SAFETY CONTROLLER
Type
SC22-3
For use with E-stop Buttons, Gate Switches, Safety Light Screens including Point & Grid, Two-Hand Control,
Non-Safety Devices, Safety Mats/Edges, Muting Sensors, Bypass Switches & Live Man Pendants
Instruction Manual
European UK English Version
All rights reserved.
No part of this publication may be reproduced or transmitted, in any form or by any means, without prior written permission.
© - Banner Engineering Corp., 9714 10th Avenue North, Minneapolis, MN 55441, USA.
135369 06.03.08
Intentionally left blank
SC22-3 Safety Controller
Table of Contents
Contents
1 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 SAFETY NOTICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.3 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 PRODUCT SAFETY LABELLING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 SAFETY STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 INGRESS PROTECTION RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 ELECTRICAL SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 CONDITIONS OF EQUIPMENT USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6.1 SC22-3 Safety Controller Interfacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 SECURITY PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.8 DESIGNATED & QUALIFIED PERSONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.8.1 Designated Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.8.2 Qualified Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9 Safety Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9.1 Signals Run & Stop States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.10 RESETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.10.1 Manual Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.10.2 System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.11 MUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.12 DISCLAIMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.13 EQUIPMENT NOISE LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.14 EQUIPMENT VIBRATION LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.15 EQUIPMENT RADIATION LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.15.1 Electromagnetic Immunity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.16 DESIGN & TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.17 MINIMUM SAFETY DISTANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.17.1 Minimum Safety Distance for Optical Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.17.2 Minimum Safety Distance for Two-Hand Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.17.3 Minimum Safety Distance for Safety Mats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.18 EXTERNAL DEVICE MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 RESET ADDITIONAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.1 Automatic Reset & Manual Reset Inputs Mapped to Same Safety Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.2 Safety Inputs with Common Manual Reset Mapped to Same Safety Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 SAFETY INPUTS & NON-SAFETY INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.1 Internal Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.2 Two-Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.2.1 Two-Hand Control activation on power-up protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.3 Enabling Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.3.1 Enabling Device time limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.4 Mute Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.4.4.1 Mute Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.4.2 Muting Time Limit (Backdoor Timer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.4.3 Mute on Power-up function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.5 Bypass Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.5.1 Bypass Switch Time Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.5.2 Bypass with mute.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.6 EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.6.1 Single channel monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.6.2 Dual channel monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 CONFIGURING THE SAFETY CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.1 Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.1.1 Functional stops as per IEC 60204-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.1.2 OSSD output connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.1.3 Safety Output On-Delays & Off-Delays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.2 Status Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.2.1 Monitored Mute Lamp Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.3 I/O Mapping & the I/O Control Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.3.1 Safety Inputs & Non-Safety Inputs Mapped to Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.3.2 Inputs Mapped to Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 SYSTEM SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.1 Settings Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.1.1 Configuration Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.1.2 Author’s name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.1.3 Power-up mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.2 Mute on Power-Up Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.3 Monitored System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 INTERNAL LOGIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7.1 Additional Logic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.8 PASSWORD OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9 CONFIRMING A CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.10 PC INTERFACE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.11 ON BOARD INTERFACE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 PRODUCT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.1 CE Marking / Product Identification Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.2 Certificate of Adequacy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.3 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.2 Model/Type Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.2.1 SC22-3 Safety Controller Model/Type Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.3 SC22-3 Safety Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 CUSTOMER SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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INSTRUCTION MANUAL - EUROPEAN VERSION
SC22-3 Safety Controller
Table of Contents
Contents (cont’d)
4 INSTALLATION - SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 SC22-3 SAFETY CONTROLLER INTERFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 CONNECTING SC22-3 SAFETY CONTROLLER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.1 Electrical Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.2 USB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.3 SC-XMP Programming Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.4 SC-XM1 External Memory XM Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 SAFETY DEVICE CONNECTION CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5 SAFETY INPUT DEVICE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5.2 Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5.3 Circuit Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5.4 Reset Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5.5 Input terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5.6 Mapped to:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5.7 Advanced Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5.7.1 Signal Change-of-State (Simultaneity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5.7.2 Closed-open debounce time / Open-closed debounce time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.8 Enable startup test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.9 Device Time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.10 Muting Sensor Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.11 Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6 NON-SAFETY INPUT DEVICE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6.1 Manual Reset Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6.2 ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6.3 Mute Enable Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.7 CONFIGURING THE SAFETY CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7.1 OBI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7.2 PC Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.7.3 Defining Safeguarding Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.7.4 Building the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.7.5 Confirming Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8 EDM, OSSD SAFETY OUTPUT & FSD CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8.1 EDM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8.1.1 Single channel monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8.1.2 Dual channel monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8.1.3 No monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8.2 FSD Interfacing Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.8.2.1 Safety (protective) stop circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.8.2.2 Safety Controller connection to interface modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.8.3 DC Common Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.9 STATUS OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.9.1 Status Output Signal Convention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.10 COMMISSIONING CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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4.11 SOFTWARE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.1 PCI Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.1.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.1.2 Installing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 OPERATING INSTRUCTIONS - PCI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 WORKING WITH THE PCI PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.1 Installing PCI Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.2 Starting PCI Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.2.1 Diagrams & Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.3 Configuration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.4 Creating a New Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.5 Adding Safety Input & Non-Safety Input Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.6 Selecting Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.6.1 Adding Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.6.2 Adding Gate Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.6.3 Adding Optical Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.6.4 Adding Two-Hand Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.6.5 Adding Muting Sensor Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.6.6 Adding External Device Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1.7 Add Non-Safety Input devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1.7.1 Adding ON/OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1.7.2 Adding Mute Enable switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1.8 Assigning Safety Output(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1.9 Configuring Status Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1.10 Confirming Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.10.1 Configuration Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.10.2 Editing Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.11 System Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.12 Editing an Existing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.13 Receiving a Configuration from SC22-3 Safety Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.14 Sending a Configuration to the SC22-3 Safety Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.15 Opening a Configuration from the XM Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.16 Sending a Configuration to the XM Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.17 Locking the XM Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1.18 Changing Password Using PCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1.19 Exporting Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1.20 Printing Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1.21 Accessing Fault Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1.22 Scheduled Fault Log Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1.23 Live Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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Contents (cont’d)
6 OPERATING INSTRUCTIONS - OBI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1 RUN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1.1 Fault Diagnostics Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1.2 Configuration Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.2.1 Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.2.2 Input/Output Mapping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.2.3 Status Output Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.2.4 View Response Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.3 Model # (Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1.4 Set Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1.5 Save Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 ENTERING CONFIGURATION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2.1 Entering Controller Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3 CONFIGURATION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3.1 Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3.1.1 Edit Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3.1.2 Send File to XM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.3.1.3 Receive File from XM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.3.1.4 Erase Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.3.2 Confirm Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3.2.1 Confirm Configuration of Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3.2.2 Confirm Configuration of Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3.2.3 Confirm Configuration of System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3.2.4 Final Confirmation Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.3.3 System Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.3.3.1 Edit Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.3.3.2 Set Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.3.4 Exit Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7 OPERATING INSTRUCTIONS — GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 DISPLAYING CONTROLLER INFORMATION — PCI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2 DISPLAYING CONTROLLER INFORMATION — OBI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2.1 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2.1.1 Configuration Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2.1.2 Safety Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2.1.3 Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2.1.4 System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2.1.5 XM Card OBI Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3 MANUAL RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.4 SYSTEM RESET & LOCKOUT CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.5 RESET SIGNAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.5.1 Monitored Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.5.2 Non-Monitored Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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Table of Contents
SC22-3 Safety Controller
Contents (cont’d)
8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1 PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 SYSTEM CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.1 Schedule of Check-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.2 Commissioning Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.3 Periodic (6 Monthly) Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.4 Daily Operational Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.5 Commissioning Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.5.1 Commissioning Pre-checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.5.2 Verifying System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.5.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2.6 Initial Setup & Commissioning/Periodic Check-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2.6.1 Safety System & Safeguarding Device Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2.6.2 Power-up & Reset Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2.6.3 Two-Hand Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2.6.4 E-Stop & Rope Pull Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2.6.5 Other Stopping Device Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2.6.6 Mute Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2.6.7 Mute on Power-Up Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.6.8 Bypass Switch Function (with Mute) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.6.9 Bypass Switch Function (without Mute) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.6.10 Enabling Device Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.6.11 System (Final) Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.2 Repairs and Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.3.1 Recovering from a Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.3.3.2 Fault Diagnostics via PCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.3.3.3 Fault Diagnostics via OBI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.4 SPARE PARTS, SPECIAL TOOLS & MATERIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.4.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.4.1.1 Safety Controller Starter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.4.1.2 Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.4.1.3 Mechanically Linked Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.4.2 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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SC22-3 Safety Controller
Table of Contents
Contents (cont’d)
A1 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
A2 Input Device & Safety Category REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A2.1 Safety Circuit Integrity & ISO 13849-1 (EN954-1) Safety Circuit Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A2.1.1 Safety Circuit Integrity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A2.1.2 Fault Exclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A2.2 Protective Stops (safety) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.2.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.2.2 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.2.2.1 Single channel, 1 terminal - Single channel, 2 terminal - Single channel, PNP switch . . . . . . . . . . . . . . . . . . . 89
A2.2.2.2 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.2.2.3 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.2.2.4 Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.2.2.5 Complementary, 2 terminals - Complementary, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.2.2.6 Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A2.3 Gate Switches (or Interlocked Guard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A2.3.1 Safety Circuit Integrity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A2.3.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A2.3.2.1 Positive-Opening Safety Interlocking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A2.3.2.2 Magnetically Operated Safety Interlocking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A2.3.2.3 Monitoring Series-Connected Safety Interlocking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A2.3.2.4 Series Connection & Safety Circuit Integrity Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A2.3.2.5 Category 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A2.3.2.6 Category 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A2.3.2.7 Category 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A2.3.3 Gate Switch (or Interlocked Guard) Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A2.3.3.1 Single channel, 1 terminal - Single channel, 2 terminal - Single channel, PNP switch . . . . . . . . . . . . . . . . . . . 92
A2.3.3.2 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A2.3.3.3 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A2.3.3.4 Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A2.3.3.5 Complementary, 2 terminals - Complementary, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A2.3.3.6 Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
A2.3.3.7 2X Complementary, 4 terminals - 2X Complementary, 5 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
A2.3.3.8 2X Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
A2.4 Optical Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
A2.4.1 Safety Circuit Integrity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
A2.4.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
A2.4.3 Minimum Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
A2.4.4 Generic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A2.4.4.1 Single channel, 1 terminal - Single channel, 2 terminal - Single channel, PNP switch . . . . . . . . . . . . . . . . . . . 95
