Banner Safety Mat Monitoring Modules User Manual

SM-xA-5A Safety Mat Monitoring Modules

0 122364 4

SM-GA-5A (12-24V dc / 115V ac operation) and SM-HA-5A (12-24V dc / 230V ac operation)

The user is responsible for satisfying all local, state, and national laws, rules,
codes, and regulations relating to the use of this product and its application. Banner
Engineering Corp. has made every effort to provide complete application, installa­tion, operation, and maintenance instructions. Please direct any questions regard­ing the use or installation of this product to the factory applications department at
the telephone numbers or address shown found at http://www.bannerengineer-

ing.com.

The user is responsible for making sure that all machine operators, maintenance
personnel, electricians, and supervisors are thoroughly familiar with and understand
all instructions regarding the installation, maintenance, and use of this product, and
with the machinery it controls. The user and any personnel involved with the instal­lation and use of this product must be thoroughly familiar with all applicable stand­ards, some of which are listed within the specifications. Banner Engineering Corp.
makes no claim regarding a specific recommendation of any organization, the accu­racy or effectiveness of any information provided, or the appropriateness of the pro­vided information for a specific application.

Model Supply Voltage Outputs Output Rating

SM-GA-5A 12-24V dc or 115V ac 4 Normally Open Safety

SM-HA-5A 12-24V dc or 230V ac

For complete technical information about this product, including dimensions, accessories, and specifications, see www.BannerEngineering.com and search
122364_web.

WARNING: Not a Stand-Alone Safeguarding Device

This Banner product is not a stand-alone point-of-operation guarding device, as defined by OSHA regulations. It is necessa-

ry to install point-of-operation guarding devices, such as safety light screens and/or hard guards, to protect personnel from hazardous
machinery. Failure to install point-of-operation guards on hazardous machinery can result in a dangerous condition which

could lead to serious injury or death.

1 Normally Closed Aux.

2 Solid-State Aux.

N.O. Safety Outputs: 6 A

N. C. Aux. Outputs: 5 A

SS Aux Outputs: 100 mA

for

Overview

Safety Mat Monitor Modules SM-GA-5A and SM-HA-5A (the "Safety Module") are used to verify the proper operation of 4-wire presence-sensing switching mats (sensors).

P/N 122364 rev. C 8/22/2012

POWER

FAULT

CH. 1

CH. 2

K1

K2

51 52

13 14 23

A1 A2 B1 B2 S11 S12 S21 S22

24 33 34 43 44

Y30 Y31 Y32 Y35 51 52

S31 S32 S33 S34 S32 S35

SM-GA-5A

13

Y30 Y31 Y32

14 23 24 33

Y35 51 52

34 43 44

A1 A2 B1 B2 S11 S12 S21 S22

S31 S32 S33 S34 S32 S35

SM-xA-5A Safety Mat Monitoring Modules

Multiple mats may be switched in series to one Safety Module. The Safety Module provides the redun­dant safety outputs required for creating a control-reliable safety circuit. The Safety Module has two
functions:

•

To monitor the conductive elements (plates) and the wiring of one or more safety mat(s) for failures
and prevent the machine from restarting if any mat or the Module fails, and

• To provide a reset routine after the operator steps off the safety mat. This prevents the controlled
machinery from restarting automatically after the mat is cleared. This necessary reset/restart func­tion is required by ANSI B11 and ANSI NFPA 79 machine safety standards. If the Module is used in
auto-reset mode, the reset/restart function must be provided by the machine control system.

NOTE:

NOTE:The Safety Module is not designed to monitor 2-wire mats,
bumpers, or edges (with or without sensing resistors).

Figure 1. Indicator and Terminal Locations

In operation, the Safety Module monitors the conductive elements (plates) of the pressure-sensitive mat for shorting of those elements (i.e., when the mat is stepped on)
and certain faults, such as shorts to other sources of power or ground (0V), or open connecting wires. With a +24V dc supply, Channel 1 (S11-S12) supplies > 20V dc that
is pulsed low and Channel 2 (S21-S22) supplies < 2V that is pulsed high; when these two channels are shorted together, the safety output contacts open (13-14, 23-24,
33-34, and 43-44).

If a fault is detected, the Module will lock out, open its safety outputs, and indicate the problem on its LED display, which can be diagnosed by using the troubleshooting
table in this document. After repairing the fault, step on the mat and off it again to clear the lockout condition (or cycle power). If the fault has been cleared and no other
faults exist, the Fault LED turns OFF and the Module can be reset (if configured for Auto Reset, the safety outputs will turn ON immediately).

The output relays energize automatically if the Module is wired for Auto Reset mode, all sensors are clear, all faults are removed or corrected, and power is applied. The
Module requires a manual reset if it is wired for Manual Reset mode.

WARNING: Application of Safety Mats

Requirements vary widely for the level of control reliability or category as described by ISO 13849-1 (EN 954-1) in the application of
safety mats. While Banner Engineering always recommends the highest level of safety in any application, it is the responsibility of

the user to safely install, operate, and maintain each safety system per the manufacturer's recommendations and comply
with all relevant laws and regulations.

Do not use safety mats as a tripping device to initiate machine motion (such as in a presence-sensing device initiation applica-

tion), due to the possibility of unexpected start or re-start of the machine cycle resulting from failure(s) within the mat and the inter­connect cabling.

Do not use a safety mat to enable or provide the means to allow the machine control to start hazardous motion by simply
standing on the safety mat (e.g., at a control station). This type of application uses reverse/negative logic and certain failures (e.g.,

loss of power to the Module) can result in a "false" enable signal.

