SC22-3/-3E Safety Controller Instruction Manual P/N 133487 rev.
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) ..................................
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 ........................................................................................................
Contents 8.2.1 Verifying System Operation ........................................................................................................76 8.3 Initial Setup, Commissioning and Periodic Checkout ............................................................................76 9 Troubleshooting .................................................................................................................82 9.1 Cleaning ..............................................................................
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 ............................................................................................
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.
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 ANSI B11.
SC22-3/-3E Safety Controller Instruction Manual ISO 13851 (EN 574) Two-Hand Control Devices – Functional Aspects – Principles for Design IEC 61496 Electro-sensitive Protection Equipment IEC 60529 Degrees of Protection Provided by Enclosures ISO 62061 Functional Safety of Safety-Related Electrical, Electronic and Programmable Control Systems IEC 60947-1 Low Voltage Switchgear – General Rules ISO 13849-1 (EN 954-1) Safety-Related Parts of Control Systems IEC 60947-5-1 Low Voltage Switchgear – Electromec
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.
SC22-3/-3E Safety Controller Instruction Manual 2.2 Applications The Safety Controller can be used wherever safety modules are used.
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.
SC22-3/-3E Safety Controller Instruction Manual 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
SC22-3/-3E Safety Controller Instruction Manual Model 11-BG00-31-D024 11-BF18C01-024 Supply Voltage Inputs Outputs 24V dc 2 (dual-channel hookup) 3 N.O. and 1 N.C. Output Rating 10 amps 18 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.
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.
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 – Functiona
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.
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.
SC22-3/-3E Safety Controller Instruction Manual Inputs Inputs S1.............S11 S12...........S22 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.
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.
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.
SC22-3/-3E Safety Controller Instruction Manual CAUTION: . . . Debounce and Response Any changes in the closed-to-open debounce time will affect the Safety Output response (turn OFF) time. This value is computed and displayed for each Safety Output when a configuration is created. The values are also listed in the OBI and the PCI Configuration Summary documents. (Default setting is 6 ms.) Open-to-Closed Debounce Time (from 10 to 500 milliseconds in 1 ms intervals, except 10 to 1,500 ms for mute sensors).
SC22-3/-3E Safety Controller Instruction Manual Cancel OFF-Delay Devices. This feature provides the option to cancel a configured OFF-delay time. It functions in one of two ways: • Keeps the Safety Output ON, or • Turns the Safety Output OFF immediately, after the Controller receives a Cancel OFF-Delay signal. A new Status Output (O.K. to Cancel Output's OFF-Delay Status) will indicate when a Cancel Delay Input can be activated, in order to keep the OFF-delayed Safety Output ON.
SC22-3/-3E Safety Controller Instruction Manual Manual Safety Input(s) Run Stop Latch Reset Performed Latch Reset Input (Monitored Reset Shown) Reset Run Cancel Delay Performed Cancel Delay Input (Monitored Option Shown) Reset Run Off Delay Ended Safety Output Status Output (OK to Cancel OFF-Delay) Off Delay ON OFF Off Delay Normal End Off Delay Started Active Inactive Figure 13.
SC22-3/-3E Safety Controller Instruction Manual area unnoticed (a "pass-through hazard"). See section 4.5.3 Perimeter Guarding and Pass-Through Hazards on page 35 for more informaton. WARNING: . . . Reset Switch Location All reset switches must be accessible only from outside, and in full view of, the hazardous area. Reset switches must also be out of reach from within the safeguarded space, and must be protected against unauthorized or inadvertent operation (e.g., through the use of rings or guards).
SC22-3/-3E Safety Controller Instruction Manual Safety Device 1 Manual Monitored Reset Safety Device 2 Manual Monitored Reset Manual Reset Safety Output Figure 16. Timing logic: Safety Outputs with a common reset, mapped to the same Safety Output 4.5.
SC22-3/-3E Safety Controller Instruction Manual 4.6.2 Two-Hand Control (THC) The two-hand control function requires that two hand actuators (e.g., hand/palm buttons) each be activated within 0.5 seconds of each other in order to produce a Run signal to start a machine cycle. THC devices are always the last input (in time) to turn the Safety Output ON.
SC22-3/-3E Safety Controller Instruction Manual Enable Device Safety Device Safety Output (ON-Delayed) Don’t Care* ONDelay ONDelay System Reset Enable Mode OFF Enable Mode ON Enable Mode *Unless it’s an E-Stop or a Rope-Pull Figure 18. Timing logic: Enabling device and enable mode See section 10.9 Enabling Device on page 112 for more information. 4.6.
SC22-3/-3E Safety Controller Instruction Manual Directional Muting. As soon as two mute sensor pairs are configured and mapped to a muteable Safety Input, an advanced setting option appears in the PCI to provide the option of directional muting. Check the box "Enable Directional Muting," then select the muting sensor pair to be blocked first.