A2.4.4.2 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A2.4.4.3 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A2.4.4.4 Complementary, 2 terminals - Complementary, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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Table of Contents
SC22-3 Safety Controller
Contents (cont’d)
A2.4.4.5 Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A2.5 Two-Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A2.5.1 Minimum Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A2.5.2 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A2.5.2.1 Dual channel, 2 terminals - Dual channel, 3 terminals - Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . 97
A2.5.2.2 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A2.5.2.3 2X Complementary, 4 terminals - 2X Complementary, 5 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
A2.5.2.4 2X Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
A2.6 Safety Mats (Safety Edges) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
A2.6.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
A2.6.1.1 Safety Mat System Design & Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
A2.6.2 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
A2.6.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
A2.6.4 Minimum Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A2.7 E-Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
A2.7.1 Safety Circuit Integrity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
A2.7.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
A2.7.2.1 Safety Circuit Integrity Levels & Multiple E-Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.7.2.2 Category 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.7.2.3 Category 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.7.2.4 Category 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.7.3 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.7.3.1 Single channel, 1 terminal - Single channel, 2 terminal - Single channel, PNP switch . . . . . . . . . . . . . . . . . 103
A2.7.3.2 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.7.3.3 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.7.3.4 Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A2.8 Rope Pulls (cable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A2.8.1 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A2.8.2 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A2.8.2.1 Single channel, 1 terminal - Single channel, 2 terminal - Single channel, PNP switch . . . . . . . . . . . . . . . . . 104
A2.8.2.2 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A2.8.2.3 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A2.8.2.4 Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A2.8.2.5 Complementary, 2 terminals - Complementary, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
A2.8.2.6 Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
A2.9 Enabling Device (Pendants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
A2.9.1 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
A2.9.2 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
A2.9.2.1 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
A2.9.2.2 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
A2.9.2.3 Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
A2.9.2.4 Complementary, 2 terminals - Complementary, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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Table of Contents
Contents (cont’d)
A2.9.2.5 Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A2.9.2.6 2X Complementary, 4 terminals - 2X Complementary, 5 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A2.9.2.7 2X Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A2.10 Bypass Switch (Bypassing Safeguards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A2.10.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A2.10.1.1 Safe Working Procedures and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A2.10.1.2 Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A2.10.2 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A2.10.2.1 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A2.10.2.2 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A2.10.2.3 Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
A2.10.2.4 Complementary, 2 terminals - Complementary, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
A2.10.2.5 Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
A2.10.2.6 2X Complementary, 4 terminals - 2X Complementary, 5 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
A2.10.2.7 2X Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
A2.11 Mute Sensor (pair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
A2.11.1 Muting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
A2.11.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
A2.11.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
A2.11.2.2 Examples of Muting Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A2.11.3 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A2.11.3.1 Dual channel, 2 terminals - Dual channel, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A2.11.3.2 Dual Channel, PNP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A2.11.3.3 Dual channel, 4 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A2.11.3.4 Complementary, 2 terminals - Complementary, 3 terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A2.11.3.5 Complementary, PNP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A2.11.4 Mute Enable (ME) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A2.11.4.1 Simultaneity Timer Reset Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A2.11.5 Mute Lamp Output (ML) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A2.11.6 Muting Time Limit (Backdoor Timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A2.11.7 Mute on Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A2.11.8 Corner Mirrors, Optical Safety Systems & Muting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A2.11.9 Multiple Presence Sensing Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
A2.11.10 Mute Timing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
A3 DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
A3.1 DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
A4 GLOSSARY & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
A4.1 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
A4.2 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
A5 CUSTOMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
ALPHA-NUMERICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
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List of Figures
Figure 1 Auto & Manual Monitored Manual Reset Safety Inputs Mapped to Same Safety Output (Safety Output has no Delay) Timing
Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2 Safety Inputs with a Common Manual Monitored Reset, Mapped to the Same Safety Output, Timing Logic . . . . . . . . . . . . . . 7
Figure 3 Two-Hand Control Device & Manual Reset Safety Input Timing Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 4 Enabling Device & Enable Mode Timing Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5 Timing Diagram for One Mute Sensor Pair with Mute Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 6 Light Screen with Mute Sensors & Bypass Switch Timing Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 7 Timing for Single channel EDM Status with Respect to Safety Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 8 Timing for Dual channel EDM Between Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9 Dual channel EDM Status, with Respect to Safety Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 10 Safety Output with OFF Delay Timing Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 11 Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 12 Input & Output Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 13 OBI Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 14 SC22-3 Safety Controller CE Marking / Production Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 15 SC22-3 Safety Controller Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 16 SC22-3 Safety Controller Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 17 PC to Safety Controller USB Port Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 18 PC to SC-XMP Programming Tool Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 19 SC22-3 Safety Controller Connections to SC-XM1 External Memory Card (XM Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 20 Safety Input Properties Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 21 Onboard Interface Including Push Buttons, LCD Display & Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 22 SC22-3 Safety Controller OBI Run Mode Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 23 SC22-3 Safety Controller OBI Configuration Mode Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 24 Editing OBI Status Outputs - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 25 Safety Output Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 26 Single channel EDM Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 27 Dual channel EDM Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 28 Generic Connection Showing Single channel, Dual channel, & No EDM options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 29 Single channel EDM Connection to SC-IM9A Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 30 Dual channel EDM Connection to IM-T-9A Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 31 Single channel EDM Connection to IM-T-9A Interface Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 32 DC Common Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 33 Category 2 Circuit - Gate Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 34 Category 3 Circuit - Gate Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 35 Category 4 Circuit - Gate Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 36 Category 2 Circuit E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 37 Category 3 Circuit E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 38 Category 4 Circuit E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 39 Determining Minimum Safety Distance (S) for the Safety Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 40 Mute Timing Diagram with Muting Sensor Pair, Mute Enable, Safety Light Screen and Limited Mute Time with Mutable
Safety Device Configured for Automatic Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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Table of Contents
List of Figures (cont’d)
Figure 41 Mute Timing Diagram with four Mute Sensors, Mute Enable, Safety Light Screen & Limited Mute Time with
Safety Light Screen Configured for Automatic Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 42 Mute Timing Diagram with Muting Sensor Pair, Mute Enable, Two-Hand Control & Limited Mute Time. . . . . . . . . . . . . . . . 114
Figure 43 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 44 Declaration of Conformity - Translation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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SC22-3 Safety Controller
List of Tables
Table 1 Safety Notice Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 2 Label Identification SC22-3 Safety Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 3 Safety Input Internal Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 4 SC22-3 Safety Controller General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 5 SC22-3 Safety Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 6 Safety Controller Safety Input Device & Circuit Type Monitoring Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 7 Signal Change-of-State (COS)(Simultaneity) Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 8 Non-Safety Input devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 9 Onboard Interface Status Indicator Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 10 Signal Convention Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 11 Safety Input & Non-Safety Input Configurable Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 12 Breakdown of Additional Safety Input Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table 13 Additional Safety Input Device Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table 14 Safety Output Status Message Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table 15 Input Device Status Message Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table 16 XM Card Status Message Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table 17 Diagnostic Display Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table 18 Kit & Accessory Information for SC22-3 Safety Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table 19 Interface Modules Series SC-IM9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table 20 Interface Modules Series IM-T-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table 21 Mechanically Linked Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table 22 Documentation Order Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Table 23 Input Devices, Circuit Options, & their Potential Safety Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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General Safety
1 GENERAL SAFETY
! WARNING BEFORE PROCEEDING FURTHER READ THIS GENERAL SAFETY CHAPTER FIRST.
This Chapter details all the necessary safety information relating to
the SC22-3 Safety Controller and its intended use.
! WARNING
Table 1 Safety Notice Breakdown
Description
Example
General
Warning
IT IS THE RESPONSIBILITY OF THE QUALIFIED PERSON WHO
CONFIGURES, INSTALLS, OR MAINTAINS THE
SC22-3 SAFETY CONTROLLER TO:
• CAREFULLY READ, UNDERSTAND AND FOLLOW THE INFORMATION IN THIS
MANUAL
• PERFORM A RISK ASSESSMENT OF THE SPECIFIC MACHINE GUARDING APPLI-
Definition
Indicates a general hazard. Details about
this hazard appear in the safety notice
explanation.
!
High
Voltage
Indicates a high voltage hazard.
CATION
• DETERMINE WHAT SAFEGUARDING DEVICES AND METHODS ARE APPROPRIATE
AS PER THE REQUIREMENTS DEFINED IN ISO 13849-1 AND EN 945-1 AND
THAT ARE REFERENCED IN THE SC22-3 SAFETY CONTROLLER MANUAL
• CREATE AND CONFIRM EACH SC22-3 SAFETY CONTROLLER CONFIGURATION
AND THEN VERIFY THAT THE ENTIRE SAFEGUARDING SYSTEM (INCLUDING
INPUT DEVICES AND OUTPUT DEVICES) IS OPERATIONAL AND WORKING AS
INTENDED
• PERIODICALLY RE-VERIFY AS NEEDED, THAT THE ENTIRE SAFEGUARDING SYSTEM IS WORKING AS INTENDED
FAILURE TO FOLLOW ANY OF THESE RECOMMENDATIONS CAN POTENTIALLY CREATE A DANGEROUS CONDITION THAT MAY LEAD TO SERIOUS INJURY OR DEATH.
1.1 SAFETY NOTICES
The Safety Notices comply with ISO 7010 and ISO 3864-2.
Table 1 on page 1 gives a breakdown of safety notices that may be
used in this document.
CAUTION
! WARNING
Example
Definition
! WARNING
A signal word accompanied by a safety
shape that indicates a potentially hazardous situation. If not avoided, the action
could result in serious injury or death. A
WARNING is highlighted in yellow.
! CAUTION
A signal word accompanied by a safety
shape that indicates a potentially hazardous situation or unsafe practice. If not
avoided, the action may result in minor or
moderate personal injury or equipment
damage. A CAUTION is highlighted in yellow.
CAUTION
A signal word that indicates a situation or
unsafe practice, which if not avoided may
result in equipment damage. A CAUTION
is highlighted in yellow.
INSTRUCTION MANUAL - EUROPEAN VERSION
is posted, preferably, prior to
or as near as possible to the information they are applicable to
throughout the Manual (see Table 1 on page 1 for breakdown). In
cases where identical notices are duplicated, a cross reference is
used at the relevant position in the text or graphic to direct the reader
to the applicable notice.
There are two different types used:
!
! WARNING
is indicted by the symbol
(see example warning on page 3)
• An Electrical Shock Hazard
WARNING indicated by the
(see example warning on page 4)
The User must read the relevant
! WARNING
appertaining to
the event before proceeding further.
1.1.2
Cautions
These type of notices
Table 1 Safety Notice Breakdown
CAUTION
This type of notice
symbol
All Cautions and Warnings contain signal words, which call attention
to safety messages and designate the degree of hazard seriousness.
WARNING
Warnings
• A general
In order to install and operate the product in a safe and efficient way,
safety notices are displayed on the product and throughout this Instruction Manual.
Description
1.1.1
! CAUTION CAUTION
are posted,
preferably, prior to or as near as possible to the information they are
applicable to throughout the Manual (see Table 1 on page 1 for
breakdown). In cases where identical notices are duplicated, a cross
reference is used at the relevant position in the text or graphic to direct the reader to the applicable notice.
1.1.3 Notes
☛ A note is posted where the information is purely advisory and is
non-mandatory. They are written and positioned close to the information they are applicable to.
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1
General Safety
SC22-3 Safety Controller
1.2 PRODUCT SAFETY LABELLING INFORMATION
Table 2 on page 2 lists the safety labels used on the product together
with their descriptions and locations.
Table 2 Label Identification SC22-3 Safety Controller
SYMBOL
Yellow background
! WARNING
LOCATION/MEANING
Located on SC22-3 Safety Controller left side panel.
Indicates the following important information:
1.3 SAFETY STANDARDS
☛ The list of standards below is included as a convenience for users of this Banner product. Inclusion of these standards does not
imply that the product complies specifically with any standard,
other than those listed in the Specifications (block 3.2.1 on
page 20) and Declaration of Conformity (appendix A3.1 on
page 115) in this Manual.
ISO 7010 (2003)
Graphical symbols -- Safety colours and safety signs -- Safety signs
used in work places and public areas
ISO 3864-2 (2004)
Graphical symbols -- Safety colours and safety signs -- Part 2: Design
principles for product safety labels
SC22-3
Safety Controller
Power
Status
Tx/Rx
ISO 12100-1 (2003) & -2 (2003)(EN 292-1 & -2)
Safety of Machinery – Basic Concepts, General Principles for Design
SO1
SO2
SO3
ISO 13849-1 (2006)(EN 954-1)
Safety-Related Parts of Control Systems
ISO 13850 (2006) (EN418)
Emergency Stop Devices, Functional Aspects – Principles for Design
! WARNING
Correct use of this control device is an essential part of proper machine control. Always follow the instructions in the Manual. Failure to
follow all instructions or warnings could lead
to serious bodily injury or death.
CONFIGURABLE SAFETY CONTROLLER
BANNER ENGINEERING CORP., USA
www.bannerengineering.com • +1 763 544 3164
ISO 13851 (2002)(EN 574)
Two-Hand Control Devices – Functional Aspects – Principles for Design
ISO 13852 (1996)(EN 294)
Safety Distances - Upper Limbs
ISO 13853 (1998) (prEN 811)
Safety Distances - Lower Limbs
ISO 13855 (2002)(EN 999)
The Positioning of Protective Equipment in Respect to Approach
Speeds of Parts of the Human Body
ISO 14119 (1998) (EN 1088)
Interlocking Devices Associated with Guards – Principles for Design
and Selection
ISO 14121-1 (2007)(EN 1050)
Principles of Risk Assessment
IEC 60204-1 (2005-10)
Electrical Equipment of Machines Part 1: General Requirements
IEC 61496-1 (2004-02), & IEC 61496-2 (2006-04)
Electro-sensitive Protection Equipment
IEC 60529 (2001-02)
Degrees of Protection Provided by Enclosures
IEC 60947-5-1 (2003-11)
Low Voltage Switch Gear – Electro-mechanical Control Circuit
Devices
IEC 60947-5-5
Low Voltage Switchgear - Electrical Emergency Stop device with mechanical latching function
IEC 60947-1 (2004-03)
Low Voltage Switch Gear – General Rules
2006/42/EC
Safety of Machinery
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General Safety
1.4 INGRESS PROTECTION RATINGS
The SC22-3 Safety Controller meets the following Ingress Protection
IP class as per IEC 60529:
• IEC IP20*
*The SC22-3 Safety Controller must be installed inside an enclosure
rated IEC IP54 or better for IP20 rating.
! WARNING
READ THIS block 1.6 on page 3 CAREFULLY BEFORE INSTALLING THE
SYSTEM
THE BANNER SC22-3 SAFETY CONTROLLER IS AN ACCESSORY DEVICE THAT IS
TYPICALLY USED IN CONJUNCTION WITH A MACHINE. ITS ABILITY TO PERFORM THIS
FUNCTION DEPENDS UPON THE APPROPRIATENESS OF THE APPLICATION AND UPON
THE SC22-3 SAFETY CONTROLLER’S PROPER MECHANICAL AND ELECTRICAL IN-
1.5 ELECTRICAL SAFETY
STALLATION AND INTERFACING TO THE MACHINE TO BE SAFEGUARDED.
IF ALL MOUNTING, INSTALLATION, INTERFACING, AND CHECKOUT PROCEDURES
ARE NOT FOLLOWED PROPERLY, THE SC22-3 SAFETY CONTROLLER CANNOT PRO-
WARNING
VIDE THE PROTECTION FOR WHICH IT WAS DESIGNED. THE USER HAS THE RESPON-
SHOCK HAZARD - DISCONNECT POWER
SIBILITY TO ENSURE THAT ALL LOCAL, STATE, AND NATIONAL LAWS, RULES,
ALWAYS DISCONNECT POWER FROM THE SAFETY CONTROLLER AND THE GUARDED
CODES, OR REGULATIONS RELATING TO THE INSTALLATION AND USE OF THIS CON-
MACHINE BEFORE MAKING ANY CONNECTIONS OR REPLACING ANY COMPONENT.
TROL SYSTEM IN ANY PARTICULAR APPLICATION ARE SATISFIED. EXTREME CARE
PROPER ELECTRICAL CONNECTION
ELECTRICAL CONNECTION MUST BE MADE BY qualified persons AND MUST COMPLY
WITH LOCAL ELECTRICAL STANDARDS. DO NOT MAKE CONNECTIONS TO THE SYSTEM OTHER THAN THOSE DESCRIBED IN chapter 4 OF THIS MANUAL. DOING SO
COULD RESULT IN SERIOUS INJURY OR DEATH.
