Pinnacle Systems STTS User Manual

STTS

Safety Mat System™

Soft Tactile Transducer Sensor Safety Mat System for Robotics

and Hazardous Machinery Area Guarding

Installation Manual

Rev. 2.0

STTS

Safety Mat System™

INSTALLATION MANUAL

Pinnacle Systems, Inc.

3715 Swenson Avenue

St. Charles, IL 60174

P/N: 28-023r2-0

Customer Service: 630-443-8542

Sales and Marketing: 800-569-7697

www.pinnaclesystems.com  [e-mail]  [e-mail]

Proper Use and Limitations

The information disclosed herein includes proprietary rights of the manufacturer. Neither this document
nor the information disclosed herein shall be reproduced or transferred to other documents, used or
disclosed to others for manufacturing purposes, or for any other purposes, except as specifically
authorized in writing by the manufacturer. If this manual is supplied in connection with the sale or delivery
of manufacturer’s equipment, it is to be used solely for maintenance, repair, or installation of such
equipment.

The STTS was manufactured in the United States. The Installation Manual was printed in the United
States.

You must read and fully understand the following information pertaining to the proper use and limitations
of your STTS:

• The STTS must be installed by qualified personnel only.

• The STTS must NOT be used on full revolution presses or any machine that cannot be commanded
to stop at any time.

• You must NOT wire the Safety Output contacts of the STTS to an external relay unless you use the
External Relay Checking feature.

• The mechanical power press on which the STTS is installed must meet ANSI B11.1-2001and
OSHA 1910.217 regulations. These include inspection and maintenance procedures that must be
followed to comply with the regulations. The manufacturer will NOT take responsibility for
improperly maintained machinery.

• Point of operation safeguarding is defined in ANSI B11.19-2003. This regulation is used to
determine a safe distance to place your STTS. The manufacturer takes no responsibility for injury
as a result of improper safeguarding or improper safe distances.

• The STTS may not be able to safely stop a press which has a faulty stopping mechanism. The
manufacturer cannot be held responsible for an improperly maintained or faulty stopping
mechanism.

• The STTS must be checked before put into operation. Follow instructions provided in this manual
for procedures on how to do this.

• The STTS should never be modified or repaired except by qualified personnel and upon
authorization of the manufacturer. Never operate machinery that is not in full working order.

• Make sure that all maintenance people, machine operators, die-setters, foreman, and supervisors
have read and understood this manual and all procedures have been and will be followed.

• All procedures in this manual must be followed. The manufacturer cannot take responsibility for
operation if all procedures and warnings in this manual are not followed.

Warranty

Manufacturer warrants that this product will be free from defects in material and workmanship for a period
of 2 years from the date of shipment thereof. Within the warranty period, manufacturer will repair or
replace such products which are returned with shipping charges prepaid and which will be disclosed as
defective upon examination by the manufacturer. This warranty will not apply to any product which will
have been subject to misuse, negligence, accident, restriction, and use not in accordance with
manufacturer’s instructions or which will have been altered or repaired by persons other than the
authorized agent or employees of the manufacturer.

DISCLAIMER
The provisions of the paragraph "WARRANTY" are the sole obligations of the manufacturer and exclude
all other warranties of merchantability, expressed or implied. Further, there are no warranties which
extend beyond the above warranty.

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LIMITATION OF LIABILITY
In the event of any claim for breach of any obligations of manufacturer under any order, whether
expressed or implied, and particularly in the event of any claim of a breach of the warranty or warranties
contained in the paragraph "WARRANTY" or of any other warranties, expressed or implied, which might
despite the paragraph entitled "DISCLAIMER," be determined to be incorporated in any order, the
company shall, under no circumstances, be liable for any consequential or special damages, either in law
or in equity, or for losses or expenses or claims for the same arising from the use of, or inability to use,
the products of the manufacturer for any purpose whatsoever.

We have designed our equipment to the very highest performance and safety standards known to the
current technological state of the art. However, the installation, usage, suitability, and fitness of our
equipment for any purpose, known or unknown, is interdependent upon the performance of other
equipment not manufactured, installed, secured, or maintained by Pinnacle Systems, Inc.