SC22-3/-3E Safety Controller Instruction Manual Bypass Time Limit. A bypass function time limit can be established to limit how long the safety input device bypass is active. The time limit can be adjusted from 1 second to 12 hours and cannot be disabled. Only one time limit can be set, and this limit will apply to all safety devices that are bypassed. At the end of the time limit, Safety Output control authority is handed back to the bypassed safety input devices. Two-Hand Control Bypassing.
SC22-3/-3E Safety Controller Instruction Manual CAUTION: . . . Adjustable Valve Monitoring (AVM) Operation When an input is configured with automatic reset logic and is quickly cycled (from Run to Stop to Run), the Safety Output(s) will not turn ON until the AVM input is satisfied. This could result in an ON-delay up to the configured AVM monitoring time.
SC22-3/-3E Safety Controller Instruction Manual Safety Input Device Safety Input Device +24V dc EDM EDM EDM Safety Controller MPCE 1 Safety Controller MPCE 1 SO 1 MPCE 2 SO 1 MPCE 2 MPCE1 MPCE1 MPCE2 Single-channel EDM used to monitor both MPCE feedback signals. If one or both channels do not close, the system goes into a Lockout condition. MPCE2 Figure 22. One-channel EDM hookup Dual-channel EDM is used to monitor both MPCE feedback signals.
SC22-3/-3E Safety Controller Instruction Manual OSSD Output Connections The output signal switching device (OSSD) outputs must be connected to the machine control such that the machine’s safety related control system interrupts the circuit or power to the machine primary control element(s) (MPCE), resulting in a non-hazardous condition. Final switching devices (FSDs) typically accomplish this when the Safety Outputs go to the OFF state.
SC22-3/-3E Safety Controller Instruction Manual WARNING: . . . Safety Output Lead Resistance In order to ensure proper operation, the resistance in the Safety Output wires should not exceed 10 ohms. A higher resistance than 10 ohms may mask a short between the dual-channel Safety Outputs and could create an unsafe condition that may lead to serious bodily injury or death. 4.7.
SC22-3/-3E Safety Controller Instruction Manual • Properly installing multi-conductor cabling and multiple wires that pass through strain-relief fittings. Over-tightening of a strain-relief can cause short circuits at that point. • Using positive-opening or direct-drive components installed and mounted in a positive mode. WARNING: . . . Use of Transient Suppressors Transient suppressors are recommended. They MUST be installed across the coils of the FSDs.
SC22-3/-3E Safety Controller Instruction Manual Generic Hookup: 1-channel, 2-channel, and No EDM Options The following figure is generic in nature and represents all three EDM options: • Safety Output SO1 is shown with NO EDM configured (typically used with self-monitored devices). • Safety Output SO2 is shown with Two-Channel EDM configured. • Safety Output SO3 is shown with One-Channel EDM configured.
SC22-3/-3E Safety Controller Instruction Manual One-Channel EDM Hookup to SC-IM9A Interface Module The SC-IM9A interface module depicted in the following figure is shown in one-channel EDM hookup. The SC-IM9B and SC-IM9C modules are connected in the same manner, using individual one-channel EDM circuits (terminals 21/22 on each pair of contactors).
SC22-3/-3E Safety Controller Instruction Manual Two-Channel EDM Hookup to IM-T-9A Interface Module The IM-T-9A interface module depicted in the following figure is shown in two-channel EDM hookup. The IM-T-11A module is connected in a similar manner. Depending on the application, each Safety Output requires a separate and individually wired IM-T-..A module.
SC22-3/-3E Safety Controller Instruction Manual One-Channel EDM Hookup to IM-T-9A Interface Module The IM-T-9A interface module depicted in the following figure is shown in one-channel EDM hookup. The IM-T-11A module is connected in a similar manner. Depending on the application, each Safety Output requires a separate and individually wired IM-T-..A module.
SC22-3/-3E Safety Controller Instruction Manual 4.7.4 Common Wire Installation To avoid nuisance lockout codes 1.1, 1.2, or 1.5, give thoughtful consideration to the leadwire resistance of the 0V common wire and to the currents flowing in that wire. Notice the location of the block in the diagram below representing leadwire resistance (RL). Power Supply 0V 24V dc Safety Controller 24V dc 0V SO1 Other Equipment SO2 SO3 RL = Leadwire resistance Vo = Voltage > 0.
SC22-3/-3E Safety Controller Instruction Manual 4.8 Status Outputs 4.8.1 Status Output Signal Conventions Two signal conventions are selectable for each Status Output. The default convention provides a 24V dc signal when the monitored input or output is active (closed, high or ON), when the system is in a Lockout, when there is an I/O-fault, when the system waits for a Reset, when the output waits for a reset or during an active mute cycle.
SC22-3/-3E Safety Controller Instruction Manual 4.8.2 Status Output Functionality Track Input A Status Output configured for this function will indicate the current state of an input. Track Output A Status Output configured for this function will indicate the current physical state of a Safety Output, either ON or OFF. Track Output’s Logical State When selecting the Status Output function ‘Track output,’ an option to track the logical state, rather than the physical state, of a Safety Output is provided.