The SC22-3 Safety Controller has been designed to meet with the
Electrical Safety Standards as detailed in DOC.
SHOULD BE TAKEN TO ENSURE THAT ALL LEGAL REQUIREMENTS HAVE BEEN MET
AND THAT ALL TECHNICAL INSTALLATION AND MAINTENANCE INSTRUCTIONS CONTAINED IN THIS MANUAL ARE FOLLOWED. READ ALL OF THE safety information in
chapter 1 OF THIS MANUAL CAREFULLY BEFORE INSTALLING THE SYSTEM. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY
OR DEATH. THE USER HAS THE SOLE RESPONSIBILITY TO ENSURE THAT THE BANNER SC22-3 SAFETY CONTROLLER IS INSTALLED AND INTERFACED TO THE SAFEGUARDED MACHINE BY A qualified person as specified in block 1.8.2 on page 4
IN ACCORDANCE WITH THIS MANUAL AND APPLICABLE SAFETY REGULATIONS.
1.6 CONDITIONS OF EQUIPMENT USE
NOT A STAND ALONE POINT-OF-OPERATION GUARDING
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. THIS MANUAL ATTEMPTS TO PROVIDE COMPLETE INSTALLATION,
OPERATIONAL, AND MAINTENANCE INSTRUCTION. READING THE MANUAL COMPLETELY IS HIGHLY RECOMMENDED. PLEASE DIRECT ANY QUESTIONS REGARDING THE APPLICATION OR USE OF THE PRODUCT TO THE BANNER ENGINEERING
APPLICATIONS DEPARTMENT AT THE PHONE NUMBER OR ADDRESS SHOWN ON
THE BACK COVER. FOR MORE INFORMATION REGARDING U.S. AND INTERNATIONAL INSTITUTIONS THAT PROVIDE SAFEGUARDING APPLICATION AND SAFEGUARDING PRODUCT PERFORMANCE STANDARDS, SEE THE LIST ON THE INSIDE OF THE
BACK COVER.
USE OF WARNINGS
WARNINGS ARE INTENDED TO REMIND THE MACHINE DESIGNER, CONTROL ENGINEER, MACHINE BUILDER, MAINTENANCE ELECTRICIAN, OR END USER HOW TO
AVOID MIS-APPLICATION OF THIS PRODUCT AND EFFECTIVELY APPLY THE SAFETY
CONTROLLER TO MEET THE VARIOUS SAFEGUARDING APPLICATION REQUIREMENTS. READING AND ABIDING BY THE WARNINGS IS HIGHLY RECOMMENDED.
THE SC22-3 SAFETY CONTROLLER IS NOT A STAND ALONE POINT-OF-OPERATION,
AS DEFINED BY EUROPEAN SAFETY STANDARDS. IT IS THEREFORE NECESSARY TO
INSTALL POINT-OF-OPERATION, SUCH AS SAFETY LIGHT SCREENS AND/OR FIXED
GUARDS, TO PROTECT PERSONNEL FROM HAZARDOUS MACHINERY. FAILURE TO
PROPERLY INSTALL POINT-OF-OPERATION SAFEGUARDING ON HAZARDOUS MACHINERY, AS INSTRUCTED BY THE APPROPRIATE INSTALLATION MANUALS, CAN RESULT IN A DANGEROUS CONDITION WHICH COULD LEAD TO SERIOUS INJURY OR
DEATH.
USER RESPONSIBILITY FOR APPLICATION SAFETY
THE APPLICATION EXAMPLES DESCRIBED IN appendix A3 DEPICT GENERALIZED
SAFEGUARDING SITUATIONS. EVERY SAFEGUARDING APPLICATION HAS A UNIQUE
SET OF REQUIREMENTS. EXTREME CARE IS URGED TO ENSURE THAT ALL LEGAL REQUIREMENTS ARE MET AND THAT ALL INSTALLATION INSTRUCTIONS ARE FOLLOWED. IN ADDITION, ANY QUESTIONS REGARDING SAFEGUARDS SHOULD BE
1.6.1
SC22-3 Safety Controller Interfacing
SC22-3 Safety Controller interfacing 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. It is the user’s responsibility to verify whether the Safeguarding is
appropriate for the application and is installed as instructed by the appropriate installation Manuals.
If there is any doubt about whether or not your machinery is compatible with this Controller, contact Corporate Office as listed on
page 121.
INSTRUCTION MANUAL - EUROPEAN VERSION
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3
General Safety
SC22-3 Safety Controller
1.7 SECURITY PROTOCOL
1.9 SAFETY INPUTS
The SC22-3 Safety Controller must be mounted inside a lockable enclosure or cabinet IP rated IP54 or better, both to protect the
Controller from environmental conditions and in order to prevent access by unauthorized personnel, if required by applicable standards.
The key (or combination) to the enclosure should be kept in the possession of a qualified person as specified in block 1.8.2 on page 4
and only they should have access to the configuration switches.
1.8 DESIGNATED & QUALIFIED PERSONS
1.8.1
Designated Person
A Designated Person (designated person on page 117) is identified
and designated in writing, by the employer, as being appropriately
trained and able to perform the specified checkout procedures on the
SC22-3 Safety Controller.
1.8.2
Qualified Person
A Qualified Person (qualified person on page 119) by possession of
a recognised degree or certificate of professional training, or by extensive knowledge, training and experience, has successfully demonstrated the ability to solve problems relating to the implementation
of this safety system.
! WARNING
FAILURES AND FAULTS
THE SC22-3 SAFETY CONTROLLER CAN BE INTERFACED WITH Input Devices AT
DIFFERING LEVELS OF INTEGRITY AS DESCRIBED IN appendix A2. THE USER MUST
CONDUCT A RISK ASSESSMENT TO DETERMINE THE APPROPRIATE LEVEL OF INTEGRATION. THE USER ALSO MUST ELIMINATE OR MINIMIZE THE POSSIBILITY OF FAILURES AND FAULTS THAT COULD RESULT IN THE LOSS OF THE SAFETY FUNCTION(S).
Safety Input devices allow for the cessation of motion, for an otherwise hazardous situation, by controlling the Safety Output of the
SC22-3 Safety Controller. A Safety Output in the OFF state results in
a stop of motion and removal of power from the machine actuators
(assuming this does not create additional hazards).
For a Safety Output to turn ON, all of its controlling Safety Inputs must
be in their Run state. A few special Safety Input functions can, under
pre-defined circumstances, temporarily suspend the Safety Input
Stop signal to keep the Safety Output ON (e.g. muting and bypassing).
The SC22-3 Safety Controller input configurations, depending on the
type, have means to detect failures and faults that would otherwise
result in a loss of that control of the safety function. Once such a failure or fault is detected, the SC22-3 Safety Controller locks out until
the problem is fixed.
Other input configurations do not have this detection capability. It is
recommended that in all circumstances the installation of the
SC22-3 Safety Controller and its associated safety and Safeguarding
Devices be installed to eliminate or minimize the possibility of failures
and faults that could result in the loss of the safety function(s).
Methods to eliminate or minimize the possibility of these failures include but are not limited to:
• Physically separating interconnecting control wires from each
other and from secondary sources of power
• Routing interconnecting control wires in separate conduit, runs, or
channels
• Locating all elements (modules, switches, and devices under control) within one control panel, adjacent to each other, and directly
connected with short wires
• Properly installing multi-conductor cabling and multiple wires
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
For further information see block 2.4 on page 8
1.9.1
Signals Run & Stop States
Dual channel Safety Inputs have two separate signal lines. Dual
channel signals for some devices are both positive (+24 V dc) when
the device is in the Run state. Others have a complementary circuit
structure where Single channel is at 24 V dc and the other is at 0 V
dc when the device is in the Run state. For the sake of clarity, instead
of referring to a Safety Input as being ON (e.g. 24 V dc) or OFF (e.g.
0 V dc), this Manual adopts the Run state/Stop state convention.
4
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SC22-3 Safety Controller
General Safety
1.10 RESETS
1.12 DISCLAIMER INFORMATION
! CAUTION
! WARNING
RESET SWITCH LOCATION
The System Reset push button must be accessible only from outside, and
in full view of, the hazardous area. Manual 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). If any areas are not visible from the Manual Reset
switch(es), additional means of Safeguarding must be provided. Failure
to do so could result in serious bodily injury or death.
ALL APPLICABLE REQUIREMENTS DEPENDS UPON FACTORS THAT ARE BEYOND THE
CONTROL OF BANNER ENGINEERING CORP. THESE FACTORS INCLUDE THE DETAILS OF HOW THE SAFETY CONTROLLER IS APPLIED, INSTALLED, WIRED, OPERATED, AND MAINTAINED. IT IS THE RESPONSIBILITY OF THE PURCHASER AND USER TO
APPLY THIS SAFETY CONTROLLER IN FULL COMPLIANCE WITH ALL RELEVANT APPLICABLE REGULATIONS AND STANDARDS. SAFETY CONTROLLER CAN ONLY SAFEGUARD AGAINST ACCIDENTS WHEN THEY ARE PROPERLY INSTALLED/INTEGRATED
Two Manual Reset types are available:
1.10.1 Manual Reset
Used to manually Reset a Safety Output that has turned OFF in response to a Stop signal from Safety Input configured for (Latch mode)
Manual Reset. The Manual Reset signal type can be configured to be
either monitored or non-monitored (the default setting is monitored).
For further information see block 2.3.1 on page 7 and block 7.3 on
page 68.
1.10.2 System Reset
Used to recover from a fault condition or to restart the Controller after
a new configuration has been altered. This Manual Reset device (a
button or switch) connects to a dedicated input terminal on the Safety
Controller, labelled SR & Sys Res. The Manual Reset signal type can
be configured to be either monitored or non-monitored (the default
setting is monitored). For further information see block 2.3.1 on
page 7 and block 7.4 on page 68.
INTO THE MACHINE, PROPERLY OPERATED, AND PROPERLY MAINTAINED. BANNER
ENGINEERING CORP. HAS ATTEMPTED TO PROVIDE COMPLETE APPLICATION, INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS.
THE USER HAS THE RESPONSIBILITY TO ENSURE THAT ALL LOCAL, STATE, AND NATIONAL LAWS, RULES, CODES, AND REGULATIONS RELATING TO THE USE OF THIS
Safeguarding SYSTEM IN ANY PARTICULAR APPLICATION ARE SATISFIED.
EXTREME CARE IS URGED TO ENSURE THAT ALL LEGAL REQUIREMENTS HAVE BEEN
MET AND THAT ALL INSTALLATION AND MAINTENANCE INSTRUCTIONS CONTAINED IN
THIS Manual ARE FOLLOWED.
FOR A LIST OF EUROPEAN & INTERNATIONAL STANDARDS APPERTAINING TO THIS
EQUIPMENT, REFER TO DOC.
1.13 EQUIPMENT NOISE LEVELS
The Safety Controller does not generate noise and is therefore in
compliance with:
• IEC 61000-6-1
• EN 55011 (CISPR11)
1.14 EQUIPMENT VIBRATION LEVELS
1.11 MUTING
Safety device muting is the automatically controlled suspension of
one or more Safety Input Stop signals during a portion of a machine
operation when no immediate hazard is present or when access to
the hazard is safeguarded.
Muting sensors can be Mapped to one or more of the following “mutable” Safety Inputs:
• Gate Switches (Interlocking)
• Optical Sensors
• Two-Hand Controls
• Safety Mats
At least two mute sensors are required for each muting operation.
One or two pairs of mute sensors can be Mapped to one or more
Safety Inputs so that their assigned Safety Output can remain ON to
complete the operation (see block 2.4.4 on page 9 and
appendix A2.11 on page 110 for more information).
INSTRUCTION MANUAL - EUROPEAN VERSION
IMPORTANT... READ THIS BLOCK BEFORE PROCEEDING!
WHETHER OR NOT ANY PARTICULAR SAFETY CONTROLLER INSTALLATION MEETS
For shock and vibration levels, the SC22-3 Safety Controller is in
compliance with:
• IEC 61496-1
1.15 EQUIPMENT RADIATION LEVELS
1.15.1 Electromagnetic Immunity Levels
For electro-magnetic levels, the SC22-3 Safety Controller is in compliance with IEC 61496-1.
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General Safety
SC22-3 Safety Controller
1.16 DESIGN & TESTING
1.18 EXTERNAL DEVICE MONITORING
The Safety Controller was designed for up to Category 4
PL (Performance Level) “e” (ISO 13849-1) and SIL (Safety Integrity
Level) 3 (IEC 61508 and IEC 62061) Safeguarding applications. It
has been extensively tested to ensure that it meets IEC and ISO
product performance requirements for both safety functionality and
operational reliability. This self-checking Safety Controller incorporates:
• Redundant micro controllers
• Redundant input signal detection circuitry
• Redundant Safety Output control circuitry
It should be noted that the safety circuit performance (e.g. categories) of a specific Safety Input or Output will be primarily determined
by the devices and their interconnection to the SC22-3 Safety Controller. See appendix A2 for further information.
! CAUTIONS
EDM Configuration
If the application does not require this function, it is the User’s responsibility to ensure that this does not create a hazardous situation.
NOTICE Regarding External Device Monitoring Connection
It is strongly recommended that at least one N.C., forced-guided monitoring contact of each MPCE or external device be wired in order to monitor
the state of the MPCEs (as shown in figure 28, figure 29, figure 29, figure 30
and figure 31). If this is done, proper operation of the MPCEs are verified.