We cannot and do not accept responsibility for any overall system performance when factors, such as
these, are beyond our control.

WARNING: The entire machine safety system must be tested at the start of every shift. Machine
testing should include: (1) proper machine operation and stopping capability; and (2) verification of
proper installation and settings of all point of operation guards and devices before the operation is
released for production.

WARNING
This installation manual must be read in full prior to any installation work being started.

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TABLE OF CONTENTS

Proper Use and Limitations ....................................................................................................... i

Warranty ......................................................................................................................................... i

System Overview ........................................................................................................................ 1

Circuit Description ...................................................................................................................... 1

Technical Specifications

Metal Box Controller ......................................................................................................................... 2

DIN-rail Controller ............................................................................................................................ 3

DeviceNet ....................................................................................................................................... 20

Setup and Installation

Metal Box Controller

Installation .............................................................................................................................. 4

Control Setup ......................................................................................................................... 5

Operation Guide ..................................................................................................................... 6

Jumper Settings ..................................................................................................................... 7

Accessible Connections ......................................................................................................... 9

Computer Board Connector / Jumper Layout ...................................................................... 11

Power Supply Board Connector Layout ............................................................................... 12

Wiring Diagram for Mat(s) .................................................................................................... 14

Wiring Diagram for Zone(s) (outputs) ................................................................................... 15

Dimensions ........................................................................................................................... 18

DIN-rail Controller

Installation .............................................................................................................................. 4

Control Setup ......................................................................................................................... 5

Operation Guide ..................................................................................................................... 6

Jumper Settings ..................................................................................................................... 8

Accessible Connections ....................................................................................................... 10

Board Connector / Jumper Layout ....................................................................................... 13

Wiring Diagram for Mat(s) and Zone .................................................................................... 16

Remote Status Display ......................................................................................................... 17

Dimensions ........................................................................................................................... 19

Diagnostics and Troubleshooting (for both controllers)

Display Codes and Messages ............................................................................................ 21-22

Guidelines and Regulations for Safe Operation (for both controllers)

Safety Evaluation ..................................................................................................................... 23

Maintenance ............................................................................................................................ 24

Annex A (Mat + per pfEN999) ................................................................................................. 25

Annex B (informative) .............................................................................................................. 26

Annex C (Installation Practices for Industry) ...................................................................... 27-28

Annex D (Replacement Part Listing) ....................................................................................... 29

WARNING

“Categories in accordance with EN 954-1 for pressure sensitive mats and pressure sensitive floors on
machines are stated in type “C” standards.

This installation manual is written in English language only. Installation of this equipment must be done
by qualified personnel with fluent English language understanding skills.

All “CE” marked products for the European Community must be 24VDC input power.

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SYSTEM OVERVIEW

Together with a new patented mat technology, eliminating internal metal plates, and the STTS control
using diverse redundant technology, Pinnacle Systems has achieved a system compliant with OSHA,
ANSI, and the European standards EN954-1 & EN1760-1. These standards dictate safety of machinery­related parts of control systems and pressure deflection sensitive protective devices and focus on
creating a fault tolerant system. All safety related faults cause a lockout condition requiring internal reset.

The STTS Metal Box Controller system can be ordered with 1 to 3 separate output zones, each with 3
separate isolated dry contact outputs and user option external relay checking for each zone. Up to 8
separate mat inputs allow any combination of mats to control any combination of zones and at the same
time provide instant information of mat faults via a scrolling diagnostic message display and LED's.
DEVICENET industrial data network is optionally available.

In addition to the above-mentioned compliance with various standards, the STTS DIN-rail controller has
been evaluated and approved by the CSA (for electrical safety only). The STTS Din-Rail controller
system comes standard with 1 output zone (2 safety relays, 1 form C auxiliary relay, and 1 fault relay),
external relays checking, and inputs for up to 4 mats. Diagnostic messages are the same as the metal
box, but the din-rail allows for an optional remote diagnostics display. DEVICENET industrial data
network is optionally available.

