STI MC6 Series User manual

Mat Controller
MC6 Series
Installation and Operating Manual
Scientific Technologies Inc.
Optical Sensor Division
Manufacturing and Sales Office
6550 Dumbarton Circle,
Fremont, CA 94555
Phone [phone]
Fax [phone]
http://www.sti.com
European Sales Office
Bötzinger Straße 29
79111 Freiburg, Germany
Phone [phone]
Fax [phone]
© STI P/N 99610-0010 rev.C 021601

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Mat Controller MC6 Manual 99610-0010 Rev. C
1
SCIENTIFIC TECHNOLOGIES INC.
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Mat Controller MC6
Table of Contents
Section 1— Important Safety Message . . . . . . . . . . . . . page 2
Section 2—
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
Section 3—
Introduction . . . . . . . . . . . . . . . . . . . . . . . . page 6
Section 4—
Description of Controls . . . . . . . . . . . . . . . . page 6
Section 5—
Operating and Wiring Instructions . . . . . . page 9
Section 6—
Machine Control Connections . . . . . . . . . page 12
Section 7—
Troubleshooting . . . . . . . . . . . . . . . . . . . . page 15
Section 8—
Specifications . . . . . . . . . . . . . . . . . . . . . . page 18
Section 9—
Dimensional Drawing . . . . . . . . . . . . . . . . page 21
Section 10—
Warranty and Additional Information . . page 22
Section Appendix A—
— Test Procedure . . . . . . . . . . . page 24

Mat Controller MC6 Manual 99610-0010 Rev. C 2
I
MPORTANT
S
AFETY
M
ESSAGE
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1
1 I MPORTANT S AFETY M ESSAGE 1
WARNING! Read and understand this section prior to installing the MC6 system.
A presence sensing mat (UM Series) and controller (MC6) 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, checked 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 in 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.
• 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...”
Employer’s Responsibility
• All other machinery or equipment must meet OSHA standard 1910.212 for general
machine guarding plus all applicable governmental and local rules, codes, and regulations
must be satisfied. All safety-related machine control elements must be designed so that a
fault in the control logic or failure of the control circuit does not lead to a failure or danger.
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I
MPORTANT
S
AFETY
M
ESSAGE
Mat Controller MC6 Manual 99610-0010 Rev. C
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SCIENTIFIC TECHNOLOGIES INC.
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• Additional guarding may be required for access to dangerous areas not covered by the MC6
controller and the Universal Safety Mat system.
• 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.
• Perform the STI test procedure at installation and after maintenance, adjustment, repair or
modification to the machine controls, tooling, dies or machine, or on the presence sensing
mat and controller.
• The Test Procedure is presented in this manual. (See Appendix A ).
• 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 MC6
controller. The enforcement of these requirements is beyond STI’s control. The employer
has the sole responsibility to follow the preceding requirements and any procedures,
conditions and requirements specific to his machinery.

Mat Controller MC6 Manual 99610-0010 Rev. C 4
G
LOSSARY
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2
2 G LOSSARY 2
Automatic Start
Upon completion of power-up, the control unit will enter the Machine Run state as soon
as all of the selected sensing inputs are in the
Mat Clear state. STI has traditionally
referred to this as the
Normal mode.
Control unit
A device that responds to the condition of the sensor(s) and controls the state of the
output signal switching device. It may also monitor the integrity of the pressure sensitive
mat or pressure sensitive floor and it may contain facilities to process a start signal. The
control unit may be integrated with the machine control system.
Failure
The state of an item characterized by its inability to perform a required function.
Fault
The state of an item characterized by its inability to perform a required function,
excluding the inability during preventative maintenance or other planned actions, or due
to a lack of external resources.
Interlock
For the controller to enter this state the controller must be set to either the Start
Interlock
or Start/Restart Interlock mode. In this state the safety outputs (OSSDs) are
inactive and all of the mat zones are clear. In this state the yellow
Interlock LED is on and
Red
Machine Stop LED is on.
Lockout(Fault)
When the control unit detects a fault, it transitions to this state. The safety outputs
(OSSDs) will be held to the inactive state and the control unit will not attempt to leave
this state without performing a comprehensive power-up self-test. A power-up-self-test
will be initiated by either cycling the control unit power or by a Start signal transition.
Machine Run
When the control unit is in this state the two safety outputs (OSSDs) are both active. In
this state the Green
Machine Run and Mat Clear LEDs are on and the Red Machine Stop
LED is off.
Machine Stop
When the control unit is in this state the two safety outputs (OSSD’s) are both inactive. In
this state the Green Machine Run LED is off, the Red Machine Stop LED is on.
Mat Clear condition
When the pressure applied to the pressure sensitive mat is less than the required sensing
weight, the pressure sensitive mat zone inputs to the controller are at electrical levels
that set the controller in a
Mat Clear condition. Mat Clear indicator is on.
MPCE Monitoring
MPCE is the abbreviation for Machine Primary Control Element. The safety controller
monitors the state of the MPCE signal produced by the guarded machine to insure that it
is in the correct state with respect to
Machine Run and Machine Stop .