Mechanical Installation

Route the mat cable to the Safety Module location. The Safety Module must be installed inside an enclosure. It is not designed for exposed wiring. It is the user’s responsi­bility to house the Safety Module in an enclosure with NEMA 3 (IEC IP54) rating, or better.

The Safety Module mounts directly to standard 35 mm DIN rail; see Dimensions.

Heat Dissipation Considerations. For reliable operation, ensure that the operating specifications are not exceeded. The enclosure must provide adequate heat dissipa­tion, so that the air closely surrounding the Module does not exceed the maximum operating temperature stated in the Specifications. Methods to reduce heat build-up
include venting, forced airflow (e.g., exhaust fans), adequate enclosure exterior surface area, and spacing between modules and other sources of heat.

Electrical Installation

CAUTION: Shock Hazard

Always disconnect power from the Banner product and the guarded machine before making any connections or replacing any com­ponent. Electrical installation and wiring must be made by qualified personnel and must comply with the NEC (National Electrical
Code), ANSI NFPA79 or IEC 60204-1 and -2, and all applicable local standards and codes. Use extreme caution to avoid electri-

cal shock at all times. Serious bodily injury or death could result.

2 www.bannerengineering.com - tel: [phone] P/N 122364 rev. C

SM-xA-5A Safety Mat Monitoring Modules

The Safety Module is powered by either a 12-24V dc supply at 4W or an ac supply (115V ac, model SM-GA-5A, or 230V ac, model SM-HA-5A) at 7VA. The sensor circuit,
which monitors the conductive elements (plates) of the safety mat, consists of two channels (A and B) that issue a stop command (i.e., open the safety outputs) when an
individual steps onto the safety mat, shorting the two channels together.

It is not possible to give exact wiring instructions for a safety module which interfaces to a multitude of machine control configurations. The following guidelines are general
in nature.

Since the Safety Module functions by detecting the short circuit between the channels, resistance to electrical current flow in the contact monitoring circuit impacts the
operation and the safety of the system. Total resistance includes contact resistance of the internal mat contacts, the number of mats in the circuit, and the wire resistance of
the interconnect cables and connections.

The only limitation on the number of mats that can be connected in series is the amount of resistance. The total resistance within each channel can not exceed 250 ohms
when the Module is supplied by 24V dc or an ac power supply, and no more than 25 ohms when the Module is supplied by 12V dc.

The resistance between the channels when shorted together (i.e., when an individual steps on the mat) can not exceed 150 ohms (24V dc or an ac supply) or 10 ohms
(12V dc supply).

WARNING: Multiple Safety Mats

Whenever two or more safety mats are connected to the same Safety Mat Monitor Module, the corresponding conductive elements
(plates) of all mats must be connected together in series, as shown in the hookup drawing. Never connect the conductive ele-

ments (plates) of multiple safety mats in parallel; this defeats the ability of the Safety Module to detect open connection
wires to each mat, which would create an unsafe condition that could result in serious injury or death.

NOTE: The minimum amount of time for the Module to detect a STOP condition is 15 ms. This "recovery time" (OFF state) is required for the internal integrity tests to
complete, allowing a reliable reset to occur. A lockout may occur if the Module is cycled too quickly. To clear the lockout, the inputs must be re-cycled, meeting the mini­mum recovery time requirements.

Safety Mat Device Checkout - Prior to Module Connection

Before connecting the safety mat to the Module, verify the installation does not exceed the maximum resistance specification. Check the mat with an ohmmeter to verify

that none of the following values are exceeded.

1.

Check the leadwire resistance.

a) Keeping track of which wire goes to which terminal, disconnect all 4 wires from the terminal blocks.
b) Measure and record the resistance between the wires going to terminals S11 and S12: ________ (=Ra)
c) Measure and record the resistance between the wires going to terminals S21 and S22: ________ (=Rb)
d) Review the values for Ra and Rb.

If both Ra and Rb are Then

Less than 50 ohms The lead resistance is acceptable for all supply voltages; check the mat resistance next. If it is 50 ohms or more for either, continue below.

Less than 500 ohms The lead resistance is acceptable for an AC supply and for a DC supply >20 V. If resistance is acceptable for your supply, check the mat

resistance next. If resistance is not acceptable, lower the lead resistance by shortening the leadwires or by increasing the wire diameter.
Recheck Ra and Rb.

2. Check the mat resistance.

Step on the mat in various locations while taking the measurements listed below.

a)
b) Measure and record the highest observed resistance between S11 and S21: ________ (=Rc)
c) Measure and record the highest observed resistance between S21 and S22: ________ (=Rd)
d) Review the values for Rc and Rd.

If both Rc and Rd are Then

Less than 10 ohms The mat and leadwire resistance is acceptable for all supply voltages and the safety mat checkout is

complete.

Less than 150 ohms AND you are using an AC supply

The mat and leadwire resistance is acceptable and the safety mat checkout is complete.

or DC supply greater than 20V dc

Any other value If resistance is not acceptable, proceed to the next step.

3. Connect the ohmmeter to the wires to be connected to S11-S12 (Channel A), and note the resistance.

Connect the ohmmeter to the wires to be connected to S21-S22 (Channel B), and note the resistance.

4.

5. Perform the following calculation: Rm = (Rc + Rd - Ra - Rb)/2.

If Rm is: Then

Less than 10 ohms The mat resistance is acceptable for all supply voltages; the safety mat checkout is complete.

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