Omron MC3 Installation And Operating Manual

. . . . .

Mat Controller

MC3 Series

Installation and Operating Manual

Original Instructions

OMRON Scientific Technologies Inc.

Manufacturing and Sales Office

6550 Dumbarton Circle

Fremont CA 94555-3605 USA

1 / 888 / 510-4357

Tel: [phone]

Fax: [phone]

www.sti.com

© OSTI 0411 PN99307-0010 Rev. D

. . . . .

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA
Tel: [phone] in USA and Canada

3

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

MC-3 Mat Controller

Table of Contents

Section 1—Important safety message . . . . . . . . . . . . . . . . . . . . . .page 4

Section 2—Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6

Section 3—Description of Controls . . . . . . . . . . . . . . . . . . . . . . . . page 6

Section 4—Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 7

Section 5—Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8

Section 6—Machine Control Connections . . . . . . . . . . . . . . . . . .page 11

Section 7—Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 15

Section 8—Trouble-shooting Faults . . . . . . . . . . . . . . . . . . . . . . .page 15

Section 9—Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 16

Section 10—Warranty and Additional Information . . . . . . . . . . .page 18

Section Appendix A —

Section Appendix B —Declaration of Conformity Information. ..page 21

Test Procedure . . . . . . . . . . . . . . . . . . . . . .page 20

I M P O R T A N T S A F E T Y M E S S A G E

1

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA
Tel: [phone] in USA and Canada

4

1 I

MPO RTA N T SAFE TY MES S AGE

A presence sensing mat and controller are general purpose presence sensing
devices designed to guard personnel working around moving machinery. The
use of this type of guarding system is regulated by government safety agencies.

Whether a specific machine application and presence sensing mat and
controller installation complies with government regulations depends upon
several items, including: the proper application, installation, maintenance and
operation of the presence sensing mat and controller. These items are the sole
responsibility of the purchaser, installer and employer.

The employer is also responsible for the selection and training of the personnel
necessary to properly install, operate and maintain the machine and its
safeguarding systems. For example, the presence sensing mat and controller
should be installed, checked out and maintained only by a qualified person,
defined as “a person who, by possession of a recognized degree in applicable

field or certificate of professional standing, or who by extensive knowledge,
training, and experience, has successfully demonstrated the ability to solve
problems relating to the subject matter and work.” (ASME B30.2-2001)

The machine operator must notify management if the machine, tooling or
safety devices are not operating properly. Never use the machine if it or the
safety equipment is not is proper working order.

The following additional requirements must be met before using a safety mat
and controller system:

• The machine on which the presence sensing mat and controller are installed
must be capable of stopping motion anywhere in its cycle or stroke. Never use a
presence sensing mat and controller on a power press with a full-revolution
clutch.

• Do not use a presence sensing mat and controller:

– on any device with inconsistent stopping time or inadequate control

devices or mechanisms.

– where the environment, such as corrosive chemicals, may degrade the

performance of the mat and/or controller.

– to initiate machine motion.

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

. . . . .

I M P O R T A N T S A F E T Y M E S S A GE

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA
Tel: [phone] in USA and Canada

5

• When a presence sensing mat and controller are used as a safety device, the
employer has the responsibility to ensure that all applicable federal, state, and
local requirements, rules, codes and regulations are satisfied.

• All safety related machine control circuit elements, including pneumatic,
electric or hydraulic controls, must be control reliable as defined by ANSI
B11.19-2003, 6.1 which states in part:

— prevent initiation of hazardous machine motion (or situation) until the

failure is corrected or until the control system is manually reset: or

— initiate an immediate stop command and prevent re-initiation of hazardous

machine motion (or situation) until the failure is corrected or until the
control system is manually reset; or

— prevent re-initiation of hazardous machine motion (or situation) at the next

normal stop command until the failure is corrected or until the control
system is manually reset.

• All other machinery or equipment must meet OSHA standard 1910.212 for
general machine guarding plus any other applicable regulations, codes and
standards.

• Additional guarding such as safety light curtains or mechanical guards may be
required if the presence sensing mat and controller do not protect all areas of
entry to the point of operation hazard.

