SC22-3/-3E Safety Controller Instruction Manual
P/N 133487 rev. C -- 10/7/2010
Original Instructions
Contents
Contents
1 About This Document ..........................................................................................................6
1.1 Important . . . Read This Before Proceeding! ...........................................................................................6
1.1.1 Use of Warnings ..........................................................................................................................6
1.2 EC Declaration of Conformity (DOC) .......................................................................................................6
1.3 Standards and Regulations ......................................................................................................................7
1.3.1 U.S. Application Standards ..........................................................................................................7
1.3.2 OSHA Regulations ........................................................................................................................7
1.3.3 International/European Standards ................................................................................................7
1.3.4 Sources of Standards and Regulations ........................................................................................8
1.4 Contact Us ...............................................................................................................................................8
2 Overview ................................................................................................................................9
2.1 Ethernet-Compatible Model ......................................................................................................................9
2.2 Applications ............................................................................................................................................10
2.3 Design and Testing ................................................................................................................................10
2.4 Components ...........................................................................................................................................10
2.4.1 PC System Requirements ..........................................................................................................10
2.4.2 USB Connections .......................................................................................................................11
2.4.3 Ethernet Connections .................................................................................................................11
2.4.4 SC-XMP Programming Tool .......................................................................................................11
2.4.5 SC-XM1 External Memory (XM) Card ........................................................................................11
2.5 Configuring the Safety Controller ...........................................................................................................12
2.5.1 Onboard Interface (OBI) .............................................................................................................12
2.5.2 Personal Computer Interface (PCI) ............................................................................................14
2.6 Input and Output Connections ................................................................................................................15
2.6.1 Safety and Non-Safety Input Devices .........................................................................................15
2.6.2 Safety Outputs ...........................................................................................................................16
2.6.3 Status Outputs ............................................................................................................................17
2.6.4 Virtual Status Outputs .................................................................................................................17
2.6.5 I/O Mapping: the I/O Control Relationship ..................................................................................18
2.7 System Settings ......................................................................................................................................18
2.8 Internal Logic .........................................................................................................................................19
2.8.1 Additional Logic Functions ..........................................................................................................20
2.9 Password Overview ...............................................................................................................................20
2.10 Confirming a Configuration ..................................................................................................................20
3 Components and Specifications .......................................................................................21
3.1 Safety Controller Starter Kit Models .......................................................................................................21
3.2 Replacement Parts/Accessories .............................................................................................................21
3.3 Ethernet Cordsets ...................................................................................................................................22
3.4 Interface Modules ...................................................................................................................................22
3.4.1 Mechanically Linked Contactors .................................................................................................22
3.5 Specifications .........................................................................................................................................23
3.5.1 Dimensions ................................................................................................................................25
4 System Installation .............................................................................................................26
4.1 Appropriate Application ..........................................................................................................................26
4.2 Installing the Safety Controller ...............................................................................................................27
4.3 Safety Input Devices ...............................................................................................................................27
4.3.1 Signals: Run and Stop States .....................................................................................................28
4.3.2 Safety Input Device Properties ...................................................................................................28
4.4 Non-Safety Input Devices .......................................................................................................................31
4.5 Input Device Resets ...............................................................................................................................33
2 P/N 133487 rev. C
Contents
4.5.1 Reset Signal Requirements ........................................................................................................34
4.5.2 Automatic and Manual Reset Inputs Mapped to the Same Safety Output .................................34
4.5.3 Perimeter Guarding and Pass-Through Hazards .......................................................................35
4.6 Safety Input Function ..............................................................................................................................35
4.6.1 Internal Logic .............................................................................................................................35
4.6.2 Two-Hand Control (THC) ............................................................................................................36
4.6.3 Enabling Devices ........................................................................................................................36
4.6.4 Mute Function ............................................................................................................................37
4.6.5 Bypass Function .........................................................................................................................38
4.6.6 Adjustable Valve Monitoring (AVM) Function .............................................................................39
4.7 EDM, OSSD (Safety Output), and FSD Hookup ....................................................................................40
4.7.1 External Device Monitoring (EDM) ............................................................................................40
4.7.2 Safety Outputs ...........................................................................................................................41
4.7.3 FSD Interfacing Connections .....................................................................................................43
4.7.4 Common Wire Installation ..........................................................................................................49
4.8 Status Outputs ........................................................................................................................................50
4.8.1 Status Output Signal Conventions .............................................................................................50
4.8.2 Status Output Functionality ........................................................................................................51
4.9 Virtual Status Outputs .............................................................................................................................52
4.10 Commissioning Checkout ....................................................................................................................52
5 PC Interface Configuration (PCI) .......................................................................................53
5.1 PC Interface (PCI) Overview ..................................................................................................................53
5.1.1 Configuration Tools .....................................................................................................................53
5.1.2 Build a Configuration ..................................................................................................................54
5.1.3 Revise an Existing Configuration ...............................................................................................59
5.1.4 Other Functions ..........................................................................................................................60
6 Onboard Interface Configuration (OBI) ............................................................................62
6.1 Onboard Interface (OBI) Overview .........................................................................................................62
6.2 Run Mode ...............................................................................................................................................64
6.3 Configuration Mode ................................................................................................................................64
6.3.1 Enter Controller Password ..........................................................................................................64
6.3.2 Configuration File ........................................................................................................................64
6.3.3 Confirm Configuration ................................................................................................................65
6.3.4 System Options .........................................................................................................................66
6.3.5 Exit Configuration ......................................................................................................................66
6.4 Edit Configuration ...................................................................................................................................66
6.4.1 Name Configuration ....................................................................................................................66
6.4.2 Inputs ..........................................................................................................................................66
6.4.3 Outputs/System Settings ...........................................................................................................67
6.4.4 Configuration Summary .............................................................................................................68
6.5 Add an Input ...........................................................................................................................................68
6.5.1 Add a Safety Input .....................................................................................................................68
6.5.2 Add a Non-Safety Input .............................................................................................................68
6.5.3 Configure Input Device Properties ..............................................................................................69
7 Operating Instructions .......................................................................................................71
7.1 Monitoring Controller Operation .............................................................................................................71
7.2 Display Controller Information — PC Interface (PCI) .............................................................................71
7.3 Display Controller Information — Onboard Interface (OBI) ....................................................................71
7.3.1 Run Mode Screen—OBI .............................................................................................................72
7.4 Manual Reset ........................................................................................................................................73
7.5 System Resets and Lockout Conditions .................................................................................................74
7.6 Reset Signal Requirements ....................................................................................................................74
8 System Checkout ...............................................................................................................75
8.1 Schedule of Required Checkouts ...........................................................................................................75
8.2 Commissioning Checkout Procedure .....................................................................................................75
3
Contents
8.2.1 Verifying System Operation ........................................................................................................76
8.3 Initial Setup, Commissioning and Periodic Checkout ............................................................................76
9 Troubleshooting .................................................................................................................82
9.1 Cleaning .................................................................................................................................................82
9.2 Repairs and Warranty Service ................................................................................................................82
9.3 Troubleshooting—Finding and Fixing Faults .........................................................................................82
9.3.1 Troubleshooting Fault CodeTable ..............................................................................................83
9.4 Recovering from a Lockout .....................................................................................................................86
9.5 Fault Diagnostics—PCI ..........................................................................................................................87
9.5.1 Fault Log—PCI .........................................................................................................................87
9.5.2 Fault Log Recording—PCI ..........................................................................................................87
9.6 Fault Diagnostics—OBI ..........................................................................................................................88
9.6.1 View Current Faults—OBI ..........................................................................................................88
9.6.2 View Fault Log—OBI ..................................................................................................................89
9.6.3 Clear Fault Log—OBI .................................................................................................................89
10 Input Device and Safety Category Reference ................................................................90
10.1 Safety Circuit Integrity and ISO 13849-1 (EN954-1) Safety Circuit Principles .....................................90
10.1.1 Safety Circuit Integrity Levels ...................................................................................................90
10.1.2 Fault Exclusion .........................................................................................................................92
10.2 Protective (Safety) Stop ........................................................................................................................92
10.2.1 Protective (Safety) Stop Requirements ....................................................................................92
10.2.2 Protective (Safety) Stop Hookup Options .................................................................................92
10.3 Interlocked Guard or Gate ....................................................................................................................93
10.3.1 Safety Circuit Integrity Levels ...................................................................................................93
10.3.2 Safety Interlock Switch Requirements ......................................................................................94
10.4 Optical Sensor ......................................................................................................................................98
10.4.1 Safety Circuit Integrity Levels ...................................................................................................98
10.4.2 Optical Sensor Requirements ...................................................................................................98
10.4.3 Optical Sensor Generic Hookup ...............................................................................................99
10.5 Two-Hand Control ..............................................................................................................................100
10.5.1 Two-Hand Control Separation (Safety) Distance ....................................................................101
10.5.2 Two-Hand Control Hookup Options ........................................................................................102
10.6 Safety Mats .........................................................................................................................................103
10.6.1 Safety Mat Requirements .......................................................................................................104
10.6.2 Safety Mat Hookup Options ....................................................................................................104
10.6.3 Safety Mat Installation ............................................................................................................105
10.7 Emergency Stop Push Buttons ...........................................................................................................106
10.7.1 Safety Circuit Integrity Levels .................................................................................................106
10.7.2 Emergency Stop Push Button Requirements .........................................................................107
10.8 Rope/Cable Pull ..................................................................................................................................109
10.8.1 Rope/Cable Pull Installation Guidelines ..................................................................................109
10.8.2 Rope Pull Hookup Options .....................................................................................................111
10.9 Enabling Device ..................................................................................................................................112
10.9.1 Enabling Device Guidelines ....................................................................................................112
10.9.2 Enabling Device Hookup Options ...........................................................................................112
10.10 Bypass Switches (Bypassing Safeguards) .......................................................................................114
10.10.1 Requirements of Bypassing Safeguards ..............................................................................114
10.10.2 Bypass Switch Hookup Options ............................................................................................115
10.11 Mute Sensor Pair ..............................................................................................................................116
10.11.1 The Muting Function .............................................................................................................116
10.11.2 Muting Function Requirements .............................................................................................117
10.11.3 Muting Device Hookup Options ............................................................................................118
10.11.4 Mute Enable (ME) .................................................................................................................119
10.11.5 Mute Lamp Output (ML) ........................................................................................................119
10.11.6 Muting Time Limit (Backdoor Timer) .....................................................................................120
10.11.7 Mute on Power-Up ................................................................................................................120
4 P/N 133487 rev. C
Contents
10.11.8 Corner Mirrors, Optical Safety Systems, and Muting ............................................................120
10.11.9 Multiple Presence-Sensing Safety Devices ..........................................................................120
10.11.10 Mute Timing Sequences .....................................................................................................122
11 Ethernet Reference .........................................................................................................124
11.1 Ethernet Setting Access .....................................................................................................................124
11.2 EtherNet/IP Assembly Objects ...........................................................................................................124
11.3 Support Files ......................................................................................................................................125
11.3.1 Retrieving Current Fault Information .......................................................................................125
11.3.2 Retrieving Fault Log Information .............................................................................................125
11.4 Table Row and Column Descriptions .................................................................................................126
12 Glossary ..........................................................................................................................128