SC22-3/-3E Safety Controller Instruction Manual Bypass Status Status Outputs configured for this function will indicate when an input is truly bypassed. A Safety Input is required to be determined inactive at least once before a bypass can take place. The Status Output is active when the input is bypassed. A bypass cannot take place (the input must be open) on power-up. Track Input Fault Status Outputs configured for this function will indicate any fault on an input.
5 PC Interface Configuration (PCI) 5.1 PC Interface (PCI) Overview The PC Interface (PCI) is a computer program with real-time display and diagnostic tools that can be used to: • • • • Create, confirm, edit, store, send, and receive a configuration Display real-time Run mode information Record and display fault log data Record specific, user-defined information onto a "Notes" page. The PCI program uses Input Device icons and circuit symbols to aid making appropriate device property selections.
SC22-3/-3E Safety Controller Instruction Manual 5.1.2 Build a Configuration To install the software on your computer, double-click on the Banner Safety Controller icon . Read and understand the warning on the Start-up page, and click OK. The main PCI screen should appear. The support documents, if opened at this point, show basic information, and auto-populate as the configuration develops; see following figure.
SC22-3/-3E Safety Controller Instruction Manual Create a New Configuration Open the software program, and a new un-named file is created. You may name the Configuration and the Author, and establish the system settings at this time. Double-click the System Settings icon , on the right-hand side of the Tool Bar. When the pop-up menu appears, name the configuration file, using up to 16 alphanumeric characters. Add your name in the Author’s name box (up to 10 characters; abbreviate as needed).
SC22-3/-3E Safety Controller Instruction Manual Select the Input Device Properties After an input device is selected, the Properties menu for that device pops up. This menu presents the properties that must be established for each type of input device.
SC22-3/-3E Safety Controller Instruction Manual Figure 39. Wiring diagram populates with devices and output mapping Figure 40. Ladder logic diagram develops along with wiring diagram Finish the Configuration Repeat the steps in the previous section to include additional safety or non-safety input devices. Select Safety Outputs or Status Outputs from the tool bar to configure properties for these outputs, using the same menu-driven process as that for the inputs.
SC22-3/-3E Safety Controller Instruction Manual Save and Confirm the Configuration You will need to confirm this new configuration before it can be used in a safeguarding application. A 4-digit Controller password is required to save and confirm a configuration and to enable it to run on a Safety Controller. The confirmation process has two parts: 1.
SC22-3/-3E Safety Controller Instruction Manual Figure 42. Confirm Configuration screen, all devices confirmed by user (checklist is compressed) If the columns do not match, or if you wish to change any circuit: • • • • Select Edit for the device to be changed. The Properties menu for the device will open. Make the necessary change(s). Select OK. A message will appear asking whether you want to edit any other devices or if you want to restart the confirmation process.
SC22-3/-3E Safety Controller Instruction Manual 5.1.4 Other Functions Receive a Configuration from the Safety Controller To receive a configuration from a Controller and display it in the PCI: • Connect the Safety Controller to the PC using the USB cable. • Apply 24V dc power to the Controller. • Click on the Receive button in the tool bar. • If the configuration is not already confirmed, you may choose to confirm it at this time.
SC22-3/-3E Safety Controller Instruction Manual Changing the Password Using the Personal Computer Interface (PCI) For this procedure, the PC must be connected to the Controller via USB cable, and the Controller must be ON. 1. Go to File > Change Safety Controller Password. The Change Password screen will appear. 2. Fill in the boxes for Safety Controller password, new password, and new password again. Click OK. 3.
SC22-3/-3E Safety Controller Instruction Manual 6 Onboard Interface Configuration (OBI) 6.
SC22-3/-3E Safety Controller Instruction Manual Run Mode ESC → Configuration Mode View Fault Log ← OK ESC → ← OK Clear Fault Log Terminal Assignments Confirm Configuration ESC → Receive File from XM Confirm Safety Confirm Outputs System Settings (Section 5.3.4) Edit Password Set Language Name Configuratio n (Section 5.4.1) Edit Input Status Outputs Safety Outputs System Settings Terminal Assignments (Section 5.4.5) ESC → (Section 5.4.4) ← OK ← OK ESC → ← OK (Section 5.4.
SC22-3/-3E Safety Controller Instruction Manual 6.2 Run Mode From Run mode, press OK to view the System menu. This menu provides the ability to read fault diagnostic information, enter Configuration mode to create or edit a configuration, read the configuration summary, read the Safety Controller Model number, and adjust the contrast of the display itself. Use the up/down arrows to highlight your selection, then press OK to select.
SC22-3/-3E Safety Controller Instruction Manual To perform an Erase, use the up/down arrows to select the option from the menu and press OK. When prompted whether you want to do this, highlight Yes and press OK. Send File to XM—This selection is used to send a configuration file to the XM card plugged into the Controller’s XM port. The file can then be stored and/or transported to another Controller. Insert the XM card into the Controller’s XM port, highlight the selection and press OK.