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G
LOSSARY
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OFF state
The state in which the output circuit is interrupted and does not permit the flow of
current.
ON state
The state in which the output circuit is complete and permits the flow of current.
Safety Outputs (Output signal switching device – OSSD)
The component of the control unit connected to the control system of the machine which,
when the sensing device is actuated during normal operation, responds by going to an
Off
state.
Pressure sensitive mat system
A safety device which detects a person standing on it or who steps onto it. It comprises a
sensor(s) that responds to the application of pressure and a control unit, and one or more
output signal switching device(s). In a pressure sensitive mat the effective sensing area is
deformed locally when the sensor(s) is actuated.
Pressure Sensing condition
When the pressure applied to the pressure sensitive mat is equal or greater than the
required sensing weight, the mat zone inputs to the controller are at electrical levels that
set the controller to a pressure sensing condition.
Mat Clear indicator is Off.
Response time
The maximum amount of time required for the pressure sensitive mat system to recognize
a protection zone intrusion and activate a response through its safety outputs (OSSDs).
Start interlock
Upon completion of power-up, the control unit must go to the Interlock state. A Start
signal transition must occur before going to
Machine Run for the first time. Once the first
Start condition has been met, the control unit will operate in the Automatic Start mode.
STI has traditionally referred to this as the
Power-up Inhibit .
Start/Restart interlock
The control unit will go into the Interlock State upon completion of power-up and after a
pressure sensing condition has occured. A
Start signal transition must occur before
returning to
Machine Run following any transition to Machine Stop . STI has traditionally
referred to this as Guard mode.

Mat Controller MC6 Manual 99610-0010 Rev. C 6
I
NTRODUCTION
Relay Safety Outputs (OSSD’s)
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3 I NTRODUCTION 3
Presence sensing mats combined with an MC6 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 MC6 controller are used where perimeter access guarding
is required, such as around robots, manufacturing work cells, food processing equipment
and automated assembly equipment.
The MC6 controller is designed to meet the applicable sections of EN1760-1:1997, EN951-
1:1996, ANSI/RIA 15.06-1999, ANSI B11.19-1990, OSHA 1910.212 & 1910.217(c). CE
standards are met only when used in conjunction with STI UM series presence sensing
safety mats.
The MC6 controller is certified to operate only in conjunction with STI four-wire
normally open safety mats (such as the STI UM series safety mats). The MC6 is a Category
3 safety device, meeting the requirements of EN 954-1.
The MC6 visual indicators provide comprehensive information on the operating status.
These indicators are visible from the top cover of the enclosure. See Section 4.3.—
Indicators .
4 D ESCRIPTION OF C ONTROLS 4
4.1. RELAY SAFETY OUTPUTS (OSSD’S)
The force-guided relay outputs of the MC6 controller are referred to as safety outputs.
When the mat surface is activated by sufficient weight (77 lb. 35 kg), the safety output will
respond by going to an Off state.
Two-normally open safety outputs are provided across terminal block (TB1) position 1, 2,
4 and 5.
One normally closed safety output is provided across terminal block (TB1) position 2 and
3.
See Figure 6-1 for details.
4.2. SOLID-STATE SAFETY OUTPUTS (OSSD’S)
The solid-state safety-rated outputs of the MC6 controller provide 2 current sourcing
outputs. (See Figure 6.2 for details)
Note: The MC6 AC version is available with relay outputs only, on the MC6 DC version
either relay or solid-state outputs may be selected.
4.3. INDICATORS
•Diagnostic Display: Two-digit numeric display provides diagnostic codes.
•Mat Clear: (green) Will be lit when all the selected mat zones are properly wired, mats are
clear, and it is possible to energize the safety outputs.
•Machine Run: (green) Will be lit when the safety outputs are in the machine run state.