5
SC22-3/-3E Safety Controller Instruction Manual
1 About This Document
1.1 Important . . . Read This Before Proceeding!
It is the responsibility of the machine designer, controls engineer, machine builder and/or maintenance electrician to apply and maintain
this product in full compliance with all applicable regulations and standards. The product can provide the required safeguarding function
only if it is properly installed, properly operated, and properly maintained. This manual attempts to provide complete installation, operational, and maintenance instruction. Reading the manual completely is highly recommended. Please direct any questions regarding the
application or use of the product to the Banner Engineering Applications at the locations listed here.
For more information regarding U.S. and international institutions that provide safeguarding application and safeguarding product performance standards, see the following sections.
WARNING: . . . User Responsibility
The user is responsible to:
• Carefully read, understand and follow the information in all documentation for this product.
• Perform a risk assessment of the specific machine guarding application.
• Determine what safeguarding devices and methods are appropriate per the requirements defined in ISO 13849-1 and
other appropriate standards.
• Create and confirm each configuration and then verify that the entire safeguarding system (including input devices and
output devices) is operational and working as intended.
• Periodically re-verify as needed, that the entire safeguarding system is working as intended.
Failure to follow any of these recommendations can potentially create a dangerous condition that may lead to serious injury or death.
1.1.1 Use of Warnings
Warnings are intended to remind the machine designer, control engineer, machine builder, maintenance electrician, or end user how to
avoid misapplication of this product and effectively apply the Safety Controller to meet the various safeguarding application requirements.
Reading and abiding by the warnings is highly recommended.
1.2 EC Declaration of Conformity (DOC)
Banner Engineering Corp. herewith declares that the SC22-3 Series Safety Controller is in conformity with the provisons of the Machinery Directive (Directive 98/37/EEC) and all essential health and safety requirements have been met. For more information, visit
www.bannerengineering.com/SC22.
6 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
1.3 Standards and Regulations
The list of standards below is included as a convenience for users of this Banner product. Inclusion of the standards below does not imply
that the product complies specifically with any standard, other than those specified in the Specifications section of this manual.
1.3.1 U.S. Application Standards
ANSI B11.0 Safety of Machinery, General Requirements, and Risk
Assessment
ANSI B11.1 Mechanical Power Presses
ANSI B11.2 Hydraulic Power Presses
ANSI B11.3 Power Press Brakes
ANSI B11.4 Shears
ANSI B11.5 Iron Workers
ANSI B11.6 Lathes
ANSI B11.7 Cold Headers and Cold Formers
ANSI B11.8 Drilling, Milling, and Boring
ANSI B11.9 Grinding Machines
ANSI B11.10 Metal Sawing Machines
ANSI B11.11 Gear Cutting Machines
ANSI B11.12 Roll Forming and Roll Bending Machines
ANSI B11.13 Single- and Multiple-Spindle Automatic Bar and
Chucking Machines
ANSI B11.15 Pipe, Tube, and Shape Bending Machines
ANSI B11.16 Metal Powder Compacting Presses
ANSI B11.17 Horizontal Extrusion Presses
ANSI B11.18 Machinery and Machine Systems for the Processing
of Coiled Strip, Sheet, and Plate
ANSI B11.19 Performance Criteria for Safeguarding
ANSI B11.20 Manufacturing Systems
ANSI B11.21 Machine Tools Using Lasers
ANSI B11.22 Numerically Controlled Turning Machines
ANSI B11.23 Machining Centers
ANSI B11.24 Transfer Machines
ANSI/RIA R15.06 Safety Requirements for Industrial Robots and
Robot Systems
ANSI NFPA 79 Electrical Standard for Industrial Machinery
ANSI/PMMI B155.1 Package Machinery and Packaging-Related
Converting Machinery — Safety Requirements
ANSI B11.14 Coil Slitting Machines
1.3.2 OSHA Regulations
OSHA Documents listed are part of: Code of Federal Regulations
Title 29, Parts 1900 to 1910
OSHA 29 CFR 1910.212 General Requirements for (Guarding of)
All Machines
OSHA 29 CFR 1910.147 The Control of Hazardous Energy (lockout/tagout)
OSHA 29 CFR 1910.217 (Guarding of) Mechanical Power Presses
1.3.3 International/European Standards
ISO 12100-1 & -2 (EN 292-1 & -2) Safety of Machinery – Basic
Concepts, General Principles for Design
ISO 13857 Safety Distances . . . Upper and Lower Limbs
ISO 13850 (EN 418) Emergency Stop Devices, Functional Aspects
– Principles for Design
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 7
ISO 14121 (EN 1050) Principles of Risk Assessment
ISO 14119 (EN 1088) Interlocking Devices Associated with Guards
– Principles for Design and Selection
IEC 60204-1 Electrical Equipment of Machines Part 1: General Requirements
SC22-3/-3E Safety Controller Instruction Manual
ISO 13851 (EN 574) Two-Hand Control Devices – Functional Aspects – Principles for Design
ISO 62061 Functional Safety of Safety-Related Electrical, Electronic and Programmable Control Systems
ISO 13849-1 (EN 954-1) Safety-Related Parts of Control Systems
ISO 13855 (EN 999) The Positioning of Protective Equipment in
Respect to Approach Speeds of Parts of the Human Body
IEC 61496 Electro-sensitive Protection Equipment
IEC 60529 Degrees of Protection Provided by Enclosures
IEC 60947-1 Low Voltage Switchgear – General Rules
IEC 60947-5-1 Low Voltage Switchgear – Electromechanical Control Circuit Devices
IEC 60947-5-5 Low Voltage Switchgear – Electrical Emergency
Stop Device with Mechanical Latching Function
1.3.4 Sources of Standards and Regulations
These and other standards are available from:
OSHA Documents: http://www.osha.gov (Tel: 202.512.1800)
American National Standards Institute (ANSI): http://www.ansi.org (Tel: 212.642.4900)
Robotics Industries Association (RIA): http://www.robotics.org (Tel: 734.994.6088)
National Fire Protection Association (NFPA): http://www.nfpa.org (Tel: 800.344.3555)
NSSN National Resource for Global Standards : http://www.nssn.org/ (Tel: 212.642.4980)
IHS Standards Store: http://www.global.ihs.com/ (Tel: 303.397.7956, 800.854.7179)
Document Center: http://www.document-center.com/home.cfm (Tel: 650.591.7600)
1.4 Contact Us
For more information: Contact your local Banner representative or Banner Corporate Offices around the world.