SC22-3/-3E Safety Controller Instruction Manual The Confirm Configuration menu reappears, indicating whether the inputs and Safety Outputs are confirmed. If any boxes do not have a check mark, repeat the confirmation of those components. Confirm System Settings—The last step is to confirm the system settings. Select System Settings and press OK. The next series of menus lists the safety-critical system settings. Review each setting and press OK to confirm.
SC22-3/-3E Safety Controller Instruction Manual properties; select each property (in the same way used to define the input initially; see section 6.5 Add an Input on page 68), and press OK. The Inputs screen also reappears when ESC is pressed after all of the required inputs have been added. Press ESC when the Inputs menu reappears, to return to the Edit Configuration menu. 6.4.3 Outputs/System Settings Safety Outputs This option is used to configure the Safety Outputs.
SC22-3/-3E Safety Controller Instruction Manual 2. To save the settings for this output, select and press OK. The display returns to the Outputs/System Settings menu. To configure additional Status Outputs, select Status Outputs, select another Status Output and repeat the steps above. When the last Status Output is configured, press ESC to return to the Edit Configuration menu. System Settings Select the output’s reset mode, power up mode and whether mute will be active on power-up.
SC22-3/-3E Safety Controller Instruction Manual • Cancel OFF-delay switch Select an Input Device (Either Safety or Non-Safety)—Use the left/right arrows to select the proper device, then press OK. The arrows at the top of the screen indicate whether more options are available to the left or to the right. After the device is selected, a new screen appears with the appropriate properties to select for that device. 6.5.
SC22-3/-3E Safety Controller Instruction Manual Map Outputs—This option is used to select which of the Safety Output(s) the input controls. Any combination of 1, 2, or all 3 outputs may be selected, but at least one must be selected. All safety devices, plus reset and ON/OFF non-safety devices must be mapped to one or more Safety Outputs. Map mute enable devices, mute sensors, and bypass sensors to a safety input device. 1. Select Map Outputs in the Input Properties menu, and press OK. 2.
7 Operating Instructions 7.1 Monitoring Controller Operation The Safety Controller can be operated using either the OBI or the PCI interfaces to monitor ongoing status. 7.2 Display Controller Information — PC Interface (PCI) To display real-time Run mode information on a PC, the computer must be connected to the Controller, via a USB cable (see Section 1.3 for connection instructions).
SC22-3/-3E Safety Controller Instruction Manual 7.3.1 Run Mode Screen—OBI The OBI Run mode screen displays current information about the Safety Controller, including: • • • • • The configuration name Safety Output status Input status System status XM card status Configuration Name Arrowhead designates selected Safety Output Safety Output Status Input Status Cause of Output SO1 Status, or Required Action Figure 48.
SC22-3/-3E Safety Controller Instruction Manual • If more than one output is OFF, a small arrowhead indicates the Safety Output to which the input messages correspond, as shown in the preceding figure. Input Device Status Message Cause and/or Required Action Stop The safety input is in a state that causes the Safety Output to turn OFF. Test A start-up test needs to be completed on the safety input. To perform the test, cycle the input (RunStop-Run) to turn the Safety Output ON.
SC22-3/-3E Safety Controller Instruction Manual 7.
8 System Checkout 8.1 Schedule of Required Checkouts Verifying the configuration and proper functioning of the Safety Controller includes the verification of each safety and non-safety input device, along with each output device. As the inputs are individually switched from the Run state to the Stop state, the Safety Outputs must be checked to verify that they turn ON and OFF as expected.
SC22-3/-3E Safety Controller Instruction Manual 8.2.1 Verifying System Operation The commissioning checkout procedure must be performed by a Qualified Person, as defined in the glossary of this manual. It must be performed only after configuring the Controller and after properly installing and configuring the safety systems and safeguarding devices connected to its inputs (per section 10 Input Device and Safety Category Reference on page 90 and the appropriate standards).
SC22-3/-3E Safety Controller Instruction Manual e. Examine the electrical wiring connections between the Safety Controller’s OSSD outputs and the guarded machine’s control elements to verify that the wiring meets the requirements stated in section 4.7.1 External Device Monitoring (EDM) on page 40. 3. Verify that all two-hand control devices, enabling devices, muting sensors, and bypass switches are in the inactive (Stop) state.
SC22-3/-3E Safety Controller Instruction Manual 11. While the outputs are ON, individually actuate and re-arm each E-stop and/or rope-pull device, one device at a time. Verify that each associated Safety Output turns OFF with the proper OFF-delay, where applicable. 12. As the E-stop or rope-pull device is returned to the Run state (armed): If configured for Manual Reset or if associated with a two-hand control device: Verify that the Safety Output remains OFF.
SC22-3/-3E Safety Controller Instruction Manual a. Turn the Safety Controller power OFF. a. Activate the mute enable inputs (if used). b. Activate an appropriate muting sensor pair for starting a mute cycle. c. Ensure all input devices are in their Run (active) state (not including two-hand control devices). d. Verify that all enabling devices and bypass switches are in the Stop (inactive) state. b. Verify proper operation at power-up.