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DESCRIPTION OF CONTROLS
Mat Inputs
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•Machine Stop: (red) Will be lit when the safety outputs are in the machine stop state.
•Interlock: (yellow) Will be lit when the mat system is in the interlock state. Light will flash
in fault state.
•Mat Zones: (6 – red) Will be lit when a mat zone is stepped on or shorted. Light will flash
when a fault is detected in the related mat zone.
4.4. MAT INPUTS
Up to (6) Zones (Total of all zones cannot exceed 300 sq. ft.) of (4 wire) UM Series Safety
Mats.
4.5. OPERATING STATES AND CORRESPONDING OUTPUTS
Note: Under normal conditions, the Mat Zone indicators will be OFF when the Zone is
clear and ON when the Mat Zone is in the pressure sensing condition. When the
controller has detected a wiring error, the faulted Mat Zone indicator will blink at a 1-
second rate.
* LED turned on for a few seconds to verify operation.
OUTPUT
POWER ON
SELF TEST
MACHINE
RUN
MACHINE
STOP INTERLOCK
LOCKOUT
(FAULT)
Machine Run, Green LED OFF* ON OFF OFF OFF
Machine Stop, Red LED ON* OFF ON ON ON
Clear , Green LED OFF* ON OFF ON ON or OFF
Interlock or Fault, Yellow LED OFF* OFF OFF ON BLINKING
Diagnostic display 88 00 00 01 XX
Safety Output (A) OFF ON OFF OFF OFF
Safety Output (B) OFF ON OFF OFF OFF
MC6
AUXILIARY
OUTPUT
Follow safety
outputs
indication
mode
OFF ON OFF OFF OFF
Fault
indication
mode
OFF OFF OFF OFF ON

Mat Controller MC6 Manual 99610-0010 Rev. C 8
DESCRIPTION OF CONTROLS
Operational Flow Chart
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4.6. OPERATIONAL FLOW CHART
The MC6 safety mat controller module represents a safety control system which
integrates up to six safety mat zones together to provide a single pair of controlled safety
outputs (OSSD’s). The following operational flow chart highlights the different stages of
the decision making process.
Figure 4-1 Operational Flow Chart
Note: Any failure within the Operational flow of the MC6 will cause the Mat Controller to
transition to the Lockout(Fault) condition.
POWER ON
POWER ON
SELF-TEST
MACHINE
STOP
MAT ZONE(S)
CLEAR?
LOCKOUT
(FAULT)
INTERLOCK
MAT ZONE(S)
CLEAR?
START BUTTON,
PRESSED AND
RELEASED?
MACHINE
RUN
MAT ZONE(S)
CLEAR?
YES
NO
YES
YES
NO
NO
NO
NO NO
YES
YES
YES
START/RESTART
INTERLOCK MODE?
START BUTTON,
PRESSED AND
RELEASED?