Corporate Headquarters: Banner Engineering Corp. 9714 Tenth Ave. North, Mpls., MN 55441, Tel: 763-544-3164, www.bannerengin-
eering.com, sensors@bannerengineering.com
Europe: Banner Engineering Europe Park Lane, Culliganlaan 2F, Diegem B-1831 BELGIUM,Tel: 32-2 456 07 80, Fax: 32-2 456 07 89,
www.bannereurope.com, mail@bannereurope.com
Latin America: Contact Banner Engineering Corp. (US) or e-mail Mexico: mexico@bannerengineering.com; or Brazil: brasil@banner-
engineering.com
Asia:
Banner Engineering China Shanghai Rep Office Rm. G/H/I, 28th Flr. Cross Region Plaza No. 899, Lingling Road, Shanghai 200030
CHINA, Tel: 86-21-54894500, Fax: 86-21-54894511, www.bannerengineering.com.cn, sensors@bannerengineering.com.cn
Banner Engineering Japan Cent-Urban Building 305 3-23-15, Nishi-Nakajima Yodogawa-Ku, Osaka 532-0011 JAPAN, Tel:
81-6-6309-0411, Fax: 81-6-6309-0416, www.bannerengineering.co.jp, mail@bannerengineering.co.jp
Banner Engineering Asia ─ Taiwan Neihu Technology Park 5F-1, No. 51, Lane 35, Jihu Rd., Taipei 114 TAIWAN, Tel:
886-2-8751-9966, Fax: 886-2-8751-2966, www.bannerengineering.com.tw, info@bannerengineering.com.tw
Banner Engineering India Pune Head Quarters Office, No. 1001 Sai Capital, Opp. ICC Senapati Bapat Road, Pune 411016 INDIA, Tel:
91-20-66405624, Fax: 91-20-66405623, www.bannerengineering.co.in, india@bannerengineering.com
8 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
2 Overview
NOTE: This section of this document provides a high-level discussion of the Banner models SC22-3 / SC22-3E Safety Controller, to
acquaint the user with the Controller's capabilities and features. For in-depth information about installation, wiring, and use of the
product, refer to later sections.
The Banner models SC22-3 / SC22-3E Safety Controller (the Safety Controller or the Controller) are easy-to-use, configurable, 24V dc
safety modules designed to monitor multiple safety and non-safety input devices and control up to three independent machine primary
control elements (MPCEs). They provide safety stop and start functions for machines with hazardous motion. The Safety Controller can
replace multiple safety relay modules in applications that include such safety input devices as E-stop buttons, gate interlocking switches,
safety light curtains, and other safeguarding devices. It also can be used in place of safety PLCs and other safety logic devices when
they are excessive for the application.
Configurations are created using an Onboard LCD and push-button interface, or using a PC connected to the Safety Controller via a USB
port.
2.1 Ethernet-Compatible Model
The model SC22-3E provides the same features of the SC22-3, and in addition provides the ability to interface to Ethernet (for example
to a PLC or HMI human interface touch panel), using Modbus/TCP or EtherNet/IP™ protocols.
Modbus/TCP is an open standard protocol developed by the Modbus IDA. It is similar to Modbus RTU, except that it uses standard
Internet communication protocols, just like Web communications or email. The master is referred to as the “client,” and the slave is the
“server.” (The SC22-3E is a “server.”) Modbus/TCP follows the same structure as Modbus RTU: clients initiate all communication, servers
can only respond.
EtherNet/IP (EtherNet Industrial Protocol) is an open standard protocol developed by Allen-Bradley, but managed by the ODVA. EtherNet/IP is an adaptation of the DeviceNet serial fieldbus protocol, using Internet communications protocols. EtherNet/IP is DeviceNet over
Ethernet. Compatible devices supported are:
• EtherNet/IP connection (using the CIP protocol) to the Allen-Bradley ControlLogix family of PLCs. Both implicit and explicit messaging
is supported.
• EtherNet/IP connection (using the PCCC protocol) to the Allen-Bradley SLC and PLC5 families of PLCs.
• Modbus/TCP connection to any compatible PLCs, HMIs, or devices.
P/N 133487 rev. C
www.bannerengineering.com - tel: 763-544-3164 9
SC22-3/-3E Safety Controller Instruction Manual
2.2 Applications
The Safety Controller can be used wherever safety modules are
used. The Safety Controller is well suited to address many types of
applications, including, but not limited to:
• Two-hand control with mute function
• Robot weld/processing cells with dual-zone muting
• Material-handling operations that require multiple inputs and bypass functions
• Manually loaded rotary loading stations
• Multiple two-hand-control station applications
• Lean manufacturing stations
• Dynamic monitoring of single- or dual-solenoid valves or press
safety valves
Figure 1. A palletizing application with multiple safeguarding controlled by the Safety Controller
2.3 Design and Testing
The Safety Controller was designed for up to Category 4 PL e (ISO 13849-1) and Safety Integrity Level 3 (IEC 61508 and IEC 62061)
safeguarding applications. It has been extensively tested to ensure that it meets the UL, IEC, and ISO product performance requirements
for both safety functionality and operational reliability. This self-checking Controller incorporates:
• Redundant microcontrollers,
• Redundant input signal detection circuitry, and
• Redundant Safety Output control circuitry.
The safety circuit performance (e.g., categories) of a specific safety or safeguarding device(s) will be determined primarily by the devices
used and their interconnection to the Safety Controller.
See section 10 Input Device and Safety Category Reference on page 90 for specific information about integrating devices with the
Controller.
2.4 Components
The Safety Controller Starter Kit includes:
• 1 Safety Controller (model SC22-3 or SC22-3E)
• 1 set of removable terminals (choose screw or clamp type)
• 1 SC-XM1 external memory (XM) card
• 1 USB A/B cable (Ethernet models)
• 1 SC-XMP XM card programming tool (some models)
• 1 CD containing PCI software, instruction manual, and configuration tutorials (p/n 134534)
• 1 Quick Start Guide
Ethernet connection cables (for model SC22-3E) are user-supplied.
2.4.1 PC System Requirements
Operating system: Microsoft Windows® XP, Windows 2000, Vista®, Windows 7
10 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
Hard drive space: 100 MB (plus up to 280 MB for Microsoft .NET 2.0, if not already installed)
Third-party software: Microsoft .NET 2.0, included and installed with PCI, if not already on computer Adobe® Reader® for Windows
version 7.0 or newer
USB port: USB 1.1 or 2.0 type A port
2.4.2 USB Connections
The Safety Controller is connected to a PC by way of a USB A/B cable. The cable is also used to connect the PC to the SC-XMP
programming tool, in order to download a configuration to the XM card.
Figure 2. USB connections: PC to SC-XMP programming tool
connection
Figure 3. USB connections: PC to Safety Controller USB port
connection
2.4.3 Ethernet Connections
Ethernet connections are made using an ethernet cable
from the SC22-3E Ethernet port to a network switch or the
user’s control device. The SC22-3E supports use of either
standard or crossover-style cables. Shielded cable may be
needed in high-noise environments.
Figure 4. Safety Controller external memory card (XM card) and
Ethernet (some models) connections
Legend
1 USB port
2 XM card port
3 Ethernet port
2.4.4 SC-XMP Programming Tool
The programming tool is a handy device that can be used to transfer a configuration from a PC (running the PCI software) to an XM card
or from an XM card to the PC, without requiring a Safety Controller. It connects to the PC via the USB A/B cable and the PC’s USB port.
2.4.5 SC-XM1 External Memory (XM) Card
The model SC-XM1 external memory (XM) card is a removable memory module that can store or be used to transfer a single configuration. The XM card has a write-on label on its reverse side where a configuration name or a machine identification can be noted.
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 11
The XM card can be used to:
• Keep a backup copy of the Safety Controller’s configuration (to minimize downtime in the case of a hardware failure that may require
a Controller replacement).
• Transfer configurations from one Safety Controller to another Safety Controller.
• Send (download) identical configurations into multiple Safety Controllers.
• Transfer configurations between the Safety Controller and a personal computer.
Store a configuration on the XM card in one of two ways:
• Send a copy to the XM card using the PC Interface (PCI) and the SC-XMP programming tool.
• Send a copy from the Controller to the XM card, using the Onboard Interface (OBI).
NOTES:
1. A configuration can be stored permanently in an XM card, if the “lock” function is performed. However, once the card is locked, it
cannot be unlocked (it becomes "read-only").
2. Configurations on an XM card do NOT contain any network settings. The PCI software must be used to change network settings.
SC22-3/-3E Safety Controller Instruction Manual
2.5 Configuring the Safety Controller
Building a configuration for the Safety Controller is a simple process, using one of two interfaces: the push buttons and display on the
Controller itself (the Onboard Interface, or OBI) or the PCI software program included on the enclosed CD (p/n 134534). The process
comprises three main steps:
1. Define the safeguarding application (risk assessment).
• Determine the required devices.
• Determine the required level of safety.
2. Build the configuration.
• Select safety input device types and circuit connections.
• Map each input to one or more Safety Outputs, or to other input devices.
• Set optional Safety Output ON- or OFF-time delays.
• Select non-safety input device types and circuit connections, if needed.
• Assign Status Output signals, if needed.
• Create configuration name, file name, date, and author name.