MPCE monitoring contacts must be used in order to maintain control reliability.
This information is detailed in appendix A2.4.3.
The Safety Controller’s Safety Output can control external relays,
contactors, or other devices that have a set of Normally Closed (N.C.)
force-guided (mechanically linked) contacts that can be used for
monitoring the state of the machine power contacts. The monitoring
contacts are N.C. when the device is turned OFF. This capability permits the Safety Controller to detect if the devices under load are responding to the Safety Output, or if the Normally Open (N.O.)
contacts are possibly welded closed or stuck ON.
1.17.2 Minimum Safety Distance for Two-Hand
Controls
The EDM function provides a method to monitor these types of faults
and to ensure the functional integrity of a Dual channel system, including the MPCEs and the FSDs.
1.17 MINIMUM SAFETY DISTANCES
☛ The following information is only applicable to Œ certified
installations.
1.17.1 Minimum Safety Distance for Optical
Sensors
This information is detailed in appendix A2.5.1.
1.17.3 Minimum Safety Distance for Safety Mats
This information is detailed in appendix A2.6.4.
An EDM input can be Mapped to only one Safety Output.
The EDM Inputs can be configured in three ways: Single channel,
Dual channel, or no monitoring. Single channel and Dual channel
EDM are used when the Output Signal Switching Device (OSSD)
Outputs directly control the de-energizing of the MPCEs or external
devices.
For further information see block 2.4.6 on page 10 and block 4.8.1 on
page 32.
6
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SC22-3 Safety Controller
Overview
2 OVERVIEW
2.2 APPLICATIONS
The Banner SC22-3 Safety Controller (the Safety Controller or the
Controller) is an easy-to-use, configurable, 24 V dc Safety Module
designed to monitor multiple safety and Non-Safety Input and control
up to three independent Machine Primary Control Elements (MPCEs). It provides safety stop and start functions for machines with hazardous motion. The Safety Controller can replace multiple safety
relay modules in applications that include such Safety Inputs as Estop buttons, gate interlocking switches, safety light curtains, and
other Safeguarding Devices. It also can be used in place of safety
PLCs (Programmable Logic Controller) and other safety logic devices when they are excessive for the application.
The SC22-3 Safety Controller can be used wherever safety modules
are used. The Safety Controller is well suited to address many types
of applications, including, but not limited to:
Configurations are created using an integral LCD (Liquid Crystal Display) and push-button interface or using a PC connected to the Safety Controller via a USB (Universal Serial Bus) port.
2.3 RESET ADDITIONAL INFORMATION
2.1 FEATURES
The Banner SC22-3 Safety Controller includes the following features:
• Easy-to-use Controller with fully configurable Inputs and Outputs
• ISO 13849-1 Category 2, Category 3, or Category 4 Control Reliability Input Device connection
• Manages several safety related functions
• Twenty two Inputs for safety and Non-Safety Input devices or functions
• Three Dual channel Safety Outputs with selectable ON and OFF
delay
• Ten Status Outputs track input and output status, mute status,
lockout, fault conditions and Reset needed
• Simple configuration procedure using PC interface (PCI) or onboard controller interface (OBI) maps each Input Device to any of
three Safety Outputs
• Configurations password protected and confirmed before use, to
ensure safety integrity
• Configurations transferable to multiple SC22-3 Safety Controllers
and can be e-mailed as attachments
• 24 V dc operation
• Complies with SIL 3 (Safety Integrity Level) as per IEC 62061,
IEC 61508, & Category 4 performance Level “e” as per
ISO 13849-1
• Live display and fault log provide “real-time” status information and
historical fault tracking
• Wiring Diagrams, Ladder Logic Diagrams and Configuration Summaries can be printed or exported as .pdf or .dxf files
• Two-Hand Control with mute function
• Robot weld/processing cells with dual-zone muting
• Material-handling operations that require multiple Inputs and
bypass functions
• Manually loaded rotary loading stations
• Multiple two-hand-control station applications
• Lean manufacturing stations
2.3.1
Automatic Reset & Manual Reset Inputs
Mapped to Same Safety Output
Safety Input devices can be configured for either Manual (Latch
mode) or Automatic (Trip mode) Reset and both types can be
Mapped to the same Safety Output. In order for a Safety Output to
turn ON, all associated Safety Inputs must be in their Run state. If one
or more of these Safety Inputs is configured for Manual Reset and
one or more of them change from the Stop state to the Run state,
then the output needs a valid Manual Reset signal before it turns ON
(see figure 1 on page 7).
Safety Input 1
(Auto)
Safety Input 2
(Manual)
Manual Monitored
Manual Reset
Safety Output
Figure 1 Auto & Manual Monitored Manual Reset Safety Inputs Mapped to
Same Safety Output (Safety Output has no Delay) Timing Logic
2.3.2
Safety Inputs with Common Manual Reset
Mapped to Same Safety Output
If two Safety Inputs, each configured for Manual Reset, are Mapped
to the same Safety Output, then only one valid Manual Reset operation is required to manually Reset the Safety Output. A Manual Reset
operation is valid when all Safety Inputs mapped to the Safety Output
are in the Run state and the Manual Reset is performed. If a Manual
Reset is performed before a Safety Input is in the Run state, the Manual Reset signal is ignored (except in the case of a Two-Hand Control
and an ON/OFF input) (see figure 2 on page 7).
Safety Input 1 Manual
Monitored Reset)
Safety Input 2 Manual
Monitored Reset
Manual Monitored Reset
Safety Output
Figure 2 Safety Inputs with a Common Manual Monitored
Reset, Mapped to the Same Safety Output, Timing Logic
See block 7.3 on page 68 for more information about Resets.
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7
Overview
SC22-3 Safety Controller
2.4 SAFETY INPUTS & NON-SAFETY
INPUTS
2.4.2
The Safety Controller has 22 input terminals that can be used to monitor either Safety Input or Non-Safety Input devices. These devices
may incorporate either solid-state or contact-based Outputs. Each of
these 22 input terminals can either monitor an input signal or provide
24 V dc. The function of each input circuit depends on the type of device connected to it. This function is established when the Controller
is configured.
Refer to Chapter 4 and appendix A2 for the following:
• General and specific information about Input Devices — the
requirements
• Connection options and appropriate warnings and cautions
• Additional installation information (e.g. Minimum Safety Distances)
appendix A2 contains connection and other useful information about
integrating the following devices:
• Protective Stop (Safety) — appendix A2.2 on page 89
• Optical Sensor — appendix A2.4 on page 94
• Gate Switch (or Interlock Guard) — appendix A2.3 on page 90
• Two-Hand Control — appendix A2.5 on page 96
• Safety Mat (Edges) — appendix A2.6 on page 99
• E-Stop — appendix A2.7 on page 102
• Rope Pull (Cable) — appendix A2.8 on page 104
• Enabling Device (Pendants) — appendix A2.9 on page 106
• Bypass Switch — appendix A2.10 on page 108
• Mute Sensor — appendix A2.11 on page 110
For further information about connecting any devices to the Safety
Controller, contact Corporate Office as listed on page 121.
2.4.1
Internal Logic
The Controller’s internal logic is designed so that a Safety Output can
turn ON only if all the controlling Safety Input signals and the Controller’s self-check signals are in the Run state and report that there is no
fault condition. Table 3 on page 8 illustrates the internal logic.
Table 3 Safety Input Internal Logic
Safety Input 1
Safety Input 2
Safety Output 1
Stop
Stop
OFF
Stop
Run
OFF
Run
Stop
OFF
Run
Run
ON
Table 3 on page 8 illustrates the logic for two Safety Inputs that are
Mapped to control Safety Output 1. If any of the Safety Inputs are in
the Stop state, the Safety Output is OFF. When both Safety Inputs
and the Controller are in the Run state, then Safety Output 1 will turn
ON.
8
Two-Hand Control
The Two-Hand Control function requires that each control actuation
should be activated within 0,5 seconds of each other in order to produce a Run signal to start a machine cycle. Two-Hand Control devices are always the last input (in time) to turn the Safety Output ON. If
one or more of the other controlling Safety Input devices are configured for Manual Reset and are used to stop the machine, a Manual
Reset must be performed before the Two-Hand Control device can
cycle the machine again. See appendix A2.5 on page 96 for more information.
2.4.2.1 Two-Hand Control Activation on Power-up Protection
The Controller’s Two-Hand Control logic does not permit the assigned Safety Output to turn ON when power is initially supplied while
each Two-Hand Control actuation is in the Run state. Each TwoHand Control actuation must change to its Stop state and return to
the Run state before the Safety Output can turn ON (see figure 3 on
page 8).
Two-Hand Control
Device
Safety Input 2
(Manual)
Manual Reset
Signal
Safety Output
Figure 3 Two-Hand Control Device & Manual Reset Safety
Input Timing Logic
A two-hand control device does not have a Manual Reset option.
2.4.3
Enabling Devices
The Enabling Device actively controls the suspension of a Stop signal during a portion of a machine operation where a hazard can occur. The Enabling Device permits a hazardous portion of the machine
to Run, but must not start it. A separate machine command signal
from another device is needed to start hazardous motion. This Enabling Device must have ultimate hazard turn OFF or Stop authority when being used. The Enabling Device is sometimes referred to
as the ‘live man pendant.’
An Enabling Device can be Mapped to one or more Safety Output(s).
When the Enable signal goes from the Stop state to the Run state,
the Controller goes into Enable Mode. In this mode, the associated
Safety Outputs turn ON if any of the assigned EDM Inputs are closed
(these may open after the Outputs turn ON) and all of the controlling
E-Stop or Rope Pull devices are in their Run state. With the exception
of the E-Stop and Rope Pull devices, all other Safety Input signals
(Run or Stop) are ignored while the Controller is in Enable Mode.
Safety Output enabling control resides in the Enabling Device function when in Enable Mode. In order to exit Enable Mode, the Enabling
Device must be in the OFF state, and a System Reset must be performed. See appendix A2.9 on page 106 for more information.
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SC22-3 Safety Controller
Overview
2.4.3.1 Enabling Device Time Limit
The enabling device time limit can be adjusted between 1 second and
30 minutes and cannot be disabled. When the time limit expires, the
associated Safety Outputs turn OFF. In order to start a new Enable
mode cycle with the time limit Manual Reset set to its original time
limit value, the enabling device must switch from ON to OFF, and
back to ON (see figure 4).
2.4.4.3
Mute on Power-up function
! WARNING
MUTE ON POWER-UP
THE MUTE ON POWER-UP FUNCTION SHOULD BE USED ONLY IN APPLICATIONS
WHERE:
• MUTING THE SYSTEM (M1 AND M2 CLOSED) WHEN POWER IS APPLIED IS
REQUIRED AND
• USING IT MUST NOT, IN ANY SITUATION, EXPOSE PERSONNEL TO ANY HAZARD
Enable Device
If configured, the Mute on Power-up function initiates a Mute Cycle
after power is applied to the SC22-3 Safety Controller providing the
muted Safety Inputs are active (Run state or Closed) and either
M1-M2 or M3-M4 (but not all four) are signalling a muted condition
(e.g. Run state or Closed) (see warning above).
Only relevant if enabling device is an E-stop or Rope-Pull
Safety Input
Safety Output
(ON-Delayed)
ON Delay
ON Delay
System Reset
Enable Mode ON
Enable Mode
Enable Mode OFF
Figure 4 Enabling Device & Enable Mode Timing Logic
All ON and OFF delay times associated with the Safety Output that
are controlled by the Enabling Device function are honoured during
the Enable mode.
2.4.4
Mute Functions
2.4.4.1 Mute Enable
The optional Mute Enable ME function can be configured to ensure
that a mute function is permitted only at the appropriate time. If an ME
Input Device has been Mapped to a mutable Safety Input, this Safety
Input can be muted only if the ME switch is in the Enable state
(24 V dc) at the time the Mute Cycle is started. After the Mute Cycle
starts, the ME input can be turned OFF. An ME Input Device can be
Mapped to one or more mutable Safety Inputs (see figure 5).
Refer to appendix A2.11 on page 110 for more information about
Mute Enable conditions.
Mute on Power-up Enabled
When the Mute on Power-up option is enabled, the Controller goes
into a Mute Cycle if the conditions for a valid Mute Cycle are satisfied
at power-up. Specific valid mute signal conditions must be present for
a Mute Cycle to be initiated and maintained.
If Manual Power-Up is configured and all other conditions are satisfied, the first valid System Reset after the muted Safety Inputs are active (Run state or closed) results in a Mute Cycle.
The Mute on Power-up function should only be used if safety can be
assured when the Mute Cycle is expected, and the utilisation of this
function is the result of a Risk Assessment and is required by that
particular machine operation.
☛ Mute Enable is not a Safeguarding function but rather a machine
logic function.
Mute Enable
ON or OFF
Safety Input
Mute Sensor Pair
Safety Output
Figure 5 Timing Diagram for One Mute Sensor Pair
with Mute Enable
2.4.4.2 Muting Time Limit (Backdoor Timer)
A time limit can be established to limit how long a Mute Cycle is permitted to be active. The time limit can be adjusted from 1 second to
30 minutes. A different time limit can be set for each mutable Safety
Input. Other Safety Input devices that are also muted are affected
only by their own mute time limit setting. The Muting Time Limit can
be disabled. When disabled, the time limit for the mute function for
that Safety Input device is infinite.
INSTRUCTION MANUAL - EUROPEAN VERSION
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9
Overview
2.4.5
SC22-3 Safety Controller
Bypass Switch Function
2.4.6
EDM
For further information see also block 1.18 on page 6 and block 4.8.1
on page 32.