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OPERATING AND WIRING INSTRUCTIONS
MC6 Controller
Mat Controller MC6 Manual 99610-0010 Rev. C 9
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5 O PERATING AND W IRING
I
NSTRUCTIONS 5
WARNING! Read this manual completely before installing the MC6 controller. The
MC6 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 MC6 controller before using the
guarding system.
5.1. MC6 CONTROLLER
5.1.1 AUTOMATIC START
• DIP Switches, SW1 and SW2 Positions 1 and 2
• Set Position 1 ON, Set Position 2 ON, on both SW1 and SW2
In automatic start mode, the MC6 will power up with its safety outputs off and perform
system initialization and self-tests. If no faults are detected the control module will
transition to the machine stop state. When all of the selected mat zone inputs are in the
mat clear condition the MC6 will enter the machine run state. When any of the selected
mat zone inputs change to the pressure sensing condition, the MC6 will automatically
change from machine run to machine stop with no operator intervention. The MC6 will
remain in machine stop as long as any of the selected mat zone inputs are indicating the
pressure sensing condition. Once all of the selected mat zone inputs indicate mat clear
condition, the MC6 will automatically change from machine stop to machine run, with no
operator intervention.
5.1.2 START INTERLOCK
• DIP Switches, SW1 and SW2 Positions 1 and 2
• Set Position 1 ON, Set Position 2 OFF, on both SW1 and SW2
In start interlock mode, MC6 will power-up with its safety outputs off and perform system
initialization and self-tests. If no faults are detected and all of the selected inputs from the
mat zones are in the Mat Clear condition, the MC6 then enters the Interlock state. If any
of the selected mat zone inputs are in the pressure sensing condition, the MC6 remains in
the Machine Stop state. When all of the inputs from the selected mat zones are in the Mat
Clear condition, the MC6 automatically transitions to Interlock. The operator must cycle
the start input (from open to closed, and back to open) before the MC6 enters the Machine
Run state for the first time. If then any of the selected mat zone inputs are in the pressure
sensing condition the MC6 will automatically change from the Machine Run to Machine
Stop state. When all of the selected zone(s) are in the Mat Clear condition, the MC6 will
automatically change from the Machine Stop to Machine Run state with no operator
intervention.
5.1.3 START/RESTART INTERLOCK
• DIP Switches, SW1 and SW2 Positions 1 and 2
• Set Position 1 OFF, Set Position 2 OFF, on both SW1 and SW2
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Mat Controller MC6 Manual 99610-0010 Rev. C 10
OPERATING AND WIRING INSTRUCTIONS
MC6 Controller
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In Start/Restart Interlock mode, the MC6 shall power-up with its safety outputs off and
perform system initialization and self-tests. If no faults are detected and all of the selected
mat zone inputs are in the Mat Clear condition, the MC6 then enters the Interlock state.
If any of the mat zone inputs are in the pressure sensing condition, the MC6 remains in
the Machine Stop state. When all of the selected mat zone inputs are in the Mat Clear
condition, the MC6 automatically change to Interlock. The operator must cycle the start
input (from open to closed, and back to open) before the MC6 enters the Machine Run
state. When any of the selected mat zone inputs are in the pressure sensing condition, the
MC6 will automatically change from Machine Run to Machine Stop. When all of the
selected mat zone inputs are in the Mat Clear condition the MC6 then enters the
Interlock state. The operator must cycle the start input before the MC6 exits Interlock and
enters Machine Run.
5.1.4 START PUSHBUTTON OR KEYSWITCH (NORMALLY OPEN)
Used only in start interlock and start/restart interlock modes. When the automatic start
mode is used, no connection is required. When a start switch is required, a customer-
supplied remote start switch with a single set of normally open contacts or an optional
key-switch (may be factory installed) may be used.
Connect the remote start switch between terminals start 1 and start 2, on TB3 (See
Figure 6-1 and Figure 6-2).
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 an 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.
5.1.5 MPCE MONITORING:
• DIP Switches, SW1 and SW2 Position 3
• Set Position 3 OFF on SW1 and SW2 to enable monitoring
• Set Position 3 ON on SW1 and SW2 to disable monitoring
Connect the wiring from the circuit to be monitored to start 1 and MPCE on the
controller terminal block TB3 (See Figure 6-1 and Figure 6-2).
Note: When MPCE is disabled, MPCE must be connected to the MC6, start 1 terminal on
TB3.
5.1.6 SAFETY MAT
DIP Switches, SW1 and SW2 Positions 4, 5 and 6
•1mat zone connected:
Set Position 4 ON, 5 ON, 6 OFF, on SW1 and SW2
•2mat zones connected:
Set Position 4 ON, 5 OFF, 6 ON, on SW1 and SW2
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OPERATING AND WIRING INSTRUCTIONS
MC6 Controller
Mat Controller MC6 Manual 99610-0010 Rev. C 11
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•3mat zones connected:
Set Position 4 ON, 5 OFF, 6 OFF, on SW1 and SW2
•4mat zones connected:
Set Position 4 OFF, 5 ON, 6 ON, on SW1 and SW2
•5mat zones connected:
Set Position 4 OFF, 5 ON, 6 OFF, on SW1 and SW2
•6mat zones connected:
Set Position 4 OFF, 5 OFF, 6 ON, on SW1 and SW2
Mats must be set up and connected to zones in sequence, ie. Zones 1, 2, 3, for a 3 zone
system.
Mats cannot be connected to zones 1, 4, 5 and function as a 3 zone system.
Zones must be used in sequence.
At least one STI 4-wire mat must be connected. 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, The brown and white conductors
are connected to 1 BRN and 1 WHT. See “Figure 6.1 and 6.2 Connection Diagrams”.
Multiple mats may 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 Multiple Mat Connection to a Single Zone
ZONE 1 TERMINAL CONNECTIONS FOR SAFETY MATS
ZONE 2 ZONE 3
1BLK
1BLU
1WHT
1BRN
2BLK
2BLU
2WHT
2BRN
3BLK
3BLU
3WHT
3BRN
ZONE 4 ZONE 5 ZONE 6
4BLK
4BLU
4WHT
4BRN
5BLK
5BLU
5WHT
5BRN
6BLK
6BLU
6WHT
6BRN
MAT 1 MAT 2 MAT 3
(BRN) (WHT) (BRN) (WHT) (WHT)(BRN)
(BLK) (BLU) (BLK) (BLK)(BLU) (BLU)
(BLU)
(WHT)
(WHITE)
(BLACK)
(BLUE)
MAT 4 BROWN
MULTIPLE MATS MAY BE CONNECTED TO THE CONTROLLER USING THIS METHOD
THE ABOVE EXAMPLE SHOWS 4 MATS WIRED.
MATS MUST BE CONNECTED IN SEQUENCE, USING Z1, Z2, Z3, ETC.
DIP SWITCHES MUST BE SET TO THE NUMBER OF ZONES BEING USED.
MC6
TB4
TB1