SC22-3/-3E Safety Controller Instruction Manual Before connecting the mat to the Safety Controller, verify that the mat and the wiring to the mat does not exceed the maximum resistance specification using the following procedure. 1. Measure the resistance between wires connected to the same surface of the mat (see diagram ): W1 and W2:______A______ ohms W3 and W4:______B______ ohms W1 W2 W3 W4 2. While stepping on the mat, measure the resistance between W1 and W3.
SC22-3/-3E Safety Controller Instruction Manual • If the Safety Input is configured for auto reset: Verify that the delayed safety output turns OFF immediately for 500 ms, then turns back ON. 23. Enabling Device Function a. Verify that all inputs associated with the same output as the enabling device are in the Run state to turn the output(s) ON. The enabling device is to remain in the Stop state. Verify that the associated Safety Outputs are ON. b.
SC22-3/-3E Safety Controller Instruction Manual 9 Troubleshooting 9.1 Cleaning Disconnect power to the Controller and wring out excessive moisture from the cloth before cleaning.If cleaning of the polycarbonate enclosure and display is required, wipe it down with a soft cloth that has been dampened with a mild detergent and warm water solution. 9.
SC22-3/-3E Safety Controller Instruction Manual 9.3.1 Troubleshooting Fault CodeTable Fault Code 0.0 Displayed Message Input Fault Additional Message Cycle Input Further Steps and Checks • Check for unstable input signal. • Turn input OFF to clear the fault indication. A Safety Output appears ON when it should be OFF. 1.1 Output Fault Check for Shorts • Check for short to external voltage source. • Check DC common wire size connected to the Safety Output loads.
SC22-3/-3E Safety Controller Instruction Manual Fault Code Displayed Message Additional Message Further Steps and Checks • The AVM may be disconnected; check the wiring. • Perform a System Reset to clear the fault and cause another test to occur. 2.1 2.2 Concurrency Fault Simultaneity Fault On a dual-channel input with both inputs in the Run state, one input went to the Stop state then back to Run. Cycle Input Cycle Input • Check wiring. • Check input signals. • Consider adjusting debounce times.
SC22-3/-3E Safety Controller Instruction Manual Fault Code Displayed Message Additional Message Further Steps and Checks 2.19 Open Lead Check Terminal xx 2.20 Input Fault Check Terminal Missing test pulses. xx • Check for short to ground. 2.21 Open Lead Check Terminal xx • Check for open lead. 2.22 – 2.23 Input Fault Check Terminal xx • Check for unstable signal on the input. 2.24 Input Activated Perform System A two-hand control input was activated (turned ON) while it was bypassed.
SC22-3/-3E Safety Controller Instruction Manual Fault Code Displayed Message Additional Message Further Steps and Checks The supply voltage dropped below the rated voltage for longer than 6 ms. Supply Voltage Low 4.1 Check Power Supply • Check the power supply voltage and current rating. • Check for an overload on the outputs that might cause the power supply to limit the current. A configuration parameter has become corrupt.
SC22-3/-3E Safety Controller Instruction Manual 9.5 Fault Diagnostics—PCI The first step in diagnosing faults via the PCI is to bring up the Live Display screen (see section 7.2 Display Controller Information — PC Interface (PCI) on page 71). The Live Display screen (if the PC is connected to the Controller) shows in real time, the status of each Safety Output, which device caused an output to turn OFF, if any, and basic information about the Controller model and the configuration. 9.5.
SC22-3/-3E Safety Controller Instruction Manual 9.6 Fault Diagnostics—OBI Troubleshooting the Controller and connected I/O devices is easy using the Onboard Interface. Any event that causes a Safety Output to turn OFF or stay OFF (either for fault or input stop events) will be immediately detected and displayed on the Controller’s display. Further information about current and past faults can be accessed using the Fault Diagnostics menu.
SC22-3/-3E Safety Controller Instruction Manual 9.6.2 View Fault Log—OBI The Safety Controller keeps a record of the last ten faults that have occurred. The faults are viewable from the View Fault Log menu. To view the fault log, select View Fault Log in the Diagnostics menu and press OK. The screen shows the first fault stored in the fault log. Use the left/right arrow keys to view additional faults in the fault log. • The top line of the fault log screen indicates which device had the fault.
SC22-3/-3E Safety Controller Instruction Manual 10 Input Device and Safety Category Reference For ease in finding information about them, the specific device types discussed are presented in the following order. 10.2 Protective (Safety) Stop on page 92 10.3 Interlocked Guard or Gate on page 93 10.4 Optical Sensor on page 98 10.5 Two-Hand Control on page 100 10.6 Safety Mats on page 103 10.7 Emergency Stop Push Buttons on page 106 10.8 Rope/Cable Pull on page 109 10.9 Enabling Device on page 112 10.
SC22-3/-3E Safety Controller Instruction Manual The following sections deal only with Category 2, Category 3, and Category 4 applications, as described by ISO 13849-1 (1999). The following figure provides a snapshot of the possible safety categories that can be achieved for each device type, depending on the selected circuit option. Refer to the text sections following, as well as the appropriate standards, for further information.
