Safety Controller with Ethernet 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). This type of application uses reverse/negative logic and cer-
tain failures (e.g., loss of power to the Module) can result in a "false" enable signal.
10.6.1 Safety Mat Requirements
The following are minimum requirements for the design, construction, and installation of four-wire safety mat sensor(s) to be interfaced
with the Safety Controller. These requirements are a summary of standards ISO 13856-1, ANSI/RIA R15.06 and ANSI B11.19. The user
must review all relevant applicable regulations and standards and apply the Controller and any sensors in full compliance.
Safety Mat System Design and Construction
The safety mat system sensor, Safety Controller, and any additional devices must have a response time that is fast enough to reduce the
possibility of an individual stepping lightly and quickly over the mat’s sensing surface (less than 100 to 200 ms, depending on the relevant
standard).
For a safety mat system, the minimum object sensitivity of the sensor must detect, at minimum, a 30 kg (66 lb.) weight on an 80 mm
(3.125") diameter circular disk test piece, anywhere on the mat’s sensing surface, including joints and junctions. The effective sensing
surface or area must be identifiable and can comprise one or more sensors. The safety mat supplier should state this minimum weight
and diameter as the minimum object sensitivity of the sensor.
User adjustments to actuating force and response time are not allowed (ISO 13856-1). The sensor should be manufactured to prevent
any reasonably foreseeable failures (e.g., oxidation of the contact elements) which could cause a loss in sensitivity.
The environmental rating of the sensor must meet a minimum of IP54. When the sensor is specified for immersion in water, the sensor’s
minimum enclosure level must be IP67. The interconnect cabling may require special attention. A wicking action may result in the ingress
of liquid into the mat, possibly causing loss of sensor sensitivity. The termination of the interconnect cabling may need to be located in an
enclosure that has an appropriate environmental rating.
The sensor must not be adversely affected by the environmental conditions for which the system is intended. The effects on the sensor of
liquids and other substances which can be expected must be taken into account. For example, long-term exposure to some liquids can
cause degradation or swelling of the sensor’s housing material, resulting in an unsafe condition.
The sensor’s top surface should be a lifetime non-slip design, or otherwise minimize the possibility of slipping under the expected operat-
ing conditions.
The four-wire connection between the interconnect cables and the sensor must withstand dragging or carrying the sensor by its cable
without failing in an unsafe manner (e.g., broken connections due to sharp pulls, steady pulls, or continuous flexing). If not, an alternate
means must be employed to avoid such a failure, for example, a cable which disconnects without damage and results in a safe situation.
10.6.2 Safety Mat Hookup Options
Pressure-sensitive mats and pressure-sensitive floors must meet the requirements of the category for which they are specified and
marked. These categories are defined in ISO 13849-1 (EN 954-1).
The safety mat, its Safety Controller and any output signal switching devices must meet the requirements of safety Category 1 as a
minimum. To meet these requirements, the system must at minimum meet the requirements of ISO 13856-1 (EN 1760-1) and the rele-
vant requirements of ISO 13849-1 (EN 954-1).
The Safety Controller is designed to monitor 4-wire safety mats; the Safety Controller is not compatible with two-wire devices (mats,
sensing edges, etc., with two wires and a “sensing” resistor).
SC22-3/-3E Safety Controller Instruction Manual
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