CIRCUIT DESCRIPTION

Low voltage DC signal (+20VDC & -20VDC) is pulsed out to the mat through two wires. The wires attach
to the top and bottom (internally) of the mat and any force on the mat lowers the resistance between the
two wires causing a drop in voltage. A second pair of wires coming back from the mat is used to sense
this drop in voltage. The redundant circuits compare the voltage to a reference and shut down the zone
when the voltage drops below the reference. The circuit goes through a self-check to verify that the
reference, comparators, mat, wiring, and other circuits are all functioning normally every time it scans a
mat input. Diverse redundant technology, provided by two different computers, controls the whole system
and allows more system flexibility (i.e., diagnostic message display).

METAL BOX CONTROLLER

POWER SUPPLY BOARD
This system is capable of running off of 120VAC or 240VAC or 24VDC input and contains the
circuitry for up to 3 zones (a total of 9 force-guided contact relays) and external relay checking.
This board is connected to the computer board via a 34 pin plug-in header (J6).
COMPUTER BOARD
This board contains two computers, circuitry for eight separate mat inputs, connectors for
diagnostics display, LED's, and push-buttons.
DISPLAY BOARD
This board contains the Diagnostics display, mat input LED's, and zone output LED's.

DIN-RAIL CONTROLLER

The Din-Rail controller is actually 1 circuit board broken up into 3 boards. All 3 boards are linked
via right angle connectors. The Power input is strictly 24vdc as well as all other inputs. Outputs
come from 4 relays that provide dry contacts up to 30vdc.

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DESCRIPTION

DIMENSIONS

MOUNTING HOLE

Computer board

6.50" x 8.00"

165.1 x 203.2 mm

6.00" x 7.50"

152.4 x 190.5 mm

Power supply board

6.50" x 8.00"

165.1 x 20,32 mm

6.00" x 7.50"

152.4 x 190.5 mm

Display board

4.00" x 5.75"

101.6 x 14,60 mm

3.50" x 5.00"

88.9 x 127.0 mm

Mounting plate

(used for short stack only)

8.87" x 8.87"

225.4 x 22,54 mm

8.00" x 8.00"

203.2 x 203.2 mm

Control Box

10.00"H x 9.00"W x 5.25"D

254H x 228.6W x 133.3D mm

7.75" x 10.75"

196.8 x 273.0 mm

TECHNICAL SPECIFICATIONS (Metal box controller)

Power: 18 - 28VDC @ 18 Watts Optional, requires removal of transformer.

(3 zones) 85-125VAC @ 19 VA All AC voltages work with 50 or 60 Hz
200-245VAC @ 19 VA Jumper change required

Max # of Mats: Up to 8 separate mat inputs

Total Response
Time: 35 mSec/mat input

Outputs: Safety: 2 N.O. outputs (open when RED) per zone 8A@250vac resistive

Auxiliary: 1 N.O. or N.C. output per zone 8A@250vac resistive
Fault: 1 N.O. (open when faulted) 5A@250vac resistive

NOTE: Relay current rating is de-rated by ½ for inductive loads and again
by ½ for temperatures approaching 50C

Zone Reset
Inputs: 3 inputs for N.O. push-buttons for manual resetting of each zone (Green buttons

on front panel). J11 and J12 located on computer board (either one can be used
for remote resetting)

Settings: Jumpers to select manual or automatic reset, # of mats / zones and how many

zones, fault reset, and external relay checking. (S1, S5 and JP6)

Indicators:

Internal: Red LED on power supply board ON = +12V supply ok
Green LEDs on computer board 5v and 20V supply ok

External: 8 Yellow LED's (1 per mat input) Yellow LED on = standing on mat
Yellow LED flashing = Fault with

mat/circuitry
3 Red/Green LED’s (1 set per Green LED on = Relays energized
zone) on panel door Red LED on = Relays de-energized
Red LED flashing = Relay fault

