R MatGuard PRESSURE SENSITIVE SAFETY MAT SYSTEM INSTALLATION & USER MANUAL READ THIS MANUAL IN FULL BEFORE INSTALLATION After installation this manual should be retained in a safe and accessible place
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MatGuard - Pressure sensitive safety mat system Installation and user manual Section 1 STORAGE AND HANDLING page 4 Section 2 SYSTEM DESCRIPTION page 5 Section 3 APPLICATIONS page 8 Section 4 SPECIFICATIONS page 10 Section 5 INSTALLATION DESIGN page 14 Section 6 INSTALLATION and COMMISSIONING page 26 Section 7 USE page 36 Section 8 MAINTENANCE page 37 2
Type No: 440F-C4000P MACHINE ENABLED MANUAL RESET MODE PRESS TO RESET A1 • A2 + RESET IND 1 2 MC Y1 Y3 440F-C4000D EN 1760-1, EN 954-1 Cat 3 Response time: 35mS R RESET IND 3 4 MC Y2 13 23 31 POWER MADE IN ENGLAND -- • • Y5 MatGuard 24V AC/DC MatGuard 110/230VAC selectable R Y4 AUTO RESET MODE Isolate before opening MANUAL RESET MODE 83HA A300 IND CONT EQ Y6 MACHINE ENABLED • • 14 24 32 POWER Control unit marking MGCD1 AUTO RESET MODE MATGUARD PRESSURE SENSITIVE
INTRODUCTION The pressure sensitive mat system is designed for use as a safety product in an industrial environment by professional personnel. It provides protection against risks which can be eliminated by the isolation of electrical power when an operator is in the vicinity of the hazard. This manual covers the installation and use of all parts of the system including special shapes and sizes of sensor mats.
Section 2 - SYSTEM DESCRIPTION The system comprises one or more interconnected pressure sensitive mats and a control unit. There are no 'dead zones' within the detection zone. Individual sensor mat sections are available in rectangular standard sizes and also in specially cut shapes up to the size of the largest standard mat. All sensor mats have the same construction and operation principle. Each mat has two conductive plates which are held apart by non-conductive compressible separators.
The vinyl outer surface of the mat is completely sealed to resist the ingress of liquids. It will resist bleaches, acids, salts and most industrial chemicals. Refer to section 5.3.1 for detailed guidance on chemical resistance. The system operates at 24V DC with restricted fault current. Damage to the mats or interconnecting wiring will not therefore generate any electrical shock hazard in normal circumstances.
SENSOR MATS CONTACTOR CONTROL POWER -+ AUXILIARY OPTIONAL REMOTE INDICATION UNIT 24V AC/DC SUPPLY Y1 Y2 Y3 Y4 Y5 Y6 A2 + RESET IND 1 2 MC Y1 Y3 Y5 RESET IND 3 4 MC Y2 Y4 Y6 13 23 31 24V AC/DC 110/230VAC selectable A1 - 14 24 32 L N 110/230V AC SUPPLY REMOTE RESET PUSH BUTTON (IF REQUIRED) CONTACTOR MONITORING L1L2 L3 K1 AUX K1 AUX K1 K2 ILLUMINATION (IF REQUIRED) Fig. 3 Basic system and connections (shown with two contactors).
Section 3 - APPLICATIONS It is important that the type of safeguarding system is suitable for the application for which it is intended. A documented process of risk assessment of the machinery or process will reveal the identity and nature of the hazards together with other relevant information. The characteristics of the safeguarding system should then be compared with the results of the risk assessment to determine whether the risk can be reduced to an acceptable level.
USE AS A PRESENCE SENSING SYSTEM WITHIN A GUARDED PERIMETER FIXED GUARDING INTERLOCKED DOOR (WITH LOCKING) Fig. 6 HAZARD PRESSURE SENSITIVE MATS Use as a presence sensing system within a guarded perimeter. The system provides presence sensing to prevent any possibility of the machine being started whilst personnel are inside the enclosed area. • The safety distance calculations given in section 5.4.1 are not applicable when the system is used in this way as a secondary protective system.