3. Confirm the configuration.
• Controller verifies that the desired configuration is valid.
• User confirms that the configuration is what is expected.
2.5.1 Onboard Interface (OBI)
The Safety Controller can be configured using its built-in push buttons and LCD screen, the Onboard Interface (OBI). The LCD display
provides I/O device and system status information for any event that causes one or more of the Safety Outputs to turn OFF. The display
is used in conjunction with the six push buttons to:
• Create or modify password-protected configurations,
• Retrieve fault log information,
• Review device wiring detail and I/O logic relationships,
• Display I/O device fault details and likely remedial steps, and
• Display configuration checksum.
NOTES:
1. Onboard Interface functions are covered in more detail in Section 5 and the OBI tutorial, located separately on the disk.
2. The OBI cannot be used to change network settings; the PCI must be used for that function.
12 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
Legend:
1. Moves cursor to the left or selects settings.
2. Moves cursor to the pre-established point in the program to re-establish
a menu reference point.
3. Enters/stores the item highlighted in the display as the intended selection
or toggles a setting.
4. Moves cursor to the right or selects settings.
5. Moves cursor down or moves through a list to display individual list
items. Also used to select settings.
6. Moves cursor up or moves through a list to display individual list items.
Also used to select settings.
7. Ethernet connector indicators (Yellow and Green; Ethernet models only)
8. Status indicators
9. LCD display
Figure 5. Onboard Interface, including push buttons, LCD display and status indicators (model SC22-3E shown)
Status Indicator Condition Indicates Controller Status
All Indicators OFF — Initiation Mode
Power
Status (Controller Mode)
USB or Tx/Rx (depending on model)
Safety Output SO1, SO2, SO3
Ethernet Connector (model SC22-3E
only)
ON Green Power ON
OFF Power OFF
ON Red Configuration mode
Flashing Red Lockout mode
OFF Run mode
Flashing Green
Transmitting or receiving data (a link is established with the PC)
OFF Not transmitting or receiving data
ON Green Safety Output ON
ON Red Safety Output OFF
Flashing Red Safety Output fault detected
Flashing Green Safety Output waiting for reset
Yellow OFF No link
Yellow ON Link OK
Green OFF No activity
Green ON or flashing Activity detected
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 13
SC22-3/-3E Safety Controller Instruction Manual
Accessing Fault Codes
Fault codes are displayed in the last line of the OBI fault diagnostics
menu (see example at right). Refer to OBI Configuration and Troubleshooting sections for more information.
2.5.2 Personal Computer Interface (PCI)
The Safety Controller can also be configured using a Windows®-based computer and the Safety Controller PC Interface (PCI) program.
This user-friendly interface makes use of icons and circuit symbols to simplify the selection of device properties during configuration. The
configuration wiring and ladder logic diagrams develop automatically as the configuration progresses.
Creating a configuration is simple. Once a configuration is created, it::
• Can be stored to a computer file for archiving and future use, or
• Can be emailed to a remote location as an attachment, or
• Can be sent directly to another Safety Controller or to the plug-in external memory card.
The PCI can be used to create a configuration, save it and send it as described above, and also monitor the function of a Controller using
the live display, as well as monitor the fault log for troubleshooting purposes.
To access the Ethernet functionality of the model SC22-3E, click on the Network Settings icon and check the Enable Network Interface
box. The Virtual Status Outputs will appear on the I/O Properties menu, as will additional tabs above the document section of the screen,
as shown in the following figure.
Legend:
1. Toolbar
2. Network settings
3. I/O properties
4. Document (in this case, Wiring Diagram)
5. Virtual Status Outputs (These outputs become
visible after the Enable Network Interface box is
checked under the Network Settings tab.)
6. New tab selections also become visible.
Figure 6. PC User Interface (PCI) main screens
• PC Interface functions are covered in more detail in section 5.1 PC Interface (PCI) Overview on page 53 and in the PCI tutorial.
• PC Interface network functions are covered in more detail in sections 4.9 Virtual Status Outputs on page 52 and 11 Ethernet Refer-
ence on page 124.
14 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
PCI Software Compatibility
To identify the version of your PCI software (i.e., PC Interface), click on the "Help" tab located on the top tool bar and then click on
"Compatibility Information." The information contained in the pop-up window identifies what PCI software version is running and lists
when a feature was added or changed.
Newer PCI versions are backwards compatible with earlier SC22 firmware versions, although features must be supported by the SC22
firmware version or the feature will be unavailable. If an unsupported feature is attempted to be downloaded, an error message will be
displayed. The SC22 firmware version can be identified via the Onboard Interface (OBI) "Model #" menu item; see section 7.3 Display
Controller Information — Onboard Interface (OBI) on page 71. This screen identifies the Safety Controller model, the firmware versions
of microprocessors A and B, and the hardware version. Contact a Banner Applications Engineer with any questions.
2.6 Input and Output Connections
2.6.1 Safety and Non-Safety Input Devices
The Safety Controller has 22 input terminals that can be used to monitor either safety or non-safety devices; these devices may incorporate either solid-state or contact-based outputs. Each of these 22 input terminals can either monitor an input signal or provide 24V dc.
The function of each input circuit depends on the type of device connected to it; this function is established when the Controller is configured.
For general and specific information about input devices, their requirements, hookup options and appropriate warnings and cautions,
additional installation information (e.g., Safety Distance), refer to the sections 4 System Installation on page 26 and 10 Input Device and
Safety Category Reference on page 90, which contains hookup information and other useful information about integrating the following
devices:
• Safety Circuit Integrity
• Protective (Safety) Stop
• Optical Sensors
• Safety Gate (Interlock Guard)
• Two-Hand Control
• Safety Mat (Edges)
• Emergency Stop Push Buttons
• Rope (Cable) Pull
• Enabling Devices (Pendants)
• Bypass
• Muting
For further information about connecting any devices to the Safety Controller, contact Banner Engineering.
Safety Device Hookup Considerations
The Safety Controller inputs can be configured to interface with many types of safety devices, including safeguarding devices (e.g., safety
light curtains), complementary protective equipment (e.g., emergency stop push buttons), and other devices that impact the safe use of a
machine (e.g., equipment protection).
The way these devices interconnect impacts their ability to exclude or detect faults that could result in the loss of the safety function.
There are many standards, regulations and specifications that require certain capabilities of a safety circuit.
WARNING: . . . User Responsibility
The user is responsible for ensuring that all local, state, and national laws, rules, codes, and regulations relating to
the use of this product in any particular application are satisfied. Extreme care is urged that all legal requirements have
been met and that all installation, operation, and maintenance instructions contained in the product documentation are followed.
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 15
SC22-3/-3E Safety Controller Instruction Manual
2.6.2 Safety Outputs
The Safety Outputs are designed to control final switching devices (FSDs) and machine primary control elements (MPCEs) that are the
last in the control chain to control the dangerous motion. These control elements include relays, contactors, solenoid valves, motor controls and other devices that incorporate force-guided (mechanically-linked) monitoring contacts, or control-reliable signals needed for external device monitoring.
The Safety Controller has three independently controlled and redundant solid-state Safety Outputs. The Controller’s self-checking algorithm ensures that the outputs turn ON and OFF at the appropriate times, in response to the assigned input signals and the system’s selfchecking test signals.
The Safety Outputs, SO1, SO2 and SO3, can be controlled by input devices with both automatic and manual reset operation.
Legend:
1. Safety Controller
2. OFF-Delay
3. Solenoid locking switch
4. Robot
5. Contactors
Figure 7. Safety Outputs
See section 4.7.2 Safety Outputs on page 41 for more information about configuring Safety Outputs.
Functional Stops per IEC 60204-1 and ANSI NFPA79
The Controller is capable of performing the two functional stop types:
• Category 0: an uncontrolled stop with the immediate removal of power from the guarded machine
• Category 1: a controlled stop with a delay before power is removed from the guarded machine
Delayed stops can be used in applications where, for example, machines need power for a braking mechanism to stop the hazardous
motion.
ON-Delays and OFF-Delays
Each Safety Output can be configured to function with a time delay. There are two types of time delays: ON-delay and OFF-delay, where
the outputs turn ON or OFF only after the time limit has elapsed. The ON and OFF time delay limit options are from 100 milliseconds to 5
minutes, in 100 millisecond increments.
Safety Output ON-delays are sometimes used when a machine operation must be delayed before a safe machine startup is permitted. An
example application would be a robot weld cell.
WARNING: . . . Turning a Delayed Output ON/OFF
If an input that is mapped to both an immediate Safety Output and a delayed Safety Output opens and then closes
before the delay time of the delayed output has expired, the immediate Safety Output will turn OFF and remain OFF
while the delay time is running.
At the end of the delay time, the delayed output will also turn OFF. Both outputs will then remain OFF for about 500 ms,
before they will turn back ON. This will happen either automatically, if configured for auto reset, or after a valid manual reset
signal, if configured for manual reset.