! WARNINGS
MUTE AND BYPASS SWITCH
MUTE AND BYPASS OPERATIONS MUST BE DONE IN A WAY THAT MINIMIZES PERSONNEL RISK. THE FOLLOWING RULES AND METHODS MUST BE IMPLEMENTED WHEN
CREATING MUTE AND BYPASS APPLICATIONS:
• GUARD AGAINST UNINTENDED STOP SIGNAL SUSPENSION BY USING ONE OR
MORE DIVERSE-REDUNDANT MUTE SENSOR PAIRS OR A DUAL CHANNEL KEYSECURED BYPASS SWITCH
• SET REASONABLE (NO LONGER THAN NEEDED) MUTE AND BYPASS FUNCTION
TIME LIMITS
USE OF MUTE AND BYPASS SWITCH FUNCTIONS
FAILURE TO FOLLOW THESE RULES COULD LEAD TO AN UNSAFE CONDITION THAT
COULD RESULT IN SERIOUS INJURY OR DEATH. REFER TO appendix A2.10 on
page 108 AND appendix A2.11 on page 110 FOR MORE INFORMATION.
2.4.6.1 Single channel Monitoring
For timing information refer to figure 7 on page 10.
A series connection of closed monitor contacts that are forced-guided
(mechanically linked) from each device controlled by the Safety Controller. The monitor contacts must be closed before the Safety Controller Outputs can be System Reset (either Manual or Automatic).
After a System Reset is executed and the Safety Output (OSSDs)
turn ON, the status of the monitor contacts are no longer monitored
and may change state. However, the monitor contacts must be
closed within 250 ms of the OSSD Outputs going from ON to OFF.
Safety Output
The Bypass Switch safety device is a manually activated and temporary suspension of one or more Stop signals for Safety Input(s) when
no immediate hazard is present.
Bypass Switches can be Mapped to one or more of the following
Safety Inputs:
• Gate Switches (interlocking)
• Optical Sensors
• Two-Hand Control devices
• Safety Mats
• Protective Stops
When the Bypass Switch signal changes to the bypass (Run) state,
it turns ON or keeps ON all the Safety Outputs that are controlled by
the bypassed Safety Inputs only if all other non-bypassed Safety Input devices that are Mapped to these Safety Outputs are in the Run
state (see figure 6 on page 10).
Mute Sensor
1 (2)
Mute Sensor
2 (1)
Bypass
Switch
ON
OFF
Closed
Irrelevant
EDM
Irrelevant
Open
250 ms
Max.
Figure 7 Timing for Single channel EDM Status with
Respect to Safety Output
2.4.6.2 Dual channel Monitoring
For timing information refer to figure 8 on page 10 and figure 9 on
page 10.
An independent connection of closed monitor contacts that are
forced-guided (mechanically linked) from each device controlled by
the Safety Controller. Both EDM Inputs must be closed before the
Safety Controller can be System Reset and the OSSDs can turn ON.
While the OSSDs are ON, the Inputs may change state (either both
open, or both closed). If the Inputs remain in opposite states for more
than 250 ms, a lockout occurs.
Safety Output
Not Relevant
Bypass Time Expired
Irrelevant
Closed
EDM 1
Safety
Output
Open
Closed
EDM 2
250 ms
Max.
Open
250 ms
Max.
Figure 6 Light Screen with Mute Sensors & Bypass Switch Timing Logic
For further information on the Bypass Switch function refer to
appendix A2.10 on page 108.
Figure 8 Timing for Dual channel EDM Between Channels
2.4.5.1 Bypass Switch Time Limit.
A Bypass Switch function time limit can be established to limit how
long the Safety Input bypass is active. The time limit can be adjusted
from 1 second to 30 minutes and cannot be disabled. Only one time
limit can be set, and this limit applies to all Safety Input devices that
are bypassed. At the end of the time limit, Safety Output control authority is handed back to the bypassed Safety Inputs.
Safety Output
Closed
EDM 1
Open
Irrelevant
Must Match EDM 2
Irrelevant
Must Match EDM 1
Closed
EDM 2
2.4.5.2 Bypass with Mute.
If a mute sensor is Mapped to the Safety Input and the Safety Input
is in the Stop state, at least one of the Mute sensors must be in the
Mute (Run) state in order to start a new bypass cycle. If the conditions
are right for bypass, the mute status output indicator (if configured)
starts flashing at 1 Hz.
10
ON
OFF
135369 06.03.08
Open
Figure 9 Dual channel EDM Status, with Respect to Safety Output
INSTRUCTION MANUAL - EUROPEAN VERSION
SC22-3 Safety Controller
Overview
2.5 CONFIGURING THE SAFETY CONTROLLER
A configuration for the Safety Controller can be built up, using
one of the two interfaces:
• Push buttons and display of the OBI on Controller itself
or
• PCI software program (included on the enclosed CD p/n 134534)
The process comprises three main steps:
Defining Safeguarding Application (Risk Assessment)
• Determining required devices
• Determining required level of safety
Building Configuration
• Selecting Safety Input types and circuit connections
• Mapping each Safety Input/Non-Safety Input to one or more
Safety Output(s) or to other Safety Input/Non-Safety Input devices
• Setting optional Safety Output ON- or OFF-time delays
• Selecting Non-Safety Input types and circuit connections, if
required
• Assigning status output signals, if required
• Creating Configuration Name, file name, date, author name, and
notes
Confirming Configuration
• Safety Controller verifying that the desired configuration is valid
• User confirming that the configuration is as expected
INSTRUCTION MANUAL - EUROPEAN VERSION
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SC22-3 Safety Controller
2.5.1
Overview
Safety Outputs
NOTICE: Safety Outputs SO1, SO2 & SO3 are
Dual channel Outputs.
An individual Safety Output (e.g. SO1) is not, by itself, capable of meet-
! WARNINGS
OSSD INTERFACING
TO ENSURE PROPER OPERATION, THE SAFETY CONTROLLER OUTPUT PARAMETERS
AND MACHINE INPUT PARAMETERS MUST BE CONSIDERED WHEN INTERFACING THE
SOLID-STATE SAFETY OUTPUT TO THE MACHINE INPUTS.
MACHINE CONTROL CIRCUITRY MUST BE DESIGNED SO THAT:
• THE MAXIMUM CABLE RESISTANCE VALUE BETWEEN THE Safety Controller
SOLID-STATE SAFETY OUTPUT AND THE MACHINE INPUTS IS NOT EXCEEDED
• THE SAFETY CONTROLLER ’S SOLID-STATE SAFETY OUTPUT MAXIMUM OFF
STATE VOLTAGE DOES NOT RESULT IN AN ON CONDITION, AND
• THE SAFETY CONTROLLER ’S SOLID-STATE SAFETY OUTPUT MAXIMUM LEAKAGE
CURRENT, DUE TO THE LOSS OF 0 V, WILL NOT RESULT IN AN ON CONDITION
FAILURE TO PROPERLY INTERFACE THE SAFETY OUTPUT TO THE GUARDED MACHINE COULD RESULT IN SERIOUS BODILY INJURY OR DEATH.
INTERFACING OF BOTH OSSDS
BOTH OF THE OSSD OUTPUTS MUST BE CONNECTED TO THE MACHINE CONTROL
SO THAT THE MACHINE’S SAFETY-RELATED CONTROL SYSTEM INTERRUPTS THE CIRCUIT TO THE MACHINE PRIMARY CONTROL ELEMENT(S), RESULTING IN A NON-HAZARDOUS CONDITION. NEVER WIRE AN INTERMEDIATE DEVICE(S) (E.G. PLC, PES,
OR PC) THAT CAN FAIL IN SUCH A MANNER THAT THERE IS THE LOSS OF THE SAFETY
STOP COMMAND, OR IN SUCH A MANNER THAT THE SAFETY FUNCTION CAN BE SUSPENDED, OVERRIDDEN, OR DEFEATED, UNLESS ACCOMPLISHED WITH THE SAME OR
GREATER DEGREE OF SAFETY.
USE OF TRANSIENT SUPPRESSORS
TRANSIENT SUPPRESSORS ARE RECOMMENDED. THEY MUST BE INSTALLED
ACROSS THE COILS OF THE FSDS. NEVER INSTALL SUPPRESSORS DIRECTLY
ACROSS THE CONTACTS OF THE FSDS. IT IS POSSIBLE FOR SUPPRESSORS TO FAIL
AS A SHORT CIRCUIT. IF INSTALLED DIRECTLY ACROSS THE CONTACTS OF THE
FSDS, A SHORT-CIRCUITED SUPPRESSOR WILL CREATE AN UNSAFE CONDITION.
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 OUTPUT AND COULD
CREATE AN UNSAFE CONDITION THAT MAY LEAD TO SERIOUS BODILY INJURY OR
DEATH.
CONNECTING SAFETY CONTROLLERS IN SERIES
A SAFETY OUTPUT FROM ONE SAFETY CONTROLLER CAN BE CONNECTED TO A
SAFETY INPUT OF A SECOND SAFETY CONTROLLER. HOWEVER, THE SECOND SAFETY CONTROLLER SHOULD BE THE ONLY DEVICE TO WHICH THE OUTPUT FROM THE
FIRST SAFETY CONTROLLER IS CONNECTED. IF A THIRD DEVICE IS ALSO CONNECTED TO THE SAME SAFETY OUTPUT (NOW USED AS THE SAFETY INPUT OF THE SECOND SAFETY CONTROLLER), THEN DURING A POWER TRANSITION OF THE SECOND
SAFETY CONTROLLER, THE INPUT MAY BE A SOURCE OF CURRENT MOMENTARILY,
CAUSING A FALSE ON (RUN) SIGNAL AT THE INPUT OF THE THIRD DEVICE. FAILURE
TO CONNECT MULTIPLE SAFETY CONTROLLERS CORRECTLY COULD CREATE AN UNSAFE CONDITION THAT MAY LEAD TO SERIOUS BODILY INJURY OR DEATH.
PROPER WIRING
THE GENERALIZED WIRING CONFIGURATIONS SHOWN ARE PROVIDED ONLY TO ILLUSTRATE THE IMPORTANCE OF PROPER INSTALLATION. THE PROPER WIRING OF
THE SAFETY CONTROLLER TO ANY PARTICULAR MACHINE IS SOLELY THE RESPONSIBILITY OF THE INSTALLER AND END USER.
! CAUTIONS
Off-Delays
A SAFETY OUTPUT OFF-DELAY TIME WILL BE HONOURED EVEN IF THE SAFETY INPUT THAT CAUSED THE OFF-DELAY DELAY TIMER TO START SWITCHES BACK TO THE
RUN STATE BEFORE THE DELAY TIME EXPIRES. HOWEVER, IN CASES OF A POWER
INTERRUPTION OR A POWER LOSS, AN OFF-DELAY TIME CAN END IMMEDIATELY. IF
SUCH AN IMMEDIATE MACHINE STOP CONDITION COULD CAUSE A POTENTIAL DANGER, THEN ADDITIONAL SAFEGUARDING MEASURES MUST BE TAKEN TO PREVENT INJURIES.
INSTRUCTION MANUAL - EUROPEAN VERSION
ing Category 4 applications (per ISO13849-1). When the risk assessment
or relevant regulations require high levels of safety integrity
(i.e. Category 4), both the OSSD Outputs must be connected to the machine control so that the machine’s safety related control system interrupts the circuit or power to the MPCEs, resulting in a non-hazardous
condition.
FSDs typically accomplish this when the OSSDs go to an OFF state (see
The Safety Outputs (see figure 11 on page 13) are designed to control Final Switching Devices (FSDs) and 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 EDM.
The Safety Controller has three independently controlled and Redundant solid-state Safety Outputs, each capable of sourcing 750 mA.
The Safety Controller‘s self-checking algorithm ensures that the Outputs turn ON and OFF at the appropriate times, in response to the assigned input signals and the system’s self-checking test signals.
The Safety Outputs, SO1, SO2 and SO3, can be controlled by Safety
Input devices with both Automatic and Manual Reset operation.
The SC22-3 Safety Controller has three pairs of solid-state Safety
Outputs (SO1 a and b, SO2 a and b, and SO3 a and b). Each pair
consists of two OSSDs (see figure 14 on page 19). The solid-state
Safety Outputs are actively monitored to detect short circuits to the
supply voltage, to each other, and to other sources of electrical energy. If a failure is detected, the Outputs switch to an OFF state. For circuits requiring the highest level of safety and reliability, either OSSD
must be capable of stopping the motion of the guarded machine controlled by a Safety Output, in an emergency.
2.5.1.1 Functional Stops as per IEC 60204-1
The Safety Controller is capable of performing the two functional stop
types:
• Category 0: An uncontrolled stop with the immediate removal of
power from the guarded machine
• Category 1: A controlled stop with a delay before power is
removed from the guarded machine
Delayed stops can be used in applications where, for example, machines need power for a braking mechanism to stop the hazardous
motion.
2.5.1.2 OSSD Output Connections
The 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 MPCEs, resulting in a non-hazardous condition.
FSDs typically accomplish this when the Safety Outputs go to the
OFF state. See figure 14 on page 19.
Refer to the output specifications (table 4 on page 20) and WARNING above left before making OSSD connections and interfacing the
Safety Controller to the machine.