Tolerance: +- 0.10 inches / 02.5 cm

Environmental: 0 to 50C

2

TECHNICAL SPECIFICATIONS (Din-Rail controller)

Power:

Fuse Rating: F1: 1A fuse

Max # of Mats: Up to 4 separate mat inputs

Total Response
Time: 35 mSec/mat input

Outputs: Safety: 2 N.O. outputs (open when RED) 5A@30vdc resistive

Auxiliary: N.O. or N.C. with common 5A@30vdc resistive
Fault: N.O. (open when fault or no power) 5A@30vdc resistive

NOTE: Relay current rating is de-rated by ½ for inductive loads and again
by ½ for temperatures approaching 50C

Zone Reset
Inputs: 1 input for N.O. push button for manual resetting located on front of DIN-rail

Controller or optional Remote Status Display (RSD)

Settings: Jumpers to select manual or automatic reset, up to four mats, fault reset, and

external relay checking

Indicators:

Internal: +5V – Yellow LED’s (1) Relays – Green LED’s (4)
+12V – Red LED (1) 20v – Green LED (1)

External: 4 Yellow LED's (1 per mat input) Yellow LED on = standing on mat
Yellow LED flashing = Fault with

Red/Green LED’s Green LED on = Relays energized
Red LED on = Relays de-energized
Red LED flashing = Relay fault

Dimensions: Overall: 5.9” length x 2.9” wide x 4.3” height

DIN-rail: 35mm

Tolerance: +- 0.10 inches / 02.5 cm

Environmental: 0 to 50C

Installation category I
Pollution degree 2
Altitude: up to 2000 meters
Humidity of 80% up to 31 C decreasing linearly to 50% humidity at 40 C
Indoor use

No cleaning is required.

The unit shall be supplied by a SELV source in accordance with CSA 1010.1 Annex H

24VDC +/- 15% @ 7 Watts maximum

mat/circuitry

3

INSTALLATION

WARNING: The entire machine safety system

must be tested at the start of every shift.
Machine testing should include: (1) proper
machine operation and stopping capability; and
(2) verification of proper installation and
settings of all point of operation guards and
devices before the operation is released for
production.

The STTS mat system has been designed to
promote individual mat "homerun" wiring back
to the mat controller. This is suggested for
easing installation and diagnostics for
maintenance troubleshooting. This will also eliminate cumbersome "daisy chain" wiring practices of mat
systems. It also eliminates numerous wiring connection points buried under the perimeter trim, which are
time intensive to troubleshoot.

INSTALLATION

1) Sweep the floor area where the safety mat is to be installed. The floor should be flat and free of

foreign material.

2) Locate the safety mat in the desired location. For future reference, install the mat with the label side

up.

3) Slide the black wire raceway component under the mat edge (Part #M002). Refer to the graphic

below for proper component positioning. NOTE: The wire raceway component must be installed
whenever the surface perimeter trim component is used.

4) Route the wire/plug assembly on the raceway toward the mat controller location.

5) Lay the aluminum perimeter trim piece around the mat assembly. Determine where the mat wiring

will exit the trim and notch the trim and wire raceway for the wire to exit the assembly.

6) If surface metal raceway is used to route the wiring (Part #M005 or M006) from the mat assembly

across the floor toward the mat controller, it should be aligned with the notch in the perimeter trim and
anchored to the floor. Route wires accordingly and snap cover plate over the wires.

7) Slide the perimeter trim over the wire raceway component and align over the mat edge per Figure 1.

Drill the perimeter trim and floor for securing the perimeter trim to the floor with anchoring screws and
floor anchors.

8) If a multiple mat assembly is to be installed, use the aluminum active coupler component (Part

#M003) to connect mats end-to-end or side-to-side. Refer to graphic below.

Cross Section View of Mat Assembly Active Edging

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P.O. Box 100088
Pittsburgh, PA 15233
800-569-7697 FAX: [phone]
www.pinnaclesystems.com

CONTROL SETUP

Choose number of mat(s) per zone (metal box
controller only):

Zone 1 mats must start at Mat input #1 and work up.
Zone 2 mats must start at the next available mat input,
and so on. The S5 jumper block is used to program
the number of mats per zone (see "User Configuration
Jumpers").