Section 4 - SPECIFICATIONS Control Unit Conformity Response time (mat pressedsafety contacts open) Environmental protection Impulse withstand voltage Contamination level Min switched current/voltage Power supply - user select Power consumption Relay outputs Utilisation category Outputs: remote reset/indicator Inputs Safety inputs Indicator LEDs Internal controls Internal supply fuses Operating temperature range Humidity Vibration MC-MC Contactor monitor loop Maximum conductor size Terminals Installati
Control Unit 440F-C28013 Power supply 24V AC/DC or 110/230V selectable Relay outputs Safety inputs Indicator LEDs Terminals 2 x independant volt free N/O safety contacts 1 x independant volt free N/C monitored contact 1 x volt free N/C auxilliary contact 1 x volt free N/O auxilliary contact 8 x 4 wire mats with molded Allen Bradley connectors LED LED LED LED LED 1 2 3 4 5-12 Power Manual reset mode Auto reset mode Machine enabled Channel fault status GREEN GREEN GREEN GREEN GREEN/RED Minus termi
SENSOR MAT Add 52mm for each perimeter trim (NZG 3010) ACTIVE UNITING TRIM PERIMETER TRIM DETECTION ZONE NOMINAL MAT SIZE No.6 x 3/8" self tapping screw (Not supplied) NOMINAL MAT SIZE Add 10mm for each uniting trim joint Add 95mm for each perimeter trim (NZG 3011) Fig. 7 Detail of perimeter trim and uniting trim showing detection zone. • • For guidance on machine interfacing see Section 5. For details of the fixing and interconnection arrangements see Section 6.
113.5 (4.5) 180 (7.1) 163.5 (6.4) 10 (0.39) 130 (5.2) 11 (0.43) 75 (3.0) POLYCARBONATE ENCLOSURE 440F-C4000P 230 (9.1) 165 (6.5) 4 x M4 (0.16) 4 x M6 (0.23) Use fixing holes at bottom of lid fixing holes 210 (8.3) 225 (8.9) 11 (0.43) 143 (5.6) STEEL ENCLOSURE 440F-C4000S & 440F-C28013 73 (2.9) 120 (4.7) 152 (6.0) DIN RAIL ENCLOSURE 440F-C4000D 35mm DIN RAIL Fig. 8 Dimensions in mm (inches) - not to scale.
Section 5 - INSTALLATION DESIGN This manual should be read in full before installation is commenced. It is recommended that installations should only be designed by persons suitably competent in electrical and mechanical engineering and having experience in safety related control system design. Many factors contribute to a safe and reliable installation.
5.3 ENVIRONMENT AND OPERATING CONDITIONS By reference to the specifications given in section 4 and the information in this section, ensure that there are no adverse factors which could compromise the integrity of the system. 5.3.
5.3.5 E.M.C. The mat system complies with the requirements of the European EMC Directive. Normal operation under interference conditions likely in industrial environments is assured and has been tested and certified. NOTE: Special measures may be required in the presence of abnormally high levels of E.M.I. e.g. near to welding or induction heating equipment or near radio transmitters/transceivers. 5.3.6 FLOOR The floor or mounting surface for the sensor mats must be flat, smooth and rigid, i.e.
requirements for the size and positioning of the mats as shown in Fig. 11. FIXED GUARD HAZARD SENSOR MATS ARROWS SHOW ACCESS HAZARD SENSOR MATS EXTENDED FIXED GUARD HAZARD SENSOR MATS Fig. 11. NOTE: Fixed guarding should meet the requirements of EN 953, EN 294 & EN 811. Firstly, ascertain the route(s) where unobstructed access to the hazard zone is required across the mat system.
Are specific formulae or minimum distances given in Type-C standards ? YES Determine the minimum distance according to the Type-C standard NO Use this minimum distance Calculate minimum distance by the formulae in prEN 999 Can this minimum distance be achieved ? Reduce overall response time and/or reduce parameter C NO YES YES Does the minimum distance allow persons to be within the danger zone without being detected ? YES Use this minimum distance together with supplementary measures depending o
The overall stopping time T is made up of two parts: T = t1 + t2 t1 is the maximum time between actuation of the sensing function and the output signal switching devices being in the OFF state. For the mat system, t1 = 35mS. t2 is the response time of the machine i.e. the time required to stop the machine or remove the risks after receiving the output from the mat system. The response time of the machine used in the calculation needs to be the worst case time.
5.5 FIXED GUARDS The fixed guards should be designed so that access is not possible to the hazard zone other than via mat system. Guard construction and positioning should be in accordance with EN 953, EN 294 and EN 811. 5.6 GOOD INSTALLATION DESIGN AND MEASURES AGAINST BYPASS It must not be possible to reach the hazard without standing on the mats. Access to the hazard zone from positions which do not involve standing on the mats must be prevented.
The control unit conforms to category 3 according to EN 954-1. In common with other safety mats and floors, category 3 performance for the sensor mat cannot be achieved for faults resulting from severe mechanical damage or long term degradation. The sensor mats conform to category 1 according to EN 954-1. The system comprising of interconnecting sensor mats and control unit meets the requirements of EN 954-1 category 3.
24VDC, SUPPLY 110VAC, 230VAC SUPPLY (ALTERNATIVE SUPPLY CONNECTION) BLACK WHITE SENSOR MATS 2 3 4 L2 L3 MOMENTARY PUSH BUTTON STOP WHITE 1 L1 START AUXILIARY INPUT BLACK INTERNAL SENSOR MAT PLATES K1 (AUX) MOMENTARY PUSH BUTTON LINK LINK L +VE 31 13 23 MC MC N –VE 32 14 24 K1 CONTROL UNIT AUXILIARY OUTPUT N/O PB R IND MOTOR PROTECTION E.G. THERMAL CUT OUT FUSE M K1 Fig.