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SC22-3 Safety Controller
2.5.1.3
Overview
Safety Output On-Delays & Off-Delays
Safety Input
! WARNING
S01
TURNING A DELAYED OUTPUT ON/OFF
IF AN INPUT THAT IS MAPPED TO BOTH AN IMMEDIATE SAFETY OUTPUT AND A DE-
S02
LAYED SAFETY OUTPUT OPENS AND THEN CLOSES BEFORE THE DELAY TIME OF THE
DELAYED OUTPUT HAS EXPIRED, THE IMMEDIATE SAFETY OUTPUT WILL TURN OFF
AND REMAINS OFF WHILE THE DELAY TIME IS RUNNING.
AT THE END OF THE DELAY TIME, THE DELAYED OUTPUT ALSO TURNS OFF. BOTH
OUTPUTS THEN REMAIN OFF FOR ABOUT 500 MS, BEFORE THEY TURN BACK ON.
THIS HAPPENS EITHER AUTOMATICALLY, IF CONFIGURED FOR AUTOMATIC RESET,
OR AFTER A VALID MANUAL RESET SIGNAL, IF CONFIGURED FOR MANUAL RESET.
Delay
OFF Delay
500 ms
Figure 10 Safety Output with OFF Delay Timing Logic
Safety Output ON-delays are sometimes used when a machine operation must be delayed before a safe machine start-up is permitted.
An example application would be a robot weld cell. See block 2.5.1
on page 12 for more information.
Each Safety Output can be configured to function with either an ON
delay or an OFF delay (see figure 11 on page 13), where the output
turns ON or OFF only after the time limit has elapsed. An output cannot have both ON and OFF delays. The ON and OFF time delay limit
options are from 100 ms to 5 minutes, in 100 ms increments.
Current operation is to honour the OFF delay for internal and system
faults, whenever possible.
1
3
2
4
5
Index to figure
1. SC22-3 Safety Controller
2. OFF-Delay
3. Solenoid Locking Switch
4. Robot
5. Contactors
Figure 11 Safety Outputs
INSTRUCTION MANUAL - EUROPEAN VERSION
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13
SC22-3 Safety Controller
2.5.2
Overview
Status Outputs
! WARNING
IMPORTANT: Only terminals O9 and O10 have the extra monitoring
circuitry needed to monitor a Mute Lamp. If monitoring of the Mute
Lamp is not required (depending on applicable standards), any of the
status Outputs (O1–O10) may be used to indicate a mute condition.
STATUS OUTPUTS
☛ Because of this feature, these Status Outputs will always appear
THE STATUS OUTPUTS ARE NOT SAFETY OUTPUTS AND CAN FAIL IN EITHER THE
ON OR OFF STATE. THEY MUST NEVER BE USED TO CONTROL ANY SAFETY CRITICAL APPLICATIONS. IF A STATUS OUTPUT IS USED TO CONTROL A SAFETY-CRITICAL
APPLICATION, A FAILURE TO DANGER IS POSSIBLE AND COULD LEAD TO SERIOUS
INJURY OR DEATH.
The Safety Controller has ten configurable status Outputs which are
used to:
ON with no load (see Specifications, block 3.2.1 on page 20).
2.5.3
I/O Mapping & the I/O Control Relationship
The term map or mapping implies a control logic relationship between an input and an output or between an input and another input,
where the state of the first input determines the state of the output or
of the second input (see figure 12 on page 14).
• Send non-safety status signals to PLCs
or
2.5.3.1
Safety Inputs & Non-Safety Inputs Mapped to Outputs
• To HMIs (Human Machine Interfaces)
or
• Emergency Stop buttons
• Gate Switches
• Optical Sensors
• Two-Hand Control devices
• Safety Mats
• Protective Stop switches
• Rope Pulls
• Enabling Devices
• External Device Monitoring
• ON/OFF
The following devices can be mapped directly to the Safety Output:
• They may be used to power indicator lights
These Outputs can be configured to report on the status of Safety Input or Non-Safety Input devices, Safety Outputs, or the Controller itself. See block 4.9 on page 34 for more information.
Signal Convention
The status output signal convention can be configured to be 24 V dc
or 0 V dc to indicate when:
• An input is in the Run state
• A Safety Output is in the ON state (see note * on page 14)
• The system is in a lockout condition
• An I/O fault is present (see note on page 14)
• A system Reset is needed
• A Safety Output needs a Reset (see note on page 14)
• A Safety Input is muted
Safety
Input 1
Safety
Input 2
Safety
Input 3
Safety
Input 4
Non-Safety
Input 1
☛ Only Safety Outputs that have Inputs Mapped to them can be
Mapped to a status output.
An I/O fault is a failure of one or more Safety Inputs, Safety Outputs or Status Outputs.
Only Safety Outputs Mapped to Inputs configured with Manual
Reset logic can have a status output configured to indicate a Reset is needed.
2.5.2.1 Monitored Mute Lamp Outputs
Status Outputs O9 and O10 can be configured to create a monitored
Mute Lamp function for a mute operation. When the Mute Lamp is
ON, the Controller monitors for a short circuit in the load. When the
lamp is OFF, the Controller monitors for an open circuit in the load. If
an open circuit occurs before the start of a Mute Cycle, the next Mute
Cycle will be prevented. If an open circuit occurs during a Mute Cycle,
that Mute Cycle will finish, but the next Mute Cycle will be prevented.
If a short occurs before or during a mute, that Mute Cycle will start
and finish, but the next Mute Cycle will be prevented. If not used to
monitor a mute lamp, these Outputs may be used in the same ways
as Outputs O1–O8.
INSTRUCTION MANUAL - EUROPEAN VERSION
Safety
Output
1
Safety
Output
2
Safety
Output
3
Figure 12 Input & Output Mapping
2.5.3.2 Inputs Mapped to Inputs
Muting sensors and bypass switches work in conjunction with certain
Safety Inputs to temporarily suspend the Stop signal of a Safety Input. These sensors and switches are mapped directly to the Safety
Inputs; they are then indirectly Mapped to the Safety Output that the
muted Safety Inputs control (see block 1.11 on page 5).
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SC22-3 Safety Controller
Overview
2.6 SYSTEM SETTINGS
2.6.1.3 Power-up mode
Used for Operational Characteristics when Power Is Applied
! CAUTION
AUTOMATIC POWER-UP
When the Controller is configured for Automatic System Reset power-up
mode, the Controller acts as if all Input Devices are configured for Auto
(Trip) Reset. Each Safety Output will immediately turn on at power-up
providing the assigned Input Devices are all in the Run state, even if one
or more of the Input Devices is configured for Manual (Latch) Reset. If the
application requires that a Manual (Latch) Reset operation be performed
before the Safety Output turns ON, then either Manual or normal powerup mode configuration must be used. Failure to do so could cause a machine to operate in an unexpected way at power-up or after temporary
power interruptions.
CONTROLLER OPERATION ON POWER-UP
It is the responsibility of the person who configures, installs, and/or maintains the Controller to assess what Safeguarding Devices and methods
are appropriate for any given machine or application and to be aware that
the power-up behavior of this Controller may not be obvious to the machine operator.
The Controller’s system settings define parameters for both the configuration file and the Controller. These settings include:
• Configuration Name
• Author’s name
• Power-up mode
• Mute on Power-up enable
• Monitored System Reset
2.6.1
Settings Breakdown
2.6.1.1 Configuration Name
The Configuration Name identifies the configuration that will be used
in a Safety Controller application. The Configuration Name can be
displayed on the Controller and will be useful to be sure that the configuration in a Controller is the correct one.
2.6.1.2 Author’s name
The Author’s name may also be helpful when questions arise about
configuration settings.
The Controller provides three power-up modes to choose from to determine how the Controller will behave immediately after power is applied. These power-up modes are: Normal, Automatic and Manual.
After power is applied, when in Normal power-up mode (default):
• Only those Safety Outputs that have only Automatic Reset
Inputs will turn ON
• Safety Outputs that have one or more Manual Reset Inputs
will turn ON only after a Manual (Latch) Reset operation is
performed
• 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
After power is applied, when in Automatic power-up mode:
• 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 Switch 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 remain OFF
After power is applied, when in Manual power-up Mode:
• Safety Outputs will turn ON only after all Inputs Mapped to this
output are in the Run state and a System Reset has been performed (a Reset for a manual Latch is not required)
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
2.6.2
Mute on Power-Up Enable
If configured, the Mute on Power-Up function will initiate a Mute Cycle
after power is applied to the SC22-3 Safety Controller if the muted
Safety Inputs are active (Run state or closed), and either M1-M2 or
M3-M4 (but not all four) are signalling a muted condition (e.g. active
or closed). See also block 1.11 on page 5.
2.6.3
Monitored System Reset
A Monitored System Reset is enabled by default and requires an
OFF-ON-OFF signal at the System Reset input, where the ON-duration must be between 0,3 s and 2 s (trailing edge System Reset), in
order to Reset the system.
If unchecked (Monitored System Reset disabled), the System Reset
input requires only a signal from OFF to ON (leading edge System
Reset), in order to Reset the system.
INSTRUCTION MANUAL - EUROPEAN VERSION
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SC22-3 Safety Controller
Overview
2.7 INTERNAL LOGIC
Once confirmed, a configuration can be stored and reused without reconfirming. The configuration code will be validated automatically
each time it is downloaded to a Safety Controller and whenever the
Safety Controller powers up. Configurations, confirmed or not, can be
sent via email. Sending (down loading) a new confirmed configuration to a Safety Controller requires entry of the Safety Controller
password.
See also block 2.4.1 on page 8.
2.7.1
Additional Logic Functions
Other logic functions are slight variations of the general AND logic
rule set as follows:
• Two-Hand Control The machine initiation signal incorporating a
0,5 second actuation Simultaneity Limit and Anti-Tie-Down Logic,
designed to prevent single-actuation machine cycle operation
• Safety Device Mute Enable The automatic suspension of one or
more Safety Input(s) for Stop signals during a portion of a machine
operation when no hazard is present or when access to the hazard
is otherwise safeguarded
• Safety Device Bypass Switch The manually activated, temporary
suspension of one or more Safety Input(s) for Stop signals when
the hazard is otherwise safeguarded
• Enabling Device Control The actively controlled manual suspension of a Stop signal during a portion of a machine operation when
a hazard could occur
The rules that apply to these special cases are explained in
appendix A2.
2.8 PASSWORD OVERVIEW
To provide security, the Safety Controller requires use of a password
in some cases. For information about changing a Safety Controller’s
password, refer to block 5.1.18 on page 50 (PCI) and block 6.3.3 on
page 64 (OBI).
☛ If the password becomes lost, contact Corporate Office as listed
on page 121.
For Creating a Configuration:
• Via PC using SC22-3 PCI program (no password required)
• Via Safety Controller password protected OBI
Confirming a Configuration:
• Via password protected PCI using PC connected to a powered-up
Controller
• Via password protected OBI on a powered Controller
Sending a Confirmed Configuration to the Safety Controller:
• Via a direct connection between the PC and Controller, using SCUSB1 cable and password protected PCI
• Via password protected PCI PC, XM Card programming tool and
XM Card
2.9 CONFIRMING A CONFIGURATION
Although a Safety Controller will accept an unconfirmed configuration, it will only activate it (adopt the configuration and function according to its parameters) after the configuration is confirmed, using
the OBI.
IMPORTANT: If any modification is made to a confirmed configuration, or if a configuration is edited during the confirmation process, the
PCI and the Safety Controller OBI will recognize this modified configuration as being new and will require it to be confirmed before it can
be activated and used.
INSTRUCTION MANUAL - EUROPEAN VERSION
2.10 PC INTERFACE 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
The PCI program uses Input Device icons and circuit symbols to aid
making appropriate device property selections. As the various device
properties and I/O control relationships are established, the program
automatically builds the corresponding Wiring Diagrams and Ladder
Logic Diagrams. These diagrams provide I/O device wiring detail for
the installer and a symbolic representation of the Safety Controller’s
Safeguarding logic for the use of the machine designer or controls
engineer. Refer to block 5.1 on page 37, for further instruction on the
use of this interface.
2.11 ON BOARD INTERFACE OVERVIEW
The SC22-3 Safety Controller’s On Board Interface (OBI) consists of
a display and six push buttons that are used to:
• Select a language
• Create, confirm, edit, erase, send, and receive a configuration
• Display real-time Run mode information
• Display current fault data, fault log data, and to clear the fault log
• Display the model number of the Safety Controller
• Set a password
The configuration is used to define the Input Devices that will be connected to the Safety Controller and to establish relationships between the Input Devices themselves as well as between the Input
Devices and the Outputs.
Figure 13 on page 17 gives a breakdown of all the Run mode and
Configuration mode options available using the OBI.
To move through the menus, in most cases, the OK push button must
be pressed to make a selection or move further down the menu tree.
Pressing the ESC push button allows movement further up the tree.
When a vertical list of options appears on the screen, the up/down arrow push buttons are used to highlight an option selected. The highlighted option is selected by pressing OK. When a single option
appears on the screen (for example, an Input Device) with an arrow
running across the top of the screen, the left/right arrow push buttons
are used to step through the selections. The option shown on the
screen is selected when OK is pressed.
Refer to Chapter 6, for further instruction on the use of this interface.
