ONTROL
C
ONNECTIONS 6
6.1. T WO N ORMALLY O PEN P REFERRED
C
ONNECTION M ETHOD
The following connection scheme uses both of the normally open
output relay contacts to control the machine. This is the STI
recommended wiring method. SeeSee “Figure 6-1 Two Normaly
Open Preferred Connection” on page 12.
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 or relays, contactors, solenoids or
electromechanical valves. If relays, the MPCE must use force-
guided contact type relays.

Mat Controller MC4 Manual Rev.A 12
MACHINE CONTROL CONNECTIONS
Two Normally Open Preferred Connection Method
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Figure 6-1 Two Normaly Open Preferred Connection
AC IN
NEUT
NO 1 NO 2 NC 1 NC 2
Relay Output
T2A
250V
F3
SHIELD
START 2
+24 VDC IN
24 V RET
START 1
LED 1
LED 2
LED 3
Clear
Run
Stop
Reset
JMP 2
JMP 3
JMP 1
K2 K1
Terminal Connections for Safety Mats Terminal Connections for Safety Mats
1BLK
1BLU 2BLK 2BLU 3BLK
3BLU
4BLK
4BLU
5BLK 5BLU 6BLK 6BLU
1BRN
1WHT
2BRN
2WHT
3BRN
3WHT 4BRN 4WHT
5BRN
5WHT
6BRN
6WHT
MAT 1
MAT 2
100 to 240 VAC
Auto Selecting
MPCE 1
MPCE 2
CR
CR
MACHINE CONTROL VOLTAGE
AUX SAFETY OUTPUT
AUX SAFETY OUTPUT
Fuse
(customer
supplied)
Optional
Keyswitch
or
Push Button
Reset
Jumper Jumper
Power
Supply
Black
Brown
Blue
White
Black
Brown
Blue
White
Up to 6 mats may be connected to the controller using this method.
As each mat is connected, the jumperis moved to the last unused terminal.
The above example shows 2 mats wired, jumpers would be placed as shown
(3 blk) is jumpered to terminal labeled 6 blue and (3 brn) is jumpered to terminal labeled 6 wht.
When all 6 mats are connected, jumpers are not required.
MPCE 2
MPCE 1
To machine contr
o

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M ACHINE C ONTROL C ONNECTIONS
Suggested PLC Connection
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6.2. S UGGESTED PLC C ONNECTION
The wiring from the MC4 controller to the machine control must
be control reliable as explained in ANSI B11.19-1990 section 5.5 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
MC4 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.

Mat Controller MC4 Manual Rev.A 14
MACHINE CONTROL CONNECTIONS
Suggested PLC Connection
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Figure 6-2 Suggested PLC Connection
AC IN
NEUT
NO 1 NO 2 NC 1 NC 2
Relay Output
T2A
250V
F3
SHIELD
START 2
+24 VDC IN
24 V RET
START 1
LED 1
LED 2
LED 3
Clear
Run
Stop
Reset
JMP 2
JMP 3
JMP 1
K2 K1
Terminal Connections for Safety Mats Terminal Connections for Safety Mats
1BLK
1BLU 2BLK 2BLU 3BLK
3BLU
4BLK
4BLU
5BLK 5BLU 6BLK 6BLU
1BRN
1WHT
2BRN
2WHT
3BRN
3WHT 4BRN 4WHT
5BRN
5WHT
6BRN
6WHT
MAT 1
MAT 2
100 to 240 VAC
Auto Selecting
MPCE 1
MPCE 2
CR
CR
MACHINE CONTROL VOLTAGE
AUX SAFETY OUTPUT
AUX SAFETY OUTPUT
Fuse
(customer
supplied)
Optional
Keyswitch
or
Push Button
Reset
Jumper Jumper
Power
Supply
Black
Brown
Blue
White
Black
Brown
Blue
White
Up to 6 mats may be connected to the controller using this method.
As each mat is connected, the jumperis moved to the last unused terminal.
The above example shows 2 mats wired, jumpers would be placed as shown
(3 blk) is jumpered to terminal labeled 6 blue and (3 brn) is jumpered to terminal labeled 6 wht.
When all 6 mats are connected, jumpers are not required.
MPCE 2
MPCE 1
To machine control
MPCE 2
MPCE 1
To PLC control