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MACHINE CONTROL CONNECTIONS
Safety Output Wiring
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6
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. The MC6 metal enclosure must be connected to earth ground. Make the
earth connection through the use of the screw clamp mounted on the inside wall of the
enclosure.
5.1.7 AUXILIARY OUTPUT MODE:
• DIP Switches, SW1 and SW2 Position 7
Set Position 7 ON, on SW1 and SW2 for Follow Safety Output Indication
Set Position 7 OFF, on SW1 and SW2 for Fault Monitoring
Auxiliary outputs may be used for indicator or communications purposes.
The relay version offers 1 NO and 1NC set of relay contacts.
The solid-state version provides 1 current sourcing (PNP) and 1 current sinking output
(NPN).
NOTE: Auxuiliary outputs are for monitoring only, and shall not be used for safety.
6 M ACHINE C ONTROL C ONNECTIONS 6
6.1. SAFETY OUTPUT WIRING
The two safety outputs must be connected to the two MPCE’s of the guarded machine. one
to each. See Figure 6-1 and Figure 6-2. The relay version offers two normally open (NO)
safety outputs for this purpose. One normally closed (NC) safety output may be used as an
auxiliary control input. The solid-state version offers 2 current sourcing outputs (PNP).
The solid-state version is compatible with STI’s RM4 module and could be used as 1 input
device to the RM4. The customer shall wire the system using industry accepted methods.
For relay outputs, external over-current protection must be provided by the user.
6.2. CABLE LENGTHS
The following table lists the recommended maximum lengths for the MC6 input & output
signals.
Table 6-1 MC6 Output & Input Signal Cable Lengths
Signal Names Wire Gauge minimum Specified max. length
Safety Outputs A & B (solid
state)
20 AWG wire with cable
capacitance less than
100pF/ft.
Unshielded: 50 meter (164ft)
Safety Outputs A & B
(mechanical relay)
14 AWG wire Unshielded:
7 Ampere load: 40 meter (131ft)
4 Ampere load: 79 meter (260ft)
Auxiliary output (solid
state or mechanical)
20 AWG wire Unshielded: 50 meter (164ft)
Four-wire Mat inputs 18 AWG wire Unshielded: 30 meter (100ft)
Start Input 22 AWG wire Unshielded: 50 meter (164ft)
MPCE Monitor Input 22 AWG wire Unshielded: 50 meter (164ft)
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MACHINE CONTROL CONNECTIONS
Two Normally Open Preferred Connection Method
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It is recommended that cables connected to the mat controller not be run in parallel with
voltage power lines. Having the signal and power lines separate will insure the reliable
operation of the mat sensing system.
6.3. 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 STI recommended wiring method. See “Figure 6-1 Two
Normally Open Preferred Connection” on page 13.
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 are used, the MPCE must use force-guided contact type
relays.
Figure 6-1 Two Normally Open Preferred Connection
MC6
54321
AC IN
NEUT
MPCE
START 2
START 1
+24 VDC
0 VDC
UNIVERSAL
POWER SUPPLY
(OPTIONAL)
FOR AC POWER
F1
T2A
250V
7
6
5
4
3
2
1SW1
7
6
5
4
3
2
1
SW2
54321
k1 k2 CNO NC
SAFETY RELAY OUTPUT BOARD
ZONE 1
OPTIONAL
KEY SWITCH OR
PUSH BUTTON
RESET
FACTORY
INSTALLED JUMPER
REMOVE WHEN
MPCE IS USED
MPCE1
MPCE2
100 TO 240 VAC
POWER TO CONTROLLER
CONNECTS TO
TERMINAL INSIDE
ENCLOSURE
FUSE
CUSTOMER
SUPPLIED
FUSE
7 AMPS
OR LESS
CR
SNUBBER
MPCE1
SNUBBER
MPCE2
CR
MACHINE CONTROL VOLTAGE
SAFETY OUTPUTS
AUX OUTPUTS NO
NC
C
MPCE2
MPCE1
TO PLC CONTROL
TO MACHINE CONTROL
TWO NORMALLY OPEN SAFETY RELAY OUTPUT
SUGGESTED MACHINE AND PLC CONNECTIONS
TERMINAL CONNECTIONS FOR SAFETY MATS
ZONE 2 ZONE 3
1BLK
1BLU
1WHT
1BRN
2BLK
2BLU
2WHT
2BRN
3BLK
3BLU
3WHT
3BRN
MAT 2 BROWN
WHITE
BLUE
BLACK
BLACK
BLUE WHITE
MAT 1 BROWN
BOTTOM PLATE
TOP PLATE
UP TO 6 MATS MAY BE CONNECTED TO THE CONTROLLER USING THIS METHOD.
THE ABOVE EXAMPLE SHOWS TWO 4-WIRE SAFETY MATS CONNECTED.
MATS MUST BE CONNECTED IN SEQUENCE, USING Z1, Z2, Z3, ETC.
DIP SWITCHES MUST BE SET TO THE NUMBER OF ZONES BEING USED.
ZONE 4 ZONE 5 ZONE 6
4BLK
4BLU
4WHT
4BRN
5BLK
5BLU
5WHT
5BRN
6BLK
6BLU
6WHT
6BRN
TB2
TB3
TB1
TB1 TB4
H (+) N (–)
J2