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SC22-3 Safety Controller
Run Mode
Overview
Configuration
Mode
Fault
Diagnostics
Clear Fault
Log
Terminal
Assignments
Set Display
Contrast
Input/Output
Mapping
Status Output
Settings
View Response
Times
Exit
Configuration
(block 6.3.3)
(block 6.3.4)
Receive File
from XM
Confirm
Inputs
Confirm Safety
Outputs
Edit
Password
Confirm System
Settings
Set Language
Name
Configuration
(block 6.3.1.1)
Configuration
Summary
Save
Configuration
(block 6.1.2)
(block 6.1.5)
OK ➝
OK ➝
OK ➝
ESC ➝
(OUTPUTS/SYSTEM
SETTINGS on page 61)
ESC ➝
Outputs/System
Settings
Inputs
(Inputs page 56)
ESC ➝
OK ➝
ESC ➝
Send File to
XM
OK ➝
OK ➝
Erase
Configuration
ESC ➝
System
Options
(block 6.3.2)
ESC ➝
Confirm
Configuration
(block 6.3.1)
ESC ➝
Configuration
File
OK ➝
(block 6.3.1.1)
software and
hardware versions
Enter Password
(block 6.2.1)
Configuration
Mode
Edit
Configuration
ESC ➝
ESC ➝
View Fault
Log
OK ➝
OK ➝
OK ➝
View Current
Faults
Model Number
Configuration
Summary
(block 6.3)
ESC ➝
OK ➝
ESC ➝
System Menu
Add Input
(Add Inputs
page 56)
Delete Input
Edit Input
Status
Outputs
Safety
Outputs
System
Settings
Terminal
Assignments
Input/Output
Mapping
Status Output
Settings
View Response
Times
Safety Input
Non-Safety
Input
(SAFETY INPUTS PAGE 56)
Mute
Enable
ESC ➝
ON/OFF
Reset
Bypass
Switch
Mute
Sensor
Enabling
Device
Rope Pull
EDM
Protective
Stops
Safety Mat
Two-Hand
Control
Optical
Sensor
Gate
Switch
E-Stop
OK ➝
OK ➝
ESC ➝
(NON-SAFETY INPUTS PAGE 58)
Figure 13 OBI Configuration Options
INSTRUCTION MANUAL - EUROPEAN VERSION
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SC22-3 Safety Controller
Overview
Intentionally left blank
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SC22-3 Safety Controller
General Information
3 GENERAL INFORMATION
This Chapter details information of a general nature on the equipment.
3.1 PRODUCT
This block details product information such as CE and Product Identification Plates together with their location.
3.1.1
CE Marking / Product Identification Plate
The CE information is combined with Product Identification Information as shown in figure 14 on page 19.
Configurable SC22-3 Safety Controller
Rated Supply:
Safety Type:
Enclosure Rating:
24 V dc, 0,4 A
Cat. 4 (ISO 13849 / EN954), SIL 3 (IEC 61508)
IEC IP20
Temperature Rating:
0 - 55 C
Safety Output Rating:
24 V dc, 0,75 A
°
Status Output Rating:
24 V dc, 0,5 A*
* Total Status Output (O1-O10) Rating: 1 A
Figure 14 SC22-3 Safety Controller CE Marking /
Production Identification Plate
3.1.2
Certificate of Adequacy
The SC22-3 Safety Controller Instruction Manual (Part No. 135369
Dated 06.03.08) satisfies the requirements of:
Machine Directive 2006/42/EC, Safety of Machinery, Block 1.7.4 Instructions.
3.1.3
Declaration of Conformity
The SC22-3 Safety Controller is delivered with a Declaration of Conformity as shown in appendix A3.1 on page 115.
This declaration is delivered to the Customer to certify that the product complies with the CE-Norm.
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General Information
SC22-3 Safety Controller
3.2 TECHNICAL DATA
3.2.1
This block details the most important technical data for the product.
Table 4 on page 20 lists the specifications for the SC22-3 Safety
Controller.
Specifications
Table 4 SC22-3 Safety Controller General Specifications
Nomenclature
Power
Value/Meaning
24 V dc, ± 20%
0,4 A (Safety Controller only),
5,9 A (all Outputs ON @ full rated load)
The Safety Controller should be connected only to a SELV or PELV power supply.
Safety Input & Non-Safety Input
(22 terminals)
Safety Outputs
(6 terminals, 3 Redundant Outputs)
Status Outputs
(10 terminals)
Input ON threshold: > 15 V dc (guaranteed on), 30 V dc max.
Input OFF threshold: < 5 V dc (guaranteed off with any 1 fault), – 3 V dc min.
Input ON current:
8 mA typical @ 24 V dc, > 2 mA (guaranteed with 1 fault)
50 mA peak contact cleaning current @ 24 V dc
Sourcing current:
30 mA minimum continuous (3 V dc max. drop)
Input lead resistance: 300 Ω max. (150 Ω per lead)
Rated output current:
Output OFF threshold:
Output leakage current:
Load:
0,75 A max. @ 24 V dc (1,0 V dc max. drop)
0,6 V dc typical (1,2 V dc max. guaranteed with 1 fault)
50 µA max. with open 0 V
0,1 µF max., 1 H max., 10 Ω max. per lead
Rated output current: 0,5A @ 24 V dc (individual), 1,0 A @ 24 V dc (total of all Outputs)
O1 to O8 (General Purpose) Output OFF voltage: < 0,5 V dc (no load)
O9 and O10 (Monitored Mute Lamp) Output OFF voltage: Internal 94 KΩ pull up to V supply
Output ON/OFF threshold: 15 V dc ± 4 V dc @ 24 V dc supply
If O9 and O10 are not being used to monitor a mute lamp, they can also be used for general
purposes, similar to O1 - O8.
☛ For O9 and O10, if a short circuit or other fault condition causes the output to drop below this threshold while the output
is ON, a lockout occurs. If an open circuit or other fault condition causes the output to rise above this threshold while the
output is OFF, a lockout occurs.
Response time (ON to OFF):
Response and
Reaction Times
Reaction time (OFF to ON):
Reaction time (OFF to ON):
10 ms max. (with standard 6 ms debounce; this can increase if debounce time increases.
Refer to the Configuration Summary for actual response time.
400 ms max. (with Manual Reset option)
400 ms max. plus input debounce time (Automatic Reset)
Onboard LCD Information Display —
Password Requirements
Password is not required:
Run mode (I/O status)
Fault (I/O fault detection and remedial steps)
Review configuration parameters (I/O properties and
terminals)
Environmental Rating
IEC IP20, for use inside IEC IP54 or better enclosure
Operating Conditions
Temperature range: 0° to +55° C
Mechanical Stress
Shock:
15 g for 11 ms, half sine, 18 shocks total (per IEC 61131-2)
Bump:
10 g for 16 ms, 6000 cycles total (per IEC 61496-1)
Vibration: 3,5 mm occasional / 1,75 mm continuous @ 5 Hz to 9 Hz, 1,0 g occasional and 0,5 g continuous @ 9 Hz to
150 Hz: (per IEC 61131-2) and 0,35 mm single amplitude / 0,70 mm peak-to-peak @ 10 Hz to 55 Hz (per
IEC 61496-1), all @ 10 sweep cycles per axis
EMC
Meets or exceeds all EMC requirements in IEC 61131-2, IEC 61496-1 (Type 4), and IEC 62061 Annex E, Table E.1
(increased immunity levels)
Password is required:
Configuration mode (create/modify/confirm/download
configurations)
Screw Terminals
Removable Terminals
Wire sizes:
Wire strip length:
Tightening torque:
Tightening torque:
0,20 mm2 – 1,31 mm2
5,00 mm
0,23 Nm nominal
0,34 Nm maximum
Clamp Terminals
Wire size:
0,20 mm2 – 1.31 mm2
Wire strip length:
9,00 mm
IMPORTANT: The clamp terminals are designed for 1 wire only. If more than 1 wire is connected to a terminal, a wire
could loosen or become completely disconnected from the terminal, causing a short.
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General Information
Table 4 SC22-3 Safety Controller General Specifications
Nomenclature
Value/Meaning
• SIL 3 as per IEC 62061 Safety of Machinery – Functional Safety of Safety-Related Electrical, Electronic and
Programmable Electronic Control Systems
• SIL 3 as per as per IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related
Systems
Product Performance Standards
• Category 4 as per ISO 13849-1 (EN954-1) Safety of Machinery. Safety Related Parts of Control Systems
• Performance Level (PL) as per ISO 13849-1
• IEC 61131-2 Programmable Controllers, Part 2: Equipment Requirements and Tests
• IEC 60204-1 Electrical Equipment of Machines: General Requirements
• EN 954-1 Safety of Machinery. Safety Related Parts of Control Systems. General Principles.
• ISO 13851 (EN574) Safety of Machinery – Two-Hand Control Devices – Functional Aspects and Design Principles
• ISO 13850 (EN418) Emergency Stop Devices
Also see DOC for a list of other applicable International Standards.
Declaration of Conformity (DOC)
3.2.2
Model/Type Numbering
Included with the SC22-3 Safety Controller are the following documents
(for order numbers see table 5 on page 21):
• European Instruction Manual (this document; for further breakdown, see block 8.4.2 on page 82)
• Quick Start Guide (for order numbers, see block 8.4.2 on page 82)
3.2.2.1
SC22-3 Safety Controller Model/Type Numbering
Table 5 SC22-3 Safety Controller
Model No.
Description
Order No.
SC22-3-C
Safety Controller Kit
30 779 13
SC22-3
Safety Controller only
30 797 15
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Model
21
General Information
3.2.3
SC22-3 Safety Controller
SC22-3 Safety Controller Dimensions
figure 15 on page 22 gives the dimensions for the SC22-3 Safety Controller.
Dimensions in mm
Allow minimum 65 mm
clearance for USB cable
and 43 mm for XM Card
insertion
64
35
131
112
130
Figure 15 SC22-3 Safety Controller Dimensions
3.3 CUSTOMER SERVICE INFORMATION
For Customer service information refer to appendix A5 on page 121.
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Installation
4 INSTALLATION - SYSTEM
4.2 COMPONENTS
! WARNING
BEFORE CARRYING OUT ANY INSTALLATION OF THE SC22-3 SAFETY CONTROLLER,
READ THE SAFETY INFORMATION CONTAINED IN CHAPTER 1.
4.1 SC22-3 SAFETY CONTROLLER INTERFACING
SC22-3 Safety Controller interfacing 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. It is the user’s responsibility to verify whether the Safeguarding is
appropriate for the application and is installed as instructed by the appropriate installation Manuals.
If there is any doubt about whether or not your machinery is compatible with this Controller, contact Corporate Office as listed on
page 121.
The SC22-3 Safety Controller Starter Kit (see block 8.4.1 on page 80
for further breakdown and replacement parts) includes the following
(see figure 16 on page 23):
• x1 SC22-3 Safety Controller
• x1 set of removable terminals (choose screw or clamp type)
• x1 SC-XM1 external memory card (XM Card)
• x1 USB A/B cable (some models)
• x1 SC-XMP XM Card programming tool (some models)
• x1 CD containing PCI software, Instruction Manual, and configuration tutorials (p/n 134534)
• x1 Quick Start Guide (p/n 133485)
• Standard US English Manual (Part No. 133487)*
• European Language Kit **
! *Users please note that the Manual (133487) is NOT suitable for use
within the EU. European users of the Safety Controller should use the European English version (this Manual 135369) or a translated equivalent.
**For details contact your corporate office as listed on page 121.
1
7
6
5
4
2
3
Index to figure
1. SC22-3 Safety Controller
2. USB A/B Cable
3. External memory card (XM Card)
5. CD containing PCI software instruction Manual & configuration tutorials
6. Quick Start Guide
7. Removable Terminals
4. SC-XMP XM Card programming tool (some models)
Figure 16 SC22-3 Safety Controller Kit Components
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SC22-3 Safety Controller
4.3 CONNECTING SC22-3 SAFETY CONTROLLER
4.3.1
1)
Electrical Connection
Referring to appropriate Vendor Installation instructions in conjunction with SC22-3 Safety Controller configuration information
contained in this Instruction Manual, connect supplied SC22-3
Safety Controller terminal blocks (shown in figure 16 on
page 23) to Power Supply, Status Outputs, Safety Outputs and
Inputs.
4.3.2
USB Connections
The Safety Controller is connected to a PC by way of a USB A/B cable (figure 17 on page 24). The cable is also used to connect the PC
to the SC-XMP Programming Tool (figure 18 on page 24 refers) in order to download a configuration to the XM Card.
1)
Referring to figure 17 on page 24, connect USB A/B cable to
Safety Controller and PC with PCI configured software loaded.
Figure 18 PC to SC-XMP Programming Tool Connection
4.3.4
SC-XM1 External Memory XM Card
The model SC-XM1 External Memory XM Stick is a removable memory module that can store or be used to transfer a single configuration. The XM Card has a write-on label on its reverse side where a
Configuration Name or a machine identification can be noted. The
XM Card SC22-3 Safety Controller is shown connected to the
figure 18 on page 24.
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
Store a configuration on the XM Card in one of two ways:
Figure 17 PC to Safety Controller USB Port Connection
4.3.3
SC-XMP Programming Tool
The SC-XMP Programming Tool is a handy device that can be used
to transfer a configuration from a PC (running the PCI software) to an
XM Card or from an XM Card to the PC, without requiring an SC223 Safety Controller. It connects to the PC via the USB A/B cable and
the PC’s USB port (see figure 18 on page 24).
1)
Referring to figure 18 on page 24, connect SC-XMP Programming Tool.
2)
Plug in XM Card.
• Send a copy to the XM Card using the PC Interface (PCI) and the
SC-XMP Programming Tool (see block 5.1.16 on page 49)
• Send/Receive copy from/to Safety Controller to XM Card, using
OBI (see block 6.3.1.2 on page 62 or block 6.3.1.3 on page 62)
☛ A configuration can be stored permanently in an XM Card, if the
“lock” function is performed.