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T EST P ROCEDURE
Performing Test Procedure
Mat Controller MC4 Manual Rev.A 15
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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.
7 T EST P ROCEDURE 7
7.1. P ERFORMING T EST P ROCEDURE
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 MC4
controller or the machine and machine control circuitry. Testing
ensures that the mats, MC4 controller, machine and machine
control circuitry work properly to stop the machine. Failure to test
properly could result in serious injury to personnel.
▲
!

Mat Controller MC4 Manual Rev.A 16
TROUBLE-SHOOTING FAULTS
Performing Test Procedure
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8 T ROUBLE - SHOOTING F AULTS 8
Symptom
No indicators lit.
Possible Solutions
No power to the controller.
For 100 - 240 VAC controllers check for power to AC IN and NEUT. Also
check fuse F3 located on the controller board near terminal block.
For 24 VDC units, check power supply and its connections to +24 VDC
& 24V Return. Also see earth discussion in See “5.2.4 Earth
considerations” on page 10.
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.
Possible Solutions
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”.

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S PECIFICATIONS
Mat Controller—MC4
Mat Controller MC4 Manual Rev.A 17
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Symptom
All other conditions
Possible Solutions
Controller is defective. Replace. Call STI for details.
9 S PECIFICATIONS 9
9.1. M AT C ONTROLLER —MC4
9.1.1 G ENERAL S PECIFICATIONS
Category: Category 3 safety device
Operating Modes: Automatic Start or Start/Restart Interlock
9.1.2 Electrical
Power Input: 100 - 240 VAC, Auto-select or 24 VDC (±15%, < 3W.)
Safety Input: Connections for a four-wire mat system
Indicators: Green=Mat Clear; Green=Run; Red=Stop
Reset Function: User-supplied optional 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 series safety mat and
controller combined)
9.1.3 Construction
Case Material: 14 GA Steel
Rating: IP65
Mounting Type: Screw mount to machine
Shipping Weight: 9 pounds (4.08 kg)

Mat Controller MC4 Manual Rev.A 18
SPECIFICATIONS
Mat Controller—MC4
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9.1.4 Environmental
Temperature: 0° to +55°C (32° to 131°F)
Vibration: Per IEC 68-2-6, 0.15mm displacement, 10 to 55 Hz
Shock: Per IEC 68-2-27, 25G 6mS pulses, 3 per axis;
Bump: Per IEC 68-2-29, 15G, 6mS pulses, 1000 per axis.
Relative Humidity: 95%
9.1.5 Standards Conformity
Designed in Accordance with: EN1760-1:1997, EN954, ANSI/RIA 15.06-
1992, ANSI B11.19-1990, OSHA 1910.212 & 1910.217(b)

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S PECIFICATIONS
Mat Controller—MC4
Mat Controller MC4 Manual Rev.A 19
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9.1.6 DIMENSIONAL DRAWINGS
Figure 9-1 Mat Controller MC4 Dimensional Drawing
2.048 in.
4.00 in.
5.00 in.
6.30 in.
0.312 in.
(8 plcs)
7.55 in. CL
9.30 in.
10.10 in.
5.050 in.
10.8 in.
1.5 in.
(2 plcs)
2.5 in.
0.9 in.
1.75 in.
0.5 in.
4.375 in.
2.525 in.
0.875 in.
CL
1.0 in.
(Top Rivet) 0.75 in.
(Bottom Rivet)
2.35 in.
4.0 in.
0.75 in.
1.25 in.
0.52 in. 0.5 in.
2.0 in.
CL
3.5 in.
0.875 in.
Knockout
(3 plcs)