16 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
2.6.3 Status Outputs
The Safety Controller has 10 configurable Status Outputs, used to send non-safety status signals to programmable logic controllers
(PLCs) or to human machine interfaces (HMIs), or they may be used to power indicator lights. These outputs can be configured to report
on the status of input devices, Safety Outputs, or the Controller itself. See section 4.8.1 Status Output Signal Conventions on page 50
for more information.
Signal Convention
The Status Output signal convention can be configured to be 24V dc or 0V dc to indicate:
• When an input is in the Run state,
• When a Safety Output is in the ON state (see Note 1),
• When a Safety Output is in a logical ON state (ON or in an ON-delay; see Note 1),
• When the system is in a Lockout condition,
• When an I/O fault is present (see Note 2),
• When a system reset is needed,
• When a Safety Output needs a reset (see Note 3),
• When a Safety Input is muted,
• Which Safety Input, of a defined group of Safety Inputs, turned OFF first,
• When a Safety Input is bypassed,
• When a Safety Input has a Fault condition, or
• When a Safety Output's OFF-delay can be cancelled.
NOTES:
1. Only Safety Outputs that have inputs mapped to them can be mapped to a Status Output.
2. An I/O fault is a failure of one or more Safety Inputs, Safety Outputs, or Status Outputs.
3. Only Safety Outputs mapped to inputs configured with manual reset logic can have a Status Output configured to indicate a reset is
needed.
WARNING: . . . Status Outputs
The Status Outputs are not Safety Outputs and can fail in either the ON or OFF state. They must never be used to control
any safety-critical applications. If a Status Output is used to control a safety-critical application, a failure to danger
is possible and could lead to serious injury or death.
Monitored Mute Lamp Outputs
Status Outputs O9 and O10 can be configured to create a monitored mute lamp function for a mute operation. When the mute lamp is
ON, the Controller monitors for a short circuit in the load. When the lamp is OFF, it monitors for an open circuit in the load. If an open
circuit occurs before the start of a mute cycle, the next mute cycle will be prevented. If an open circuit occurs during a mute cycle, that
mute cycle will finish, but the next mute cycle will be prevented. If a short occurs before or during a mute, that mute cycle will start and
finish, but the next mute cycle will be prevented. If not used to monitor a mute lamp, these outputs may be used in the same ways as
outputs O1–O8.
IMPORTANT: Only terminals O9 and O10 have the extra monitoring circuitry needed for a monitored mute lamp. If monitoring of
the mute lamp is not required (depending on applicable standards), any of the Status Outputs (O1–O10) may be used to indicate a mute
condition. Because of this feature, these Status Outputs will always appear ON with no load (see Specifications on page 23).
2.6.4 Virtual Status Outputs
Using the PCI, the model SC22-3E (only) can configure up to 32 Virtual Status Outputs. These outputs can communicate the same
information as the Status Outputs, but over a network.
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 17
SC22-3/-3E Safety Controller Instruction Manual
WARNING: . . . Virtual Status Outputs
The Virtual Status Outputs are not Safety Outputs and can fail in either the ON or the OFF state. They must never be used
to control any safety-critical applications. If a Virtual Status Output is used to control a safety-critical application, a
failure to danger is possible and could lead to serious injury or death.
2.6.5 I/O Mapping: the I/O Control Relationship
The term “map” implies a control logic relationship between an input and an output or between an input and another input, where the
state of the first input determines the state of the output or of the second input.
Inputs Mapped to Outputs. The following devices can be mapped directly
to the Safety Outputs:
• Emergency stop buttons
• Safety gate switches
• Optical sensors
• Two-hand control devices
• Safety mats
• Protective stop switches
• Rope pulls
Inputs Mapped to Inputs. Muting sensors and bypass switches work in conjunction with certain safety input devices to temporarily suspend the Stop signal of a safety input device. These sensors and switches are mapped directly to the safety inputs; they are then indirectly mapped to the Safety Output(s) that the muted safety inputs control (see section 4.6.4 Mute Function on page 37).
• Enabling devices
• External device monitoring
• ON/OFF devices
• Manual reset devices
• Solenoid or press safety valves
• Cancel OFF-delay devices
Figure 8. Input and Output mapping
2.7 System Settings
The Controller’s system settings define parameters for both the configuration file and the Controller. These settings include:
• Configuration name
• Author’s name
• Power-up mode
• Mute on power-up enable
• Monitored system reset
Configuration Name
The configuration name identifies the configuration that will be used in a Safety Controller application. The configuration name can be
displayed on the Controller and will be useful to be sure that the configuration in a Controller is the correct one.
Author’s Name
The author’s name may also be helpful when questions arise about configuration settings.
Power-Up Mode (Operational Characteristics When Power Is Applied)
The Controller provides three power-up mode types to choose from, to determine how the Controller will behave just after power is supplied. These modes are: Normal, Automatic, and Manual.
• Normal Power-Up Mode (default). In normal power-up mode, after power is applied:
• Only those Safety Outputs that have automatic reset inputs will turn ON.
• Safety Outputs that have one or more manual reset inputs will turn ON only after a manual (latch) reset operation is performed.
• Exception: Two-hand control inputs, bypass inputs, and enabling device inputs must be seen to be in the Stop state at power-up,
regardless of the power-up mode selection. If these are seen to be in the Run state at power-up, the outputs will remain OFF.
• Automatic Power-Up Mode. In automatic power-up mode, after power is applied:
18 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
• All Safety Outputs will turn ON immediately if the inputs that are mapped to these outputs are all in the Run state.
• Exception: Two-hand control inputs, bypass inputs, and enabling device inputs must be seen to be in the Stop state at power-up,
regardless of the power-up mode selection. If these are seen to be in the Run state at power-up, the outputs will remain OFF.
• Manual Power-up Mode. In Manual Power-up Mode, after power is applied:
• Safety Outputs will turn ON only after all inputs mapped to this output are in the Run state and a System Reset has been performed. (A manual latch reset is not required.)
• Exception: Two-hand control inputs, bypass inputs, and enabling device inputs must be seen to be in the Stop state at power-up,
regardless of the power-up mode selection. If these are seen to be in the Run state at power up, the outputs will remain OFF.
WARNING: . . . Automatic Power-Up
When the Controller is configured for automatic system reset power-up mode, the Controller acts as if all input devices are
configured for auto (trip) reset. Each Safety Output will immediately turn on at power-up if the assigned input devices
are all in the Run state, even if one or more of the input devices is configured for manual (latch) reset. If the application requires that a manual (latch) reset operation be performed before the Safety Output turns ON, then either manual or
normal power-up mode configuration must be used. Failure to do so could cause a machine to operate in an unexpected
way at power-up or after temporary power interruptions.
WARNING: . . . Controller Operation on Power-Up
It is the responsibility of the user of the Controller to assess what safeguarding devices and methods are appropriate for
any given machine or application. The Qualified Person who configures, installs, and/or maintains it must be aware of
the power-up behavior of the Controller and instruct the machine operator on the operation of the Controller and its
associated devices.
Mute On Power-Up Enable
If configured, the Mute on Power-Up function will initiate a mute cycle after power is applied to the Safety Controller if the muted safety
inputs are active (Run state or closed), and either M1-M2 or M3-M4 (but not all four) are signaling a muted condition (e.g., active or
closed).
• For more information on the Mute On Power-Up function, see section 4.6.4 Mute Function on page 37.
Monitored System Reset
Monitored System Reset is enabled by default and requires an OFF-ON-OFF signal at the reset input, where the ON-duration must be
between 0.3 and 2 seconds (trailing edge reset), in order to reset the system.
If unchecked (Monitored System Reset disabled), the reset input requires only a signal from OFF to ON (leading edge reset), in order to
reset the system.
2.8 Internal Logic
The Controller’s internal logic is designed so that a Safety Output can turn ON only if all the controlling input device signals are in the Run
state and the Controller’s self-check signals are in the No-Fault state.
Safety Input 1 Safety Input 2 Safety Controller Safety Output 1
Stop Stop Run (No Fault) OFF
Stop Run Run (No Fault) OFF
Run Stop Run (No Fault) OFF
Run Run Run (No Fault) ON
The table above illustrates the logic for two safety input devices mapped to control Safety Output 1. If any of the safety input devices are
in the Stop state, then Safety Output 1 is OFF. When both safety inputs are in the Run state, then Safety Output 1 will turn ON.
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 19
SC22-3/-3E Safety Controller Instruction Manual
2.8.1 Additional Logic Functions
Other logic functions are slight variations of the general AND logic rule set.
• Two-Hand Control: The machine initiation signal incorporating a 0.5 second actuator simultaneity limit and anti-tie-down logic, designed to prevent single-actuator machine cycle operation.
• Safety Device Muting: The automatic suspension of one or more safety input Stop signals during a portion of a machine operation
when no hazard is present or when access to the hazard is otherwise safeguarded.
• Safety Device Bypass: The manually activated, temporary suspension of one or more safety input Stop signals when the hazard is
otherwise safeguarded.
• Enabling Device Control: The actively controlled manual suspension of a Stop signal during a portion of a machine operation when
a hazard could occur.