• All brakes and stopping mechanisms must be inspected regularly to ensure
proper working order. If the stopping mechanisms are not working properly, the
machine may not stop safely even though the presence sensing mat and
controller are functioning properly.

• The Omron STI Test Procedure must be performed at installation and after any
maintenance, modification or adjustment is performed on the machine controls
or on the presence sensing mat and controller. The Test Procedure is presented
in this manual.

• Do not perform any test or repairs other than those outlined in this manual. All
electrical wiring must be installed in accordance with local electrical codes and
regulations.

• The user must follow all procedures in this manual for proper operation of the
MC3 controller.

The enforcement of these requirements is beyond Omron STI’s control. The
employer has the sole responsibility to follow the preceding requirements and
any procedures, conditions and requirements specific to your machinery.

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

I N T R O D U C T I O N

Output Relays

2

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA
Tel: [phone] in USA and Canada

6

2 I

NTRODUCTION

2

Presence sensing mats and the MC3 controller are used where perimeter access
guarding is required, such as around robots, manufacturing work cells, food
processing equipment and automated assembly equipment.

The MC3 controller is designed to meet the applicable sections of ANSI B11.19­2003, OSHA 1910.212, EN1760-1:1997 and ISO13856-1:2001. CE standards are met

only when used in conjunction with OMRON STI UM and UMQ series presence

The MC3 controller is designed to work in conjunction with a four-wire,
normally open safety mat (such as the Omron STI UM and UMQ series safety mats).

3 D

ESC RIPT ION OF

C

ONT ROLS

3

3 . 1 . O U T P U T R E L A Y S

The safety-rated outputs of the MC3 controller are referred to as Output Signal
Switching Devices. (OSSD). When the mat surface is activated by suf cient
weight, the OSSD will respond by going to an OFF state. Two-normally open
OSSD are provided across terminal 13/14 and 23/24. Two normally closed
OSSD are provided across terminals 31/32 and 41/42.

Figure 3-1 MC3 Mat Controller

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions

No User Serviceable Parts Inside

24 VDC

2.2 VA

13 14 23 24 31 32

Outputs

250 VAC 6 A 1500 VA Max

41 42

MC3 Mat Controller

M11

Blk

M12

Brn

M21

Blu

M22
Wht

X2X1

Y1Y2

+

–

Mat Clear

Stop

Run

Start

Mat

Start/Restart Interlock – Remove 3 Jumpers

Mode Select Jumpers Located under Terminal Block

Automatic Start – Install 3 Jumpers

sensing safety mats.

. . . . .

OP ERA TI N G MO DE

Indicators

OMRON SCIENTIFIC TECHNOLOGIES INC.

Fremont CA USA
Tel: [phone] in USA and Canada

7

3.2 . I ND I CA T O RS

RUN: Will be lit when the OSSD relays are in the MACHINE RUN state.

STOP: Will be lit when the OSSD relays are in the MACHINE STOP state.

MAT CLEAR: A diagnostic indicator. Shows that the mat is properly wired, that

it is clear, and that it is possible to energize the relays.

3.3 . M AT IN P UT S

Four terminal positions (M11-Blk, M12-Brn, M21-Blu, M22-Wh) are provided
for input of a four-wire safety mat or a series of four-wire safety mats. See
details in Section 5.2.—Input Wiring.

4 O

PERATING

M

ODE

4

4.1 . A UT O MA T I C R ES T AR T

The MC3 controller will energize relays whenever the mat is clear, and de­energize whenever it has been stepped upon. During both power up and normal
operation, an ON-delay of approximately 1/10 to 2/10 second is normal. The
RUN indicator will follow the MAT CLEAR light.

4.2 . S TA R T/R ES T A RT IN T ER L OC K

The MC3 controller will interlock in de-energized state both upon application
of power and also whenever the mat is stepped upon. Requires a manual reset
operation to cause the system to energize relays. The MAT CLEAR light will
indicate that it is possible to activate the start switch and enter into the
MACHINE RUN state. The controller attempts to enter the RUN STATE upon
the release of the start switch. Press and hold the start switch for more than

0.15 seconds. The safety mat area must be clear at the time the start switch is

pressed and released.

©OSTI 0411 PN99307-0010 Rev. D

Original Instructions