VDC, SUPPLY 110VAC, 230VAC SUPPLY (ALTERNATIVE SUPPLY CONNECTION) BLACK WHITE 1 SENSOR MATS 2 3 4 L2 L3 MOMENTARY PUSH BUTTON STOP WHITE Y1 Y3 Y5 L1 START AUXILIARY INPUT BLACK INTERNAL SENSOR MAT PLATES K1 (AUX) MOMENTARY PUSH BUTTON LINK LINK A1 + 31 13 23 MC A2 – 32 14 24 MC K1 CONTROL UNIT RESET RESET IND IND AUXILIARY OUTPUT Y2 Y4 Y6 MOTOR PROTECTION E.G. THERMAL CUT OUT FUSE M K1 Fig.
After completion of the design of the safety related control system ensure that the response time assumed at 5.4.1 remains valid. If the value changes, it will be necessary to repeat the safety distance calculations. Next consider the options for reset. The consequences of the reset scheme selected should be carefully considered for hazards caused by unexpected start up etc., both under normal conditions and under fault conditions. Timing diagrams are given below for both modes of the mat system.
CONTACTOR MONITORING Contactor monitoring is provided via the two terminals marked MC. It should be used in all dual channel two contactor systems. If one of the contactors fails to isolate the power, the mat control unit will lock out and prevent the re-energisation of the other contactor until the fault is rectified. 5.8 FINAL SENSOR MAT LAYOUT Having considered these factors, the sensor mat layout can now be checked and finalised.
Section 6 - INSTALLATION AND COMMISSIONING This manual should be read in full before commencing installation. Study this section completely before starting work. The installation and commissioning should be supervised by the system designer. A mechanical technician and an electrician familiar with industrial wiring practices will be required to undertake the installation. Commissioning should be undertaken by a trained electrical technician experienced in safety installations.
Leave sufficient wire tail length to enable the connection to be remade if a mat is to be replaced, but ensure that the interconnecting wires will fit easily under the edge trim without crushing. Join the wires using butt connectors supplied as shown in Fig. 24 below. Where mat wires require extending, e.g. front mat to rear mat connections, and control unit connections, use an extra pair of the butt connectors and a length of twin wire (see wiring specification - section 6.2).
Mark out the edge trim fixing positions on the floor allowing the trim to overlap the mat. Using the holes in the trim as a guide, mark out and drill the floor (fit plugs if required). Clean off the floor and fix the mats and edge trim in place using countersunk screws to suit the application. As the perimeter trim is fitted ensure none of the wiring is trapped or crushed between the trim and the floor or the top and bottom sections (depending on trim type).
3 N –ve +ve 2 L SECONDARY FUSE 500mA 230 MANUAL RESET MODE GREEN POWER GREEN AUTO RESET MODE GREEN 1 110 LED INDICATORS MACHINE ENABLED GREEN A PRIMARY FUSE 500mA 10 Mode set Voltage set MANUAL 110V M AUTO 230V 24V N/O PB R IND MC MC 31 32 MAT CONNECTION TERMINALS tick boxes SAFETY OUTPUT TERMINALS 11 AUXILIARY TERMINALS REMOTE RESET TERMINALS REMOTE RESET INDICATION TERMINALS CONTACTOR MONITORING TERMINALS Date 13 14 23 24 1 2 3 4 BLACK 6 BLACK 7 5 WHITE 8 9 WHITE
1 110V 2 L 24V 230V N 3 +ve –ve N/C AUXILIARY 32 TERMINALS 31 4 N/O AUXILIARY 42 TERMINALS 41 6 tick boxes 24V 230V 110V N/C MONITORED OUTPUT TERMINALS CONTACTOR MONITORING TERMINALS REMOTE RESET INDICATION TERMINALS REMOTE RESET TERMINALS Date AUTO MANUAL 11 Mode set Voltage set 14 SAFETY 13 OUTPUT TERMINALS 24 23 5 34 33 7 9 8 MC MC IND R PB NO MANUAL RESET AUTO RESET MAT 2 12 MAT 1 MAT 4 MAT 3 MAT 6 MAT 5 MAT 8 10 MAT 7 4 Fig.