SC22-3/-3E Safety Controller Instruction Manual WARNING: . . . Input Devices with Solid State Outputs The Safety Controller will not detect shorts between inputs or from an input to +24V, if the input signals on these terminals are coming from input devices with Solid State Outputs. It is the user’s responsibility to use a device that can detect these shorts (e.g., the Banner EZ-SCREEN® Light Screen can detect a short between its two solid-state outputs or from each output to +24V). WARNING: . . .
SC22-3/-3E Safety Controller Instruction Manual Fault Exclusion must be used to achieve a higher level of safety circuit integrity. Dual-Channel (2 or 3 terminals): This circuit typically can meet ISO 13849-1 Category 2 or Category 3 requirements, depending on the safety rating and installation of the device(s). Dual Channel 3-terminal hookup uses pulse monitoring and can detect a short circuit to another source of power.
SC22-3/-3E Safety Controller Instruction Manual The safety performance (integrity) must reduce the risk from identified hazards as determined by the machine’s risk assessment. See section 10.1 Safety Circuit Integrity and ISO 13849-1 (EN954-1) Safety Circuit Principles on page 90 for guidance if the requirements as described by ISO 13849-1 are to be implemented. In addition to the requirements stated in this section, the design and installation of the interlocking device should comply with ANSI B11.
SC22-3/-3E Safety Controller Instruction Manual The switch and its magnet must be mounted a minimum distance from any magnetized or ferrous materials for proper operation. If either the switch or magnet is mounted on a material that can be magnetized (a ferrous metal, such as iron), the switching distance will be affected. This distance will be stated by the manufacturer.
SC22-3/-3E Safety Controller Instruction Manual Category 3 Interlocked Guard Circuit A dual-channel hookup switching +24V dc is typically a Category 3 application, because a single failure does not result in a loss of safety. Loss of the switching action in one channel is detected by the actuation of opening and closing the guard, allowing the monitoring function of the safety inputs to detect the discrepancy between the channels.
SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (2 or 3 terminals): This circuit typically can meet ISO 13849-1 Category 2 or Category 3 requirements, depending on the safety rating and installation of the switch(es). Dual Channel 3-terminal hookup uses pulse monitoring and can detect a short circuit to another source of power. Both 2- and 3-terminal hookup can detect a short between channels when the contacts are open if the short is present longer than 2 seconds.
SC22-3/-3E Safety Controller Instruction Manual 2x Complementary (4 or 5 terminals): This circuit can meet ISO 13849-1 category 4 requirements, depending on the safety rating and the installation of the switches. This circuit can detect a short circuit between channels. A coded magnetic switch would typically use this style. In the guard-closed condition (as shown), a short across the closed contact can cause the response time to increase based on the debounce time.
SC22-3/-3E Safety Controller Instruction Manual WARNING: . . . Incomplete Information Many installation considerations necessary to properly applying these devices are not covered by this document. Refer to the appropriate device installation instructions to ensure the safe application of the device. Optical safety devices also must be placed at an appropriate safety distance (separation distance), according to applicable standards.
SC22-3/-3E Safety Controller Instruction Manual cause the response time to increase based on the debounce time. In this situation, the response time could be longer than specified, based on the (selected) debounce time, see section 4.3.2 Safety Input Device Properties on page 28. Complementary (PNP device): This circuit can meet ISO 13849-1 category 2, 3, or 4 requirements depending on the safety rating and the installation of the device. This circuit can detect a short circuit between channels.
SC22-3/-3E Safety Controller Instruction Manual The installation of the hand controls must consider: • Failure modes that would result in a short circuit, a broken spring(s), mechanical seizure, etc. that would result in not detecting the release of a hand control • Severe contamination or other environmental influences that may cause slow response when released or false ON condition of the hand control(s), e.g., sticking of a mechanical linkage • Protection from accidental or unintended operation (e.g.
SC22-3/-3E Safety Controller Instruction Manual Ds = the separation (safety) distance in inches S = the minimum safety distance in millimeters K = OSHA/ANSI and ISO 13855 hand speed constant of 1600mm/s (63" per second) (NOTE 1 below) T = the overall stop time of the machine, measured from the actuation of the sensing function to the final ceasing of all motion.
SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (PNP device): This circuit is a Type IIIa Two-Hand Control circuit as described by ISO 13851, and typically can meet ISO 13849-1 (EN 954-1) category 1 requirements. The Safety Controller does not provide short circuit detection between channels in this configuration.
SC22-3/-3E Safety Controller Instruction Manual Do not use safety mats as a tripping device to initiate machine motion (such as in a presence-sensing device initiation application), due to the possibility of unexpected start or re-start of the machine cycle resulting from failure(s) within the mat and the interconnect cabling. Do not use a safety mat to enable or provide the means to allow the machine control to start hazardous motion by simply standing on the safety mat (e.g., at a control station).