Mat Controller MC6 Manual 99610-0010 Rev. C 14
MACHINE CONTROL CONNECTIONS
Suggested Solid State Connections
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6
6.4. SUGGESTED SOLID STATE CONNECTIONS
Figure 6-2 shows the MC6 solid-state output version connections. The solid-state safety
outputs are current sources that directly power the MPCE relay coils.
The wiring from the MC6 controller to the machine control must be control reliable as
explained in ANSI B11.19-1990 section 5.5, and B11.TR3 (Risk Assessment and
Reduction) and OSHA 1910.217(b)(13).
6.5. AUXILIARY OUTPUTS
The MC6 controller provides Auxiliary Contacts that allows monitoring of the non-safety
MC6 controller as a signal input to a PLC. Note that in this diagram, the PLC is not wired
directly to the MC6 controller safety outputs 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.
Figure 6-2 Suggested Solid State 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 its stroke or
cycle. Do not use this safety device on a full revolution clutch machine.
MC6
54321
MPCE
START 2
START 1
+24 VDC
0 VDC
7
6
5
4
3
2
1SW1
7
6
5
4
3
2
1
SW2
54321
SOLID STATE OUTPUT BOARD
ZONE 1
OPTIONAL
KEY SWITCH OR
PUSH BUTTON
RESET
FACTORY
INSTALLED JUMPER
REMOVE WHEN
MPCE IS USED
MPCE1
MPCE2
24 vdc
POWER TO CONTROLLER
CR
TVS
MPCE1
TVS
MPCE2
CR
TRANSIENT VOLTAGE SUPPRESSORS
ARE OPTIONAL
MPCE2
MPCE1
AUX INPUTS TO PLC
TO MACHINE CONTROL
TWO SOLID-STATE SAFETY RELAY OUTPUT
SUGGESTED MACHINE AND PLC CONNECTIONS
TERMINAL CONNECTIONS FOR SAFETY MATS
ZONE 2 ZONE 3
1BLK
1BLU
1WHT
1BRN
2BLK
2BLU
2WHT
2BRN
3BLK
3BLU
3WHT
3BRN
MAT 2 BROWN
WHITE
BLUE
BLACK
BLACK
BLUE WHITE
MAT 1 BROWN
BOTTOM PLATE
TOP PLATE
UP TO 6 MATS MAY BE CONNECTED TO THE CONTROLLER USING THIS METHOD.
THE ABOVE EXAMPLE SHOWS TWO 4-WIRE SAFETY MATS CONNECTED.
MATS MUST BE CONNECTED IN SEQUENCE, USING Z1, Z2, Z3, ETC.
DIP SWITCHES MUST BE SET TO THE NUMBER OF ZONES BEING USED.
ZONE 4 ZONE 5 ZONE 6
4BLK
4BLU
4WHT
4BRN
5BLK
5BLU
5WHT
5BRN
6BLK
6BLU
6WHT
6BRN
0 VDC
OSSD A OSSD B
0 VDC
AUX PNP
6
AUX NPN
CONNECTS AT
INSIDE OF
ENCLOSURE
(SEE FIG. 6.1)
–
TB3 J2
TB4TB1
▲
!