CONTACTOR CONTROL POWER WHITE BLACK WHITE 3 AUXILIARY 24V AC/DC SUPPLY BLACK 4 OPTIONAL REMOTE INDICATION UNIT Y1 Y2 Y3 Y4Y5Y6 5 POWER GREEN 110/230VAC selectable 8 A2 + 24V AC/DC • A1 -- RESET IND 1 2 9 RESET IND MC Y1 Y3 Y5 7 3 4 MC • • 13 23 31 6 Y2 Y4 Y6 • • AUTO RESET MODE GREEN MANUAL RESET MODE GREEN 14 24 32 MACHINE ENABLED GREEN 11 2 L N Mode set 110/230V AC SUPPLY MANUAL AUTO Date Voltage set 110v 230v 24v tick boxes 500 mAT Fuse replacement UP 110V
Connecting the mats to 440F-C28013 control unit MAT 2 MAT 1 MAT 4 MAT 3 MAT 6 MAT 5 MAT 8 MAT 7 Shorting Plug Fig. 27a Terminating unused mat connections and connecting mats If less than 8 mats are to be connected to the control unit, the other connections must be terminated with the shorting plugs supplied. The required mats should be connected in sequence (1 to 8) to the quick connect adaptors located on the outside of the unit.
10. MANUAL RESET / AUTO RESET: M/A SWITCH. Set the M/A switch to the required setting. M = MANUAL RESET MODE A = AUTO RESET MODE. 11. Mark and sign the label according to the Voltage and Mode settings established. 12. Eight six-way connectors labeled 1 to 8. These are the mat connections into the control unit and are connected to the external quick connect plugs on the outside of the unit. 13. Re-check the wiring connections including connections or modifications made to the machine control system wiring.
6. Repeat the above to check the correct operation of any status monitoring connected to the mat system. B. AUTO RESET MODE ONLY (not relevant when using 440F-C28013 control unit) 2. Check on the Control unit that: - the green LED - POWER is illuminated - the green LED - MACHINE ENABLED is on. 3. Stand on the mat and check the MACHINE ENABLED LED goes off. 4. Step off the mat, check that the MACHINE ENABLED LED goes on. 5.
Control unit - Mode of operation (440F-C28013) Auto reset On power up: Power, auto reset and machine enabled LED’s illuminate. When mat operated: Machine enabled LED goes out Stand off mat: Machine enabled LED illuminates Manual reset On power up: Power, manual reset and machine enabled LED’s illuminate.
6.5.3 ALL SYSTEM TYPES 1. Carry out any other tests required to confirm that the safety related control system meets the requirements of its Category according to EN 954-1 and works as intended. 2. Check any other safety functions associated with the machine circuits which have been affected by the installation of the mat system. There should be an existing procedure for these tests. 3. ISOLATE THE MACHINE POWER SUPPLY AT SOURCE. 4.
Section 8 - MAINTENANCE This section should be read in full before any maintenance is attempted. Attention is drawn to requirements for planned preventive maintenance. During maintenance operations, disconnect the machine’s prime mover before working on the mat system. Observe electrical safety precautions. 8.1 MAT CLEANING The sensor mats should be regularly swept to clear them of deposits such as swarf and other materials.
8.4 DISMANTLING AND DISPOSAL Dismantling the mat system is the reverse of the installation procedure and no extra hazards are presented. ENSURE THAT THE MACHINE AND MAT SYSTEM POWER IS ISOLATED AND LOCKED OFF AT SOURCE BEFORE STARTING WORK. If the system is to be reconfigured or relocated, observe the handling precautions given in section 1. The mat system does not contain any hazardous materials which require special precautions for disposal. 8.
8.5.2 Symptom – Machine does not stop or can be started with presence on the mat. DO NOT ALLOW USE OF THE MACHINE 1. With presence on the mat, is the MACHINE ENABLED LED illuminated on the mat control unit ? 2. If the MACHINE ENABLED LED is not illuminated there is a probable fault on the machine or its control system external to the mat system.– DO NOT ALLOW USE OF THE MACHINE UNTIL THE FAULT HAS BEEN RECTIFIED AND TESTED. 3. If the MACHINE ENABLED LED is illuminated.
AVAILABLE SPARES Mat Size Safety Mat Standard Perimeter Standard sIzes Model No. Standard Perimeter Trim Trim KitMGM 1010 Sensor mat 500mm x 500mm Standard Perimeter Trim millimetresmat inches 750mm Catalog No. Catalogue No. Sensor x 500mm MGM 1510 Standard Perimeter Trim 500 x 500mat19.7 x 19.7 440F-M1010BYNN Sensor 1000mm x 500mm 440F-T1010 MGM 2010 500 x 600mat19.7 x 23.6 440F-M1012BYNN Sensor 500mm x 1500mm 440F-T1012 MGM 1030 External Corner Standard Perimeter Trim 500 x 900 19.7 x 35.
Record of ROUTINE INSPECTION AND TEST (see Section 8.2) Recommended weekly. Date: Inspected by: Comments Date: Inspected by: Comments Record of THOROUGH EXAMINATION AND TEST (see Section 8.3) - Recommended 6 monthly.
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R Drawing No: 28563/2 Change No: 26190