• Cancel OFF-Delay: The option to cancel a configured OFF-delay time by either keeping the Safety Output ON, or turning it OFF
immediately.
The rules that apply to these special cases are explained in section 10 Input Device and Safety Category Reference on page 90.
2.9 Password Overview
To provide security, the Safety Controller requires use of a password in some cases. For information about changing a Controller’s password, refer to sections 5.1.4.6 Changing the Password Using the Personal Computer Interface (PCI) on page 61 and 6.3.4 System
Options on page 66. If the password becomes lost, contact the Factory for assistance.
Creating a Configuration
• Via computer using the Safety Controller PC Interface (PCI) program (no password needed)
• Via the Controller Onboard Interface (OBI) (password needed)
Confirming a Configuration
• Via the PCI, using the PC connected to a powered Controller (password needed)
• Via the OBI, on a powered Controller (password needed)
Sending a Confirmed Configuration to the Controller
• Via a direct connection between the PC and the Controller, using the SC-USB1 cable and the PC Interface program (password needed)
• Via the PC, the XM card programming tool, and the XM card (password needed)
2.10 Confirming a Configuration
Although a Controller will accept an unconfirmed configuration, it will only activate it (adopt the configuration and function according to its
parameters) after the configuration is confirmed, using the OBI or PCI.
IMPORTANT: If any modification is made to a confirmed configuration, or if a configuration is edited during the confirmation
process, the PCI and the Controller will recognize this modified configuration as being new and will require it to be confirmed
before it can be activated and used.
Once confirmed, a configuration can be stored and reused without reconfirmation. The configuration code will be validated automatically
each time it is downloaded to a Controller and whenever the Controller powers up. Configurations, confirmed or not, can be sent via
email. Sending (downloading) a new confirmed configuration to a Controller requires entry of the Controller password.
20 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
3 Components and Specifications
To order the Safety Controller ready for use, order it as part of a kit
(see following table). It also can be ordered alone, without terminals,
as a replacement part.
Kits include the Safety Controller, model SC22-3 or SC22-3E, a set of
plug-on terminal blocks (screw or cage-clamp type, depending on
model), a USB A/B cable (for direct connection between a PC and the
Safety Controller, included with some kits), external non-volatile memory card (XM card, with write-on label on reverse side), XM card programming tool (included with some models), a user CD (includes software interface, online manual, ethernet references and configuration
tutorials), and quick start guide.
3.1 Safety Controller Starter Kit Models
Kit Model
SC22-3-S Screw
SC22-3-C Clamp
SC22-3-SU1 Screw
SC22-3-CU1 Clamp
SC22-3E-S Screw
SC22-3E-C Clamp
SC22-3E-SU1 Screw
SC22-3E-CU1 Clamp
Terminal
Type
Safety
Outputs
6 PNP
Terminals
(3 pairs)
Status
Outputs
10 Status
10 Status
plus
32 Virtual
Status
Safety Out-
put Rating
0.75 amps
each output
0.5 amps
each output
3.2 Replacement Parts/Accessories
Model Description
SC22-3 Replacement Controller (no terminals)
SC22-3E Replacement Controller (no terminals), Ethernet compatible
SC-XM1 External memory card (XM card)
USB A/B
Cable
─
1.8 m Yes
─ ─
1.8 m Yes
XM
Card
Yes
XM Card Pro-
gramming Tool
Communication
Protocol
─
─
EtherNet/IP &
Modbus/TCP
SC-XM1-5 Bulk pack of 5 XM cards
SC-XMP USB programming tool for XM card
SC-TS1 Screw terminal replacement set
SC-TC1 Cage clamp terminal replacement set
SC-USB1 USB A/B cable, 1.8 m
134534 CD including PCI program and instruction manual
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 21
SC22-3/-3E Safety Controller Instruction Manual
3.3 Ethernet Cordsets
Shielded Models Cat5e Crossover Models Length
STP07 STPX07 2.1 m
STP25 STPX25 7.6 m
STP50 STPX50 15.5 m
STP75 STPX75 23 m
3.4 Interface Modules
SC-IM9 series interface modules are for use only with the Safety Controller; dry contacts for use with higher ac/dc voltage and current.
With 10A output, DIN-mount housing, removable (plug-in) terminal blocks for OSSD outputs (screw terminal block supplied). Measures
approx. 72 mm H, 170 mm D, and 45 mm , 90 mm, or 140 mm W, (2.8" H, 6.7" D, and 1.8", 3.5", or 5.5" W) depending on model. See
datasheet p/n 131845 for more information.
NOTE: External device monitoring (EDM) is required to be wired separately to the N.C. contacts to comply with ISO 13849-1
categories and ANSI/OSHA control reliability; see section 4.7.1 External Device Monitoring (EDM) on page 40.
Model Description
SC-IM9A
SC-IM9B
SC-IM9C
IM-T-9 series interface modules have 6A output, 22.5 mm DIN-mount housing, removable (plug-in) terminal blocks. Low current rating of
1V ac/dc @ 5 mA, high current rating of 250V ac/dc @ 6A. See datasheet p/n 62822 for more information.
NOTE: External device monitoring (EDM) is required to be wired separately to the N.C. contacts to comply with ISO 13849-1
categories and ANSI/OSHA control reliability; see section 4.7.1 External Device Monitoring (EDM) on page 40.
Model Supply Voltage Inputs Safety Outputs Output Rating EDM Contacts Aux. Outputs
IM-T-9A
IM-T-11A 2 N.O. 1 N.C.
For use with 1 Safety
Controller Safety Output
For use with 2 Safety
Controller Safety Outputs
For use with 3 Safety
Controller Safety Outputs
24V dc
Supply
Voltage
24V dc
(Controller
supplied)
2 (dual-channel
hookup)
Inputs (Safety
Controller Outputs)
2
(SO1)
4
(SO1 and SO2)
6
(SO1, SO2, and SO3)
3 N.O.
Safety Outputs
3 N.O.
Total of 6
(3 N.O. per output)
Total of 9
(3 N.O. per output)
6 amps 2 N.C.
Output
Rating
10 amps
EDM Con-
tacts
1 N.C. pair per
output
—
3.4.1 Mechanically Linked Contactors
Provides an additional 10 or 16 amp carrying capability to any safety system. If used, two contactors per Safety Output pair (e.g., 2 x
SO1), are required. The N.C. contacts are to be used in an external device monitoring (EDM) circuit.
NOTE: External device monitoring (EDM) is required to be wired separately to the N.C. contacts to comply with ISO 13849-1
categories and ANSI/OSHA control reliability; see section 4.7.1 External Device Monitoring (EDM) on page 40.
22 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
Model Supply Voltage Inputs Outputs Output Rating
11-BG00-31-D024
24V dc 2 (dual-channel hookup) 3 N.O. and 1 N.C.
11-BF18C01-024 18 amps
10 amps
3.5 Specifications
Power
24V dc, ± 20%
Model SC22-3: 0.4 A (Controller only), 5.9 A (all outputs ON @ full rated load)
Model SC22-3E: 0.4 A (Controller only), 4.9 A (all outputs ON @ full rated load)
The Controller should be connected only to a SELV (safety extra-low voltage, for circuits without earth ground) or a
PELV (protected extra-low voltage, for circuits with earth ground) power supply.
Safety and Non-Safety Inputs (22 terminals)
Input ON threshold: > 15V dc (guaranteed on), 30V dc max.
Input OFF threshold: < 5V dc (guaranteed off with any 1 fault), –3V dc min.
Input ON current: 8 mA typical @ 24Vdc, > 2 mA (guaranteed with 1 fault)
50 mA peak contact cleaning current @ 24V dc
Sourcing current: 30 mA minimum continuous (3V dc max. drop)
Input lead resistance: 300 Ω max. (150 Ω per lead)
Input requirements for a 4-wire safety mat:
• Max. capacity between plates: 0.5 µF
• Max. capacity between bottom plate and ground: 0.5 µF
• Max. resistance between the 2 input terminals of one plate: 20 Ω
Safety Outputs (6 terminals, 3 redundant outputs)
Rated output current:
Model SC22-3: 0.75 A max. @ 24V dc (1.0V dc max. drop)
Model SC22-3E: 0.5 A max. @ 24V dc (1.0V dc max. drop)
Output OFF threshold: 0.6V dc typical (1.2V dc max. guaranteed with 1 fault)
Output leakage current: 50 µA max. with open 0V
Load: 0.1 µF max., 1 H max., 10 Ω max. per lead
Status Outputs (10 terminals)
Rated output current: 0.5A @ 24V dc (individual), 1.0 A @ 24V dc (total of all outputs)
O1 to O8 (General Purpose)—Output OFF voltage: < 0.5V dc (no load), 22 KΩ pull down to 0V
O9 and O10 (General Purpose or Monitored Mute Lamp)—
Output OFF voltage: Internal 94 KΩ pull up to 24V dc supply
Output ON/OFF threshold: 15V dc +/−4V dc @ 24V dc supply
NOTE: For O9 and O10 (when configured as a monitored mute lamp output), if a short circuit or other fault condition causes the output to drop below this threshold while the output is ON, a lockout will occur. If an open circuit or
other fault condition causes the output to rise above this threshold while the output is OFF, a lockout will occur.