. . . . .
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TROUBLESHOOTING
Diagnostic Codes:
Mat Controller MC6 Manual 99610-0010 Rev. C 15
SCIENTIFIC TECHNOLOGIES INC.
Call: 1/888/510-4357 in USA and Canada
7 T ROUBLESHOOTING 7
7.1. DIAGNOSTIC CODES:
7.1.1 OPERATIONAL CODES:
7.1.2 DIP SWITCH FAULTS:
7.1.3 SOLID STATE SAFETY OUTPUT FAULTS:
7.1.4 RELAY SAFETY OUTPUT FAULTS
7.1.5 MPCE MONITOR FAULTS
7.1.6 CONTROLLER FAULT
Code Displayed System Status
88 Power Up Indication
00 Normal Operation, no Faults
01 Waiting for Start Input
Code Displayed Fault Indicated
21 Wrong Operation Mode Selection
22 Changed During Operation
23 DIP Switch Setting Not Redundant
27 More Mat Zones connected to MC6 than selected by
switches SW1 & SW2.
Code Displayed Fault Indicated
31 Safety Outputs shorted together
32 Safety Outputs A shorted to 24 VDC Power
33 Safety Outputs B shorted to 24 VDC Power
34 Safety Outputs A shorted to Ground
35 Safety Outputs B shorted to Ground
Code Displayed Fault Indicated
36 & 38 Safety Relay A internal fault
37 & 39 Safety Relay B internal fault
Code Displayed Fault Indicated
41 Wrong before activation
42 Wrong after activation
43 Wrong on power up
Code Displayed Fault Indicated
50 All Internal Controller Circuit Faults.
Consult STI at 888-510-4357

Mat Controller MC6 Manual 99610-0010 Rev. C 16
TROUBLESHOOTING
Symptoms and Solutions
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7
7.1.7 MAT ZONE OPEN WIRE FAULTS
7.1.8 MAT ZONE SHORTED TO GROUND WIRE FAULTS
7.1.9 MAT ZONE SHORTED BETWEEN MATS WIRING FAULTS
7.2. SYMPTOMS AND SOLUTIONS
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 F1
located on the controller board near the power input terminal block.
For 24 VDC units, check power supply and its connections to +24 VDC & 0 V Return.
Symptom
Mat Clear indicator cannot be made to light.
Possible Solutions
Mat wired improperly. See fault codes, Check connections.
Mat wire broken. Replace mat.
Mat is shorted. Is there something on the sensing area? Is the surface deformed?
Code Displayed Fault Indicated
61 Broken wire in Zone 1.
62 Broken wire in Zone 2.
63 Broken wire in Zone 3.
64 Broken wire in Zone 4.
65 Broken wire in Zone 5.
66 Broken wire in Zone 6.
Code Displayed Fault Indicated
71 Shorted wire in Mat Zone 1.
72 Shorted wire in Mat Zone 2.
73 Shorted wire in Mat Zone 3.
74 Shorted wire in Mat Zone 4.
75 Shorted wire in Mat Zone 5.
76 Shorted wire in Mat Zone 6.
Code Displayed Fault Indicated
82 Mat Zone 2 wire shorted to another Mat Zone
83 Mat Zone 2 wire shorted to another Mat Zone
84 Mat Zone 2 wire shorted to another Mat Zone
85 Mat Zone 2 wire shorted to another Mat Zone
86 Mat Zone 2 wire shorted to another Mat Zone

. . . . .
R
TROUBLESHOOTING
Symptoms and Solutions
Mat Controller MC6 Manual 99610-0010 Rev. C 17
SCIENTIFIC TECHNOLOGIES INC.
Call: 1/888/510-4357 in USA and Canada
Symptom
Cannot start in Start Interlock or Start/Restart Interlocks mode.
Possible Solutions
Check wiring and operation of Start switch. Is 24 VDC present between Start 1 and Start 2
terminals when the start switch is open and 0 VDC when start switch is closed.
Also check fuse F1 located on the controller board near terminal block.