SC22-3/-3E Safety Controller Instruction Manual This circuit typically can meet ISO 13849-1 category 2 or category 3 requirements depending on the safety rating and installation of the mat(s) or other sensor(s). This circuit can detect a short circuit between channels or to another source of power. 10.6.3 Safety Mat Installation The mounting surface quality and preparation for the sensor must meet the requirements stated by the sensor’s manufacturer.
SC22-3/-3E Safety Controller Instruction Manual Formula for U.S. Installations Formula for EU-Certified Installations The formula used to calculate separation (safety) distance (Ds) is: The formula used to calculate minimum safety distance (S) is: Ds = K x ( Ts + Tr ) + Dpf S=(KxT)+C in both cases, where: Ds = the separation (safety) distance in inches. S = the minimum safety distance in millimeters.
SC22-3/-3E Safety Controller Instruction Manual The Safety Controller Emergency Stop configuration prevents muting or bypassing of the E-Stop input(s). However, the user still must ensure that the E-Stop device remains active at all times. WARNING: . . . Reset Routine Required U.S. and international standards require that a reset routine be performed after clearing the cause of a stop condition (e.g., arming an E-stop button, closing an interlocked guard, etc.).
SC22-3/-3E Safety Controller Instruction Manual Category 2 E-Stop Circuit A single-channel emergency stop application typically provides a Category 2 level of circuit performance, because a short circuit could cause the loss of the safety function. The principle of fault exclusion must be incorporated into the design and installation to either eliminate, or reduce to an acceptable (minimal) level of risk, the possibility of undetected faults or failures that can result in the loss of the safety function.
SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (2 or 3 terminals): This circuit typically can meet ISO 13849-1 Category 3 requirements, depending on the design and installation of the switch. Dual-channel 3-terminal hookup uses pulse monitoring and can detect a short circuit to another source of power. Both 2- and 3-terminal hookup can detect a short between channels when the contacts are open if the short is present longer than 2 seconds.
SC22-3/-3E Safety Controller Instruction Manual 110 www.bannerengineering.com - tel: 763-544-3164 P/N 133487 rev.
SC22-3/-3E Safety Controller Instruction Manual 10.8.2 Rope Pull Hookup Options The device is shown in the armed (Run) state. Single-Channel (1 terminal, 2 terminals or PNP device): These circuits can typically meet ISO 13849-1 Category 2 requirements, depending on the design and installation of the switch. At a minimum, to achieve a Category 2, the switch must be a safety-rated device. The 1-terminal and the PNP device can not detect a short circuit to another source of power.
SC22-3/-3E Safety Controller Instruction Manual 10.9 Enabling Device An enabling device is a manually operated control that, when continuously actuated, will allow a machine cycle to be initiated in conjunction with a start control. Standards that cover the design and application of enabling devices include: ISO 12100-1/-2 IEC 60204-1 ANSI/NFPA 79 ANSI/RIA R15.06 ANSI B11.19 See section 4.6.3 Enabling Devices on page 36 for more information. 10.9.
SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (2 or 3 terminals): This circuit typically can meet ISO 13849-1 Category 2 or Category 3 requirements, depending on the safety rating and installation of the device(s). Dual Channel 3-terminal hookup uses pulse monitoring and can detect a short circuit to another source of power. Both 2- and 3-terminal hookup can detect a short between channels when the contacts are open longer than 2 seconds.
SC22-3/-3E Safety Controller Instruction Manual 2x Complementary (PNP device): This circuit can meet ISO 13849-1 category3 or category 4 requirements depending on the design and installation of the enabling device. This circuit can detect a short circuit between channels. In the actuated condition (e.g., S1 OFF/S2 ON) a short across the closed contact can cause the response time to increase based on the debounce time.
SC22-3/-3E Safety Controller Instruction Manual Safe work procedures provide a means for individuals to control exposure to hazards through the use of written procedures for specific tasks and the associated hazards. Such procedures also provide base documentation for a training program. Once again, personnel must be trained in the use of the safeguard and the use of the bypass.
SC22-3/-3E Safety Controller Instruction Manual Complementary (PNP device): This circuit can meet ISO 13849-1 category 2, 3, or 4 requirements depending on the safety rating and the installation of the device. This circuit can detect a short circuit between channels. In the actuated condition (e.g., S1 OFF/S2 ON as shown), a short across the closed contact can cause the response time to increase based on the debounce time.
SC22-3/-3E Safety Controller Instruction Manual WARNING: . . . Muting Limitations Muting is allowed only during the non-hazardous portion of the machine cycle. A muting application must be designed so that no single component failure can prevent the stop command or allow subsequent machine cycles until the failure is corrected (per OSHA 1910.217(c)(3)(iii)(d), and ANSI B11.19). WARNING: . . . Mute Inputs Must Be Redundant It is not acceptable to use a single switch, device, or relay with two N.O.