Response and Recovery Times
Response Time (ON to OFF): 10 ms max. (with standard 6 ms debounce; this can increase if debounce time increases.
Refer to the configuration summary for actual response time.)
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 23
SC22-3/-3E Safety Controller Instruction Manual
Recovery Time (OFF to ON): 400 ms max. (with manual reset option)
Recovery Time (OFF to ON): 400 ms max. plus input debounce time (auto reset)
Onboard LCD Information Display—Password Requirements
Password is not required:
Run mode (I/O status)
Fault (I/O fault detection and remedial steps)
Review configuration parameters (I/O properties and terminals)
Password is required:
Configuration mode (create/modify/confirm/download configurations)
Environmental Rating
NEMA 1 (IEC IP20), for use inside NEMA 3 (IEC IP54) or better enclosure
Operating Conditions
Temperature range: 0° to +55° C (+32° to 131° F)
Mechanical Stress
Shock: 15g for 11 milliseconds, half sine, 18 shocks total (per IEC 61131-2)
Bump: 10g for 16 milliseconds, 6000 cycles total (per IEC 61496-1)
Vibration: 3.5 mm occasional / 1.75 mm continuous @ 5Hz to 9Hz, 1.0g occasional and 0.5g continuous @ 9Hz to 150Hz:
(per IEC 61131-2) and 0.35 mm single amplitude / 0.70 mm peak-to-peak @ 10 to 55Hz (per IEC 61496-1), all @ 10 sweep
cycles per axis
EMC
Meets or exceeds all EMC requirements in IEC 61131-2, IEC 61496-1 (Type 4), and IEC 62061 Annex E, Table E.1 (increased immunity levels)
Removable Terminals
Screw terminals
Wire sizes: 16, 18, 20, 22 or 24 AWG (0.20 – 1.31 mm²)
Wire strip length: 5.00 mm (0.197")
Tightening torque: 0.23 Nm (2 in. lbs.) nominal; 0.34 Nm (3.0 in. lbs.) maximum
Clamp terminals
Important: Clamp terminals are designed for 1 wire only. If more than 1 wire is connected to a terminal, a wire could
loosen or become completely disconnected from the terminal, causing a short.
Wire size: 16, 18, 20, 22, or 24 AWG (0.20 – 1.31 mm²)
Wire strip length: 9.00 mm (0.35")
Network Interface (Model SC22-3E only)
Ethernet 10/100 Base-T/TX, RJ45 modular connector
Selectable auto negotiate or manual rate and duplex
Auto MDI/MDIX (auto cross)
Protocols: EtherNet/IP (with PCCC), Modbus/TCP
Data: 32 configurable virtual Status Outputs; fault diagnostic codes and messages; access to fault log
Product Performance Standards
IEC 62061 Safety of Machinery – Functional Safety of Safety-Related Electrical, Electronic and Programmable Electronic
Control Systems: SIL CL 3
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems: SIL 3
ISO 13849-1 (1999): Category 4
24 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
64 mm
(2.5")
131 mm
(5.2")
112 mm
(4.4")
130 mm
(5.1")
35 mm
(1.4")
Allow minimum 65 mm (2.6") clearance
for USB cable or Ethernet cable and
43 mm (1.7") for XM Card insertion
SC22-3/-3E Safety Controller Instruction Manual
ISO 13849-1 (2006): Category 4 Performance Level (PL) e, complies with Machinery Directive 2006/42/EC
IEC 61131-2 Programmable Controllers, Part 2: Equipment Requirements and Tests
UL 508 Industrial Control Equipment
UL 1998 Software in Programmable Components
ANSI NFPA 79 Electrical Standards for Industrial Machinery
IEC 60204-1 Electrical Equipment of Machines: General Requirements
ISO 13851 (EN574) Safety of Machinery – Two-Hand Control Devices – Functional Aspects and Design Principles
ISO 13850 (EN418) Emergency Stop Devices
Also see front section of this manual for a list of other applicable U.S. and international standards.
Agency Approvals
3.5.1 Dimensions
Figure 9. SC22-3 and SC22-3E dimensions
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 25
SC22-3/-3E Safety Controller Instruction Manual
4 System Installation
4.1 Appropriate Application
The correct application of the Safety Controller is dependent on the type of machine and the safeguards that are to be interfaced with the
Controller. The Controller is generally interfaced with safeguards that may be used only on machinery that is capable of stopping motion
immediately upon receiving a stop signal and at any point in its machine cycle. It is the user’s responsibility to verify whether the safeguarding is appropriate for the application and is installed as instructed by the appropriate installation manuals. If there is any doubt
about whether or not your machinery is compatible with this Controller, contact a Banner Applications Engineer.
WARNING: . . . Not a Stand-Alone Device
This Safety Controller is not a stand-alone point-of-operation guarding device, as defined by OSHA regulations. It is
necessary 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 dan-
gerous condition which could lead to serious injury or death.
WARNING: . . . User Is Responsible for Safe Application of this Product
The application examples described in this document depict generalized guarding situations. Every guarding applica-
tion has a unique set of requirements.
Extreme care is urged to ensure that all legal requirements are met and that all installation instructions are followed.
Direct any questions regarding safeguarding to a factory applications engineer at the number or addresses listed in the back
of this document.
WARNING: . . . Shock Hazard and Hazardous Energy
Always disconnect power from the safety system (e.g., device, module, interfacing, etc.) and the machine being controlled before making any connections or replacing any component.
Electrical installation and wiring must be made by Qualified Personnel and must comply with the relevant electrical standards
and wiring codes, such as the NEC (National Electrical Code), ANSI NFPA79, or IEC 60204-1, and all applicable local standards and codes.
Lockout/tagout procedures may be required. Refer to OSHA 29CFR1910.147, ANSI Z244-1, or the appropriate standard
for controlling hazardous energy.
WARNING: . . . Read this Section Carefully Before Installing the System
The Banner Safety Controller is an accessory device that is typically used in conjunction with a machine safeguarding device.
Its ability to perform this function depends upon the appropriateness of the application and upon the Safety Controller’s proper mechanical and electrical installation and interfacing to the machine to be guarded.
If all mounting, installation, interfacing, and checkout procedures are not followed properly, the Safety Controller
cannot provide the protection for which it was designed. The user has the responsibility to ensure that all local, state,
and national laws, rules, codes, or regulations relating to the installation and use of this control system in any particular application are satisfied. Extreme care should be taken to ensure that all legal requirements have been met and that all technical
installation and maintenance instructions contained in this manual are followed. Read Section 3 (and its subsections) of
this manual carefully before installing the system. Failure to follow these instructions could result in serious bodily
injury or death.
26 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
SC22-3/-3E Safety Controller Instruction Manual
The user has the sole responsibility to ensure that this Safety Controller is installed and interfaced to the guarded machine by
Qualified Persons (see Glossary), in accordance with this manual and applicable safety regulations.
4.2 Installing the Safety Controller
The Safety Controller mounts to a standard 35 mm DIN-rail track. It must be installed inside an enclosure rated NEMA 3 (IEC IP54) or
better. It can be mounted in any orientation. The user must comply with all instructions contained within product manuals and relevant
regulations.
For reliable operation, the user must ensure that the operating specifications are not exceeded. The enclosure must provide adequate
heat dissipation, so that the air closely surrounding the Controller does not exceed its maximum operating temperature. Methods to reduce heat build-up include venting, forced air flow (e.g., exhaust fans), adequate enclosure exterior surface area, and spacing between
the Safety Controller and other sources of heat. (See Specifications, “Operating Conditions” on page 24.)
Mount the Safety Controller in a convenient location that is free from heavy impulse force and high-amplitude vibration.
Electrostatic Discharge (ESD) can cause damage to electronic equipment. To prevent this, follow proper ESD handling practices such as:
• Wear an approved wrist strap or other approved grounding products.
• Touch a grounded object before handling the Controller.
See ANSI/ESD S20.20 for further information about managing ESD.
4.3 Safety Input Devices
Safety input devices allow for the cessation of motion, or an otherwise hazardous situation, by controlling the Safety Outputs of the Safety
Controller. A Safety Output in the OFF state results in a stop of motion and removal of power from the machine actuators (assuming this
does not create additional hazards).
For a Safety Output to turn ON, all of its controlling safety input devices must be in their Run state. A few special safety input device
functions can, under predefined circumstances, temporarily suspend the safety input “stop signal” to keep the Safety Output ON (e.g.,
muting and bypassing).
The Safety Controller input configurations, depending on the type, have means to detect failures and faults that would otherwise result in
a loss of that control of the safety function. Once such a failure or fault is detected, the Safety Controller will lock out until the problem is
fixed.