Mat Controller MC6 Manual 99610-0010 Rev. C 18
SPECIFICATIONS
General Specifications
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Call: 1/888/510-4357 in USA and Canada
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8
8 S PECIFICATIONS 8
8.1. GENERAL SPECIFICATIONS
Category 3: The STI MC6 controller & UM Series Safety mat system are a Category 3
safety device.
Response Time: Less than 30 msec.
8.2. Electrical
AC power: 100 to 240 VAC ±10%, 50 to 60 Hz, 20 VA max. (Auto-selecting). Connected to
AC IN and NEUT.
DC power: 24 VDC ± 10%, 10 Watts (Relay Outputs) 50 Watts (Solid-state Outputs).
Connected to +24 VDC and 0 VDC .
The AC line fuse shall not exceed 2 amps, 250 V, 2 Amp slow blow (Time Lag).
8.3. SAFETY OUTPUT
Relay outputs: 2 NO & 1 NC contacts. (TB1 on Relay Board).
•AC max. ratings: 230 VAC, 7 Amperes, 1600 VA.
•DC max. ratings: 24 VDC, 2 Amperes (inductive load), 6 Amperes (resistive load).
Solid-State outputs: 2 current sourcing 24 VDC outputs (PNP type). (J2 on Solid-State
board).
•Max. rating: 0.625 Amperes at 24 VDC.
8.4. AUXILIARY OUTPUTS:
•Relay outputs: 1 NO & 1 NC contacts.
— AC max. ratings: 125 VAC, 0.5 Amperes.
— DC max. ratings: 1 Ampere at 30 VDC.
•Solid State outputs: 1 current sourcing (PNP type) and 1 current sinking (NPN type).
— Current sourcing max. rating: 0.5 Amperes at 24 VDC.
— Current sinking max. rating: 0.1 Amperes at 24 VDC.
8.5. MPCE MONITOR SIGNAL
MC6 provides 24 VDC at 50 mA level at MPCE terminal connection.
When MPCE is Enabled: The MC6 enters Machine Run state, the MPCE external contacts
must open within 300 msec. The MC6 enters Machine Stop state, the MPCE external
contacts must close within 300 msec .
When MPCE is Disabled: MPCE must be connected to MC6 Start 1 terminal during all
states.

. . . . .
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SPECIFICATIONS
Start input
Mat Controller MC6 Manual 99610-0010 Rev. C 19
SCIENTIFIC TECHNOLOGIES INC.
Call: 1/888/510-4357 in USA and Canada
8.6. START INPUT
MC6 provides 24 VDC at 10 mA level at Start 2 terminal connection. When optional Start
switch is used it must have NO (normally open) contacts. When Start switch is not used
terminals Start 1 & 2 are to be left open.
8.7. SETUP
Configuration Setup Guide for switches SW1 & SW2:
Note: Corresponding mat zone indicator will flash.
8.8. CONSTRUCTION
14 Ga. Steel , Nema 12, IP65
Shipping Wt. Approx. 9 lbs, (4 kg.)
8.9. CONNECTORS (CONTROLLER)
Cage clamp terminal strips
8.10. CONNECTOR (MAT INPUT)
4 pole micro single keyway (STI Part No. 60477).
8.11. ENVIRONMENTAL
Operating Temperature: 32 to 131 Degrees F (0 to 55 C)
Relative Humidity: 90%
Vibration: Per IEC 68-2-6, 0.15mm displacement, 10 to 55 Hz
Bump: Per IEC 68-2-29, 10G, 16 msec pulses, 1000 per axis.
Position
Function
Selection Description
7 Auxiliary Output
Mode
Follow Safety Outputs
Indication, 7 ON
Fault Indication, 7 OFF
6 Invalid setting: 4 ON, 5 ON, 6 ON
1 Zone System: 4 ON, 5 ON, 6 OFF
5 Number of Mat 2 Zone System: 4 ON, 5 OFF, 6 ON
Zones 3 Zone System: 4 ON, 5 OFF, 6 OFF
4 4 Zone System: 4 OFF, 5 ON, 6 ON
5 Zone System: 4 OFF, 5 ON, 6 OFF
6 Zone System: 4 OFF, 5 OFF, 6 ON
3 MPCE
Monitoring
Enabled 3 OFF, Disabled 3 ON
2 Mode Automatic Start: 1 ON , 2 ON
1 Start Interlock: 1 ON, 2 OFF
Invalid: 1 OFF, 2 ON
Start/Restart Interlock: 1 OFF, 2 OFF