SC22-3/-3E Safety Controller Instruction Manual The user has the responsibility to satisfy all local, state, and national laws, rules, codes, and regulations relating to the use of safety equipment in any particular application. It is extremely important to be sure that all appropriate agency requirements have been met and that all installation and maintenance instructions contained in the appropriate manuals are followed.
SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (4 terminals): This circuit can meet ISO 13849-1 category 2, 3, or 4 requirements depending on the installation of the mute device(s). This circuit can detect a short circuit between channels or to another source of power. Complementary (2 or 3 terminals): This circuit can meet ISO 13849-1 category 2, 3, or 4 requirements depending on the safety rating and the installation of the output device.
SC22-3/-3E Safety Controller Instruction Manual Lamp monitoring must be selected if the application requires compliance with UL 61496. 10.11.6 Muting Time Limit (Backdoor Timer) The muting time limit (backdoor timer) allows the user to select a maximum period of time that muting is allowed to occur. This feature hinders the intentional defeat of the muting devices to initiate an inappropriate mute. It is also useful for detecting a common mode failure that would affect all mute devices in the application.
SC22-3/-3E Safety Controller Instruction Manual For example, in an entry/exit application where a pallet initiates the mute cycle by entering a cell, if both the entry and the exit PSSDs are muted, it may be possible for an individual to access the guarded area through the “exit” of the cell. An appropriate solution would be to mute the entry and the exit with separate safeguarding devices. WARNING: . . .
SC22-3/-3E Safety Controller Instruction Manual 10.11.10 Mute Timing Sequences Power Safety Light Screen Mute Enable Mute Sensor 1 < 3s Mute Sensor 2 Max. Time Backdoor Timer Max. Time Safety Output Mute cycle ends due to the expiration of the Backdoor Timer Mute cycle prevented due to open Mute Enable input Figure 67. Timing logic: two mute sensors, mute enable, safety light screen and limited mute time. Mutable safety device configured for Auto Reset.
SC22-3/-3E Safety Controller Instruction Manual Power 2-Hand Inputs Mute Enable Mute Sensor 1 < 3s < 3s Mute Sensor 2 Backdoor Timer Max. Time Max. Time Safety Output Mute cycle prevented due to open Mute Enable input Output remains OFF when mute cycle expires, even though THC is ON Output remains OFF until THC is cycled Figure 69. Timing logic: two mute sensors, mute enable, two-hand control and limited mute time P/N 133487 rev. C www.bannerengineering.
SC22-3/-3E Safety Controller Instruction Manual 11 Ethernet Reference Information on Ethernet functionality can also be found in the following sections of this manual: 2.1 Ethernet-Compatible Model on page 9: Description of supported Ethernet protocols 2.5.2 Personal Computer Interface (PCI) on page 14: Accessing Ethernet functionality 2.6.4 Virtual Status Outputs on page 17: See Warning 3.
SC22-3/-3E Safety Controller Instruction Manual • Instance ID 102 (0x66) with a size (data length) of one hundred forty 16-bit words. Instance ID 102 is used to access fault log information (it provides no Virtual Status Output information). The format of the fault log information starts with a time stamp and may be found in the appropriate Fault Log Support file (see section 11.3 Support Files on page 125). Output (O->T) Assembly Object The Output Assembly Object is not implemented.
SC22-3/-3E Safety Controller Instruction Manual 6. Access the data in the Fault Index Table file using the Fault Index number. The data in the file provides a specific fault number, a short fault description, a longer fault description, and a remedy. 11.4 Table Row and Column Descriptions The following are table row and column descriptions (listed in alphanumeric order) for the register maps found on the PCI, the computer, and the Banner website.
SC22-3/-3E Safety Controller Instruction Manual 3 Normal Operating Mode (including if I/O faults are present) 4 Configuration Mode 5 Waiting for System Reset (exiting Configuration Mode) 6 System Lockout REG:BIT Indicates the offset from 30000 or 40000 followed by the specific bit in the register. Reserved Banner has reserved these registers for internal use. Seconds Since Power-up (System Info File) The time in seconds since power was applied to the Safety Controller.
SC22-3/-3E Safety Controller Instruction Manual 12 Glossary The following terms are used in this manual. Where possible, definitions are from the U.S. and international product performance standards that govern the design of the Safety Controller. For more definitions, visit the online learning segment under Support and Training at www.bannerengineering.com.
SC22-3/-3E Safety Controller Instruction Manual Diverse-redundancy: The practice of using components, circuitry or operation of different designs, architectures or functions to achieve redundancy and to reduce the possibility of common mode failures. Dual-channel: Having redundant signal lines for each safety input or Safety Output. Enable a mute time limit: As soon as a mute sensor is mapped to a safety input device, a default time limit of 30s will show up in the properties window.
SC22-3/-3E Safety Controller Instruction Manual Run Signal: The input signal monitored by the Controller that, when detected, causes one or more Safety Outputs to turn ON, if their other associated input signals are also in the Run state. In this manual, either the input device or the device signal is said to be in the Run state. Safety-rated device: A device that is designed to an applicable safety standard and when properly applied, reduces the level of risk.