Other input configurations do not have this detection capability. It is recommended that in all circumstances the installation of the Safety
Controller and its associated safety and safeguarding devices be installed to eliminate or minimize the possibility of failures and faults
that could result in the loss of the safety function(s).
Methods to eliminate or minimize the possibility of these failures include, but are not limited to:
• Physically separating interconnecting control wires from each other and from secondary sources of power.
• Routing interconnecting control wires in separate conduit, runs, or channels.
• Locating all elements (modules, switches, and devices under control) within one control panel, adjacent to each other, and directly
connected with short wires.
• Properly installing multi-conductor cabling and multiple wires through strain-relief fittings. (Over-tightening of a strain-relief can cause
short circuits at that point.)
• Using positive-opening or direct-opening components, as described by IEC 60947-5-1 that are installed and mounted in a positive
mode.
• Periodically checking the functional integrity / safety function and training the the operators, maintenance personnel, and others with
the operation of the machine and the safeguarding, and to recognize and immediately correct all failures.
Follow the device manufacturer's installation, operation, and maintenance instructions and all relevant regulations. If there
is any question about the device(s) that are connected to the Safety Controller, contact a Banner Application Engineer for
assistance.
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 27
SO1 SO2 SO3
Safety
Outputs
Inputs
S1.............S11
2 x 24V dc (A1)
Inputs
S12...........S22
2 x 0V dc (A2)
0V dc (A2)
O1.........O10
Status
Outputs
System Reset (SR)
SC22-3/-3E Safety Controller Instruction Manual
Figure 10. Input and output terminal locations
WARNING: . . . Sharing of Safety Inputs
Multiple Safety Controllers must not share safety input devices; this includes solid-state outputs
from light curtains, Safety Controllers, or other safety devices. A Safety Output from one Controller can
be connected to a Safety Input of a second Controller. However, the second Controller should be
the only device to which the output from the first
Controller is connected.
If a third device is also connected to the same Safety Output (now used as the safety input of the second Controller): during a power transition of the second Controller, the input may be a source of current,
momentarily causing a false ON (Run) signal at the
input of the third device. Failure to connect multi-
ple Controllers correctly could create an unsafe
condition that may lead to serious bodily injury
or death.
WARNING: . . . Failures and Faults
The Safety Controller Safety control can be interfaced with input devices at differing levels of integrity, as described in Appendix A. The user must conduct a Risk Assessment to determine the appropriate level of integration. The user also must
eliminate or minimize the possibility of failures and faults that could result in the loss of the safety function(s).
4.3.1 Signals: Run and Stop States
Dual-channel safety input devices have two separate signal lines. Dual-channel signals for some devices are both positive (+24V dc)
when the device is in the Run state. Others have a complementary circuit structure where one channel is at 24V dc and the other is at 0V
dc when the device is in the Run state. For the sake of clarity, instead of referring to a safety input device as being “ON” (e.g., 24V dc) or
“OFF” (e.g., 0V dc), this manual adopts the Run state/Stop state convention.
4.3.2 Safety Input Device Properties
The Controller can be configured to accommodate many types of safety input devices. However, a number of device properties must be
established (using either the OBI or PCI interface) so that the Controller can properly monitor their signals. These configurable properties
include:
• Device name—This is generated automatically by the Controller and can be changed by the user.
• Circuit type—The circuit and signal convention options that can be selected to define the input device.
• Reset logic—Automatic (Trip mode) or Manual (Latch mode).
• Terminal number—The assignment of input terminals for a device.
• I/O mapping—The logic control relationship between inputs and outputs or between inputs.
• Signal change-of-state—Simultaneous or Concurrent type, and signal convention (high or low)
• Signal debounce time—The signal state transition time.
• Start-up test—An optional precautionary safety input device test required after each power-up.
• Function time limit—The adjustable time limit within which a function is allowed to operate.
• Muteable—Whether or not the device can be muted.
• Bypassable—Whether or not the device can be bypassed.
28 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
E-Stop Safety
Gate
Optical
Sensor
Two-Hand
Control
Rope
Pull
Protect.
Stop
Safety
Mat
Enabling
Device
Mute
Sensors
Bypass
Switch
EDM AVM
Circuit
Types
7 13 10 7 10 10 1 10 7 10 2
Reset
Logic
Auto/
Manual
Auto/
Manual
Auto/
Manual
Auto
Auto/
Manual
Auto/
Manual
Auto/
Manual
Auto Auto Auto — —
—
I/O
Mapping
I/O I/O I/O I/O I/O I/O I/O I/O I/I I/I I/O
2
I/O
Signal
COS*
S/C S/C S/C S S/C S/C — S/C S S/C S
Debounce
Times
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No
Start Up
Test
— Yes Yes — — — — — — — —
Function
Time Limit
— — — — — — Yes Yes Yes Yes—
Muteable — Yes Yes Yes — YesYes — — — —
Bypassable — Yes Yes Yes — Yes Yes — — — —
—
—
—
* Refer to change-of-state table.
S = Simultaneous
C = Concurrent
SC22-3/-3E Safety Controller Instruction Manual
Circuit Types: Contact and Solid State Circuits
The table below depicts many of the input devices and circuit types the Controller can monitor. It highlights which of these properties can
be configured, and for which devices. More description of some of these topics is included in the following paragraphs.
Not all circuit types meet the Category 4 classification per ISO 13849-1; refer to section 10.1 Safety Circuit Integrity and ISO
13849-1 (EN954-1) Safety Circuit Principles on page 90 for a discussion of safety circuit integrity levels.
Reset Logic: Manual or Automatic Reset
Safety input devices can be configured to require a manual reset before the Safety Output(s) they control are permitted to turn back ON.
This is sometimes referred to as “latch” mode because the Safety Output “latches” to the OFF state until a reset is performed. If a safety
input device is configured for automatic reset or “trip” mode, the Safety Output(s) it controls will turn back ON when the input device
changes to the Run state (provided that all other controlling inputs are also in the Run state).
Reset rules and types are discussed in section 4.5 Input Device Resets on page 33.
Terminal Numbers: Connecting the Input Devices
The Controller needs to know what device signal lines are to be connected to which wiring terminals, so that it can apply the proper signal
monitoring methods, Run and Stop convention, timing rules, and fault rules. Although terminals are assigned automatically during the
configuration process, the terminal assignments can be changed manually, using either the Onboard Interface or the PC Interface.
P/N 133487 rev. C www.bannerengineering.com - tel: 763-544-3164 29
2 Terminals 3 Terminals 2 Terminals, PNP
24V
OFFON
2-Ch, 2 Terminal
PNP
2-Ch, 2 Terminals 2-Ch, 3 Terminals 2-Ch, 4 Terminals
24V
ONON
4 Terminals 5 Terminals
PNP
24V
OFFON OFFON
2-Ch, 2 Terminals
SC22-3/-3E Safety Controller Instruction Manual
Signal Change-of-State Types
Two change-of-state (COS) types can be used when monitoring dual-channel safety input device signals: Simultaneous or Concurrent.
The rules for each circuit type are shown in the table below.
Input Circuit
Input Signal COS Timing Rules
Stop State—SO turns OFF when¹: Run State—SO turns ON when²:
Dual-Channel A and B Complementary At least 1 channel (A or B) input is in
the Stop state.
Dual-Channel A and B
2X Complementary A and B At least 1 channel (A or B) is within a
pair of contacts in the Stop state.
Simultaneous. A and B are both in the
Stop state and then both in the Run
state within 3 seconds before outputs
turn ON.
Concurrent. A and B concurrently in
the Stop state, then both in the Run
state with no simultaneity, to turn outputs ON.
Simultaneous. A and B concurrently in
the Stop state, then contacts within a
channel in the Run state within 400 ms
(150 ms for 2-hand control), both channels in the Run state within 3 seconds
(0.5 seconds for 2-hand control)
Concurrent. A and B concurrently in
the Stop state, then contacts within a
channel in the Run state within 3 seconds. Both channels in the Run state
with no simultaneity.
¹ Safety Outputs turn OFF when one of the controlling inputs is in the Stop state.
² Safety Outputs turn ON only when all of the controlling inputs are in the Run state and after a manual reset is performed (if any safety
inputs are configured for Manual reset and were in their Stop state).
Signal Debounce Times
Closed-to-Open Debounce Time (from 6 to 100 milliseconds in 1 ms intervals, except 6 to 1,500 ms for mute sensors). The
closed-to-open debounce time is the time limit required for the input signal to transition from the high (24V dc) state to the steady low (0V
dc) state. This time limit may need to be increased in cases where high-magnitude device vibration, impact shock, or switch noise conditions result in longer signal transition times. If the debounce time is set too short under these harsh conditions, the system may detect a
signal disparity fault and lock out. (Default setting is 6 ms.)
Dual-Channel Safety Mat
• Input channels are shorted together (normal operation), or
• At least 1 of the wires is disconnected, or
• One of the normally low channels
is detected high, or
• One of the normally high channels
is detected low.
Each channel detects its own pulses.
30 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev. C
Loading...