NOTE: The total number of zones your STTS
controller has was determined at the time of order
placement and is from 1 to 3. If you need to increase
the number of zones at a later date, the unit will need
to be shipped back to the place of purchase for an
upgrade.

Choose your options:
You may select manual or automatic zone resetting (see "User Configuration Jumpers").

MANUAL: If you select manual, you will have to go to the control box and press the zone reset button
each and every time you step on any mat(s) Metal box: Place jumper across JP6 MAN on the top board.
Din-Rail: Place jumper across JP3 MANUAL

AUTOMATIC: If you select automatic, the zone will clear itself when you have stepped off the mat(s).

Metal Box: Remove jumper across JP6 MAN on the top board.
Din-Rail: Remove jumper across JP3 MANUAL.

NOTE: This setting changes all mats, you cannot change some mats to manual and some to

automatic.

EXTERNAL RELAY CHECKING: External relay checking option is selected when you have to switch a
large load. This feature allows the STTS to monitor your external relays. This system requires that you
use two force-guided relays for the external switching and that the secondary pole of each relay (N.C.) be
tied in series back to the STTS control external relay input terminals for each particular zone

Metal Box: Place jumper across JP6 EXT on the top board to activate this feature.
Din-Rail: Place jumper across JP4 EXT to activate this feature.

Metal box mounting location:

After choosing an appropriate location you will need to remove the computer board and the power supply
board from the box in order to punch two holes—one for the power lines and the other for mat wiring.
See "Wiring Diagram for Mats" and "Wiring Diagram for Zones” for wiring hookups.

HOOKUP POWER AND ZONE STOP CIRCUITS TO POWER SUPPLY BOARD:

1) Attach power lines to J3 PLUG (LINE, NEUTRAL, GROUND). Line and Neutral are un-polarized
for DC use.

2) Attach stop circuit to terminals 1 & 4 of J5 for Zone 1, terminals 10 & 13 for Zone 2, terminals 19
& 22 for Zone 3.

3) Attach auxiliary circuit to terminals 5,6,7 for Zone 1, terminals 14,15,16 for Zone 2, terminals
23,24,25 for Zone 3.

4) Attach External Relay Checking input wires to terminals 8,9 for Zone 1, terminals 17, 18 for Zone
2, terminals 26,27 for Zone 3.

Din-Rail controller:

The controller must be mounted inside an enclosure since all the wiring terminates on the outside of the
controller box.

1) Attach 24vdc power, and stop circuit(s) to the POWER/OUTPUT plug

2) Hook up mats to the mat # plugs.

3) Hook up options to the INPUT/OUTPUT plug

5

OPERATION GUIDE

At power-up the control will go though a test and then, if manual reset option is enabled you must reset
the zone. If automatic reset is enabled, the unit will activate each zone that passes the test and nothing
is found on the mat(s).

WHEN YOU STEP ON THE MAT:
The corresponding yellow mat input LED will turn on and, at the same time, the green zone LED will turn
off and the red zone LED will turn on. All three relays related to this zone will de-energize and open up
the N.O. outputs.

WHEN YOU STEP OFF THE MAT:
The corresponding condition of the LED's described above will reverse. All three relays related to this
zone will energize and close the N.O. outputs

GETTING FAULT CODES:
The yellow mat input LED corresponding to the mat fault will flash to indicate which mat input circuit or
mat is faulting. All available zones will shut down and de-energize all relays. When 1 zone has a fault, all
zones shut down.

Problem: NO FAULT CODES DISPLAYED, BUT THE ZONE WILL NOT CLEAR
(No Green LED, but a Yellow LED is lit)

Cause: 1) Manual reset button needs to be pushed.

2) Something is on the mat, or the trim around the mat is too tight.

3) Mat failure (short in the wiring or the mat itself)

Cure: 1) Try swapping the mat with another mat to verify this failure.

2) Call for assistance.

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