XM Card Port
USB B Port
☛ For Information on loading configuration to XM Card, refer to
block 5.1.16 on page 49.
Figure 19 SC22-3 Safety Controller Connections to SC-XM1 External Memory
Card (XM Card)
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Installation
4.4 SAFETY DEVICE CONNECTION CONSIDERATIONS
! WARNING
THE USER IS RESPONSIBLE FOR ENSURING THAT ALL LOCAL, STATE, AND NATIONAL
LAWS, RULES, CODES, AND REGULATIONS RELATING TO THE USE OF THE SAFETY
CONTROLLER IN ANY PARTICULAR APPLICATION ARE SATISFIED. EXTREME CARE IS
URGED THAT ALL LEGAL REQUIREMENTS HAVE BEEN MET AND THAT ALL INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS CONTAINED IN THE SAFETY
DEVICE MANUAL FROM THE MANUFACTURER AND IN THIS MANUAL ARE FOLLOWED.
The Inputs of the SC22-3 Safety Controller can be configured to interface with many types of safety devices, including Safeguarding
Devices (e.g. Safety Light Screens), complementary protective
equipment (e.g. Emergency Stop Push Buttons) and other devices
that impact the safe use of a machine (e.g. equipment protection).
The way these devices interconnect impacts their ability to exclude
or detect faults that could result in the loss of the safety function.
There are many standards, regulations and specifications that require certain capabilities of a safety circuit.
4.5 SAFETY INPUT DEVICE PROPERTIES
figure 20 on page 25 gives a breakdown of the Safety Input properties menu.
Used to type in Name for Safety Input device
Used to select Circuit Type from drop-down menu
Used to select Reset Logic from drop-down menu
Shows selected Circuit Type & Input terminals assignment
“+” indicates terminal that supplies +24 V dc source for the Safety Input
device
These drop-down menus used to change Input terminals assignment
Clicking INFO button links to more information.
Tip: Clicking on the INFO button links to appendix A2 of this Manual giving more
information about a device and which Circuit Types provide what level of safety.
Allows each device to be Mapped to any of 1, 2, or 3 Safety Output
Advanced Settings used for further configuration of device type (e.g.
Simultaneity, Closed-open debounce time or Open-closed debounce
time)
Figure 20 Safety Input Properties Breakdown
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Installation
4.5.1
SC22-3 Safety Controller
General
4.5.2
The Controller can be configured to accommodate many types of
Safety Inputs. However, a number of device properties must be established (using either the OBI or PCI) so that the Controller can
properly monitor their signals.
Name
This property is used for automatically configuring the Device Name
by the Controller and can be changed by the user.
4.5.3
Circuit Type
This property is used to configure the circuit and signal convention
options that can be selected to define the Safety Input device.
Table 6 below shows a selection of the Safety Input devices and Circuit Types the Safety Controller can monitor. It also 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.
The Safety Input devices configurable properties breakdown is detailed in Table 6 below and block 4.5.2 thru’ to block 4.5.11.
☛ Not all Circuit Types meet the Category 4 classification as per
ISO 13849-1; refer to appendix A2 for more information over
safety circuit integrity levels.
Table 6 Safety Controller Safety Input Device & Circuit Type Monitoring Breakdown
Rope Pull
Protective Stop
Safety
Mat
Enabling
Device
Mute
Sensor
Bypass
Switch
External
Device Monitoring
7
10
10
1
10
7
10
2
Auto/Manual
Auto
Auto/Manual
Auto/
Manual
Auto/
Manual
Auto
Auto
Auto
—
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/I
I/I
I/O
S/C
S/C
S/C
S
S/C
S/C
—
S/C
S
S/C
S
Debounce
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Start-up Test
—
Yes
Yes
—
—
—
—
—
—
—
—
Function Time
Limit
—
—
—
—
—
—
—
Yes
Yes
Yes
—
Muteable
—
Yes
Yes
Yes
—
—
Yes
—
—
—
—
Bypassable
—
Yes
Yes
Yes
—
Yes
—
—
—
—
Emergency
Stop
Gate
Switch
Optical
Sensor
Two-Hand
Control
Circuit Types:
7
13
10
Reset Logic:
Auto/Manual
Auto/Manual
Mapped to:
I/O
COS*
(Simultaneity):
Simultaneous (S) /
Concurrent (C)
Configurable
Properties
* Signal Change-of-state (block 4.5.7.1 on page 27)
S = Simultaneity
C = Concurrency
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4.5.4
Installation
Reset Logic
4.5.6
This property is used for configuring both Automatic (Trip mode) or
Manual (Latch mode) Resets. Safety Inputs can be configured to require a Manual Reset before the Safety Output they control are permitted to turn back ON. This is sometimes referred to as Latch mode
because the Safety Output latches to the OFF state until a System
Reset is performed. If a Safety Input is configured for Automatic Reset or Trip mode, the Safety Outputs it controls turn back ON when
the Input Device changes to the Run state (provided that all other
controlling Inputs are also in the Run state). System Reset rules and
types are discussed in block 1.10 on page 5.
4.5.5
Mapped to:
This property is used for configuring the logic control relationship between Inputs and Outputs or between Inputs
4.5.7
Advanced Settings
4.5.7.1 Signal Change-of-State (Simultaneity)
Two COS types (Simultaneity see Simultaneity) can be used when
monitoring dual-channel safety Input Device signals for Dual channel; Simultaneous or Concurrent. The rules for each Circuit Type are
listed in table 7 on page 27.
Input terminals
This property is used for configuring input terminals to connect Safety
Input/Non-Safety Input devices. The Safety Controller needs to know
what device signal lines are to be connected to which wiring terminals, so that it can apply the proper signal monitoring methods, Run
and Stop convention, timing rules, and fault rules. Although terminals
are assigned automatically during the configuration process, the terminal assignments can be changed manually, using either the OBI or
the PCI Interface.
Table 7 Signal Change-of-State (COS)(Simultaneity) Types
Dual channel
A&B
Dual channel A & B
Complementary
Circuit
Type
Circuit Symbol
Complementary, 2
terminals
Complementary, 3
terminals
Input Signal Stop State COS (Simultaneity)
Timing Rules
Input Signal Run State COS (Simultaneity)
Timing Rules
The Safety Output turns OFF when1:
The Safety Output turns ON when2:
Complementary,
PNP switch
24 V
ON
OFF
At least 1 channel (A or B) input in the Stop
state.
Dual channel,
2 terminals
Dual channel,
4 terminal
Dual channel,
3 terminals
24 V
Dual Channel,
PNP
ON
turn Outputs ON.
ON
2X Complementary, 4 terminals
x2 Complementary
A&B
24V
2X Complementary, 5 terminals
At least 1 channel (A or B) within a pair of contacts in the Stop state.
2X Complementary, PNP switch
ON
OFF ON
Simultaneity
A and B are both in the Stop state and then both
in the Run state within 3 s before Outputs turn
ON.
Concurrency
A and B concurrently in the Stop state, then
both in the Run state with no simultaneity, to
OFF
Simultaneity
A and B concurrently in the Stop state, then
contacts within a channel in the Run state within
400 ms (150 ms for Two-Hand Control), both
channels in the Run state within 3 s (0,5 s for
Two-Hand Control).
Concurrency
A and B concurrently in the Stop state, then
contacts within a channel in the Run state within
x2 Complementary
A&B
3 s. Both channels in the Run state with no
simultaneity.
Safety Mat 4 Terminals
At least 1 of the wires is disconnected, or one of
the normally low channels is detected high, or
one of the normally high channels is detected
low
Each channel detects its own pulses.
☛ Safety Outputs turns OFF when one of the controlling Inputs is in the Stop state.
1
2
Safety Outputs will only turn ON when all of the controlling Inputs are in the Run state and only after a Manual Reset has been performed, if any of these
Safety Inputs are configured for Manual Reset and were in their Stop state.
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Installation
4.5.7.2
SC22-3 Safety Controller
Closed-open debounce time / Open-closed debounce
time
4.6 NON-SAFETY INPUT DEVICE PROPERTIES
The Non-Safety Input devices configurable properties breakdown is
detailed in Table 8 below and block 4.6.1 thru’ to block 4.6.3.
! CAUTIONS
Debounce and Response Time
Any changes in the Closed-open debounce time will affect the Safety Output Response Time (turn OFF). 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.)
Table 8 Non-Safety Input devices
Manual
Reset
ON/OFF
Mute
Enable
3
3
3
I/O
I/O
I/O
Closed-open debounce time /
Open-closed debounce time
Fixed at
50 ms
Closed-to-open:
6 ms-100 ms
Open-to-closed:
10 ms-500 ms
Fixed at
50 ms
Monitored Reset
Yes
—
—
Response Times
Configurable
Properties
The Response Time for a complementary device is based on the closed
contact(s) opening, not on the open contact(s) closing. Both will lead to
a Stop signal but only one determines the Response Time.
Any changes in the Open-closed debounce time affects the Safety Output
reaction (turn ON time).
The configurable Debounce of an ON/OFF input and an Enabling Device
input are not part of the calculated and confirmed Response Times.
This property is used for configuring the signal state transition time.
Closed-open debounce time
From 6 ms to 100 ms in 1 ms intervals
The Closed-open debounce time is the time limit required for the input signal to transition from the high (24 V dc) state to the steady low
(0 V dc) state. This time limit may need to be increased in cases
where high-magnitude device vibration, impact shock, or switch
noise conditions result in longer signal transition times. If the Closedopen debounce time is set too short under these harsh conditions,
the system may detect a signal disparity fault and lock out. (Default
setting is 6 ms).
Open-closed debounce time
From 10 ms to 500 ms in 1 ms intervals
The Open-closed debounce time is the time limit required for the input signal to transition from the low (0 V dc) state to the steady high
(24 V dc) state. This time limit may need to be increased in cases
where high magnitude device vibration, impact shock, or switch noise
conditions result in longer signal transition times. If the Open-closed
debounce time is set too short under these harsh conditions, the system may detect a signal disparity fault and lock out. (Default setting
is 50 ms.)
When a safety mat is used, the response time calculation for the safety mat is dependent on the Run (10 ms to 500 ms) and Stop (6 ms
to 100 ms) debounce times.
4.5.8
Circuit Types:
Mapped to:
4.6.1
Manual Reset Devices
The Manual Reset is used to create a System Reset signal after a
Safety Input that has been configured to require a Manual Reset has
been opened and closed. After the Manual Reset operation is performed, any of the Safety Outputs controlled by that Safety Input can
turn ON. See caution on page 5.
4.6.2
ON/OFF Switch
The ON/OFF switch is used to provide a machine ON or OFF command. When all of the controlling Safety Inputs are in the Run state,
this function permits the Safety Output to turn ON and OFF. This is a
Single channel signal; the Run state is 24 V dc and the Stop state is
0 V dc.
4.6.3
Mute Enable Switch.
The mute enable switch is used to signal the Controller when the
mute sensors are permitted to perform a mute function. When the
mute enable function is configured, the mute sensors will not be enabled to perform a mute function until the mute enable signal is in the
Run state. This is a Single channel signal; the enable (Run) state is
24 V dc and the disable (Stop) state is 0 V dc.
Enable startup test
This property is used for configuring an optional precautionary Safety
Input test after each power-up.
4.5.9
Device Time Limit
This property is used for configuring the adjustable time limit within a
function is allowed to operate.
4.5.10 Muting Sensor Pair
This property is used for configuring whether or not the device can be
muted.
4.5.11 Bypass Switch
This property is used for configuring whether or not the device can be
bypassed.
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4.7 CONFIGURING THE SAFETY CONTROLLER
☛ For more detailed information on OBI functions refer to
Building a configuration for the Safety Controller is a simple process,
using one of two interfaces:
Accessing Fault Codes
The Fault codes are displayed in the last line of the OBI Fault Diagnostics menu (see screen 1). Refer to chapter 6 and block 8.3.3 on
page 74 for more information.
chapter 6.
• The push buttons and display on the Safety Controller itself (OBI)
or
• The PCI software program on the CD (p/n 134534) included in the
SC22-3 Safety Controller Kit.
The process comprises three main steps:
4.7.1
OBI
The Safety Controller can be configured using the OBI with its builtin push buttons and LCD screen. The LCD display provides I/O device and system status information for any event that causes one or
more of the Safety Outputs to turn OFF. Refer to figure 21 on
page 29 and Table 9 on page 30 for OBI breakdown.
Screen 1
The display is used in conjunction with the six push buttons to:
• Create or modify password protected configurations
• Retrieve fault log information
• Review device wiring detail and I/O logic relationships and
• Display I/O device fault details and likely remedial step
1
SC22-3
2
Safety Controller
Power
Status
3
Tx/Rx
8
SO1
SO2
SO3
4
7
Index to figure
1. Liquid Crystal Display
2. Moves cursor up or causes items within a list to be
displayed as the cursor is moving up through the
list. May also be used to make selection settings.
3. Moves cursor down or causes items within a list to
be displayed as the cursor is moving down through
the list. May also be used to make selection
settings.
6
5
4. Moves cursor to the right or performs selection
setting.
5. Enters or stores the item highlighted in the display
as the intended selection or may be used to toggle
a setting
6. Moves cursor to the pre-established point in the
program to re-establish a menu reference point.
7. Moves cursor to the left or performs selection
setting
8. Status Indicators
Figure 21 Onboard Interface Including Push Buttons, LCD Display & Status Indicators
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SC22-3 Safety Controller
Table 9 Onboard Interface Status Indicator Breakdown
Status Indicator
Condition
All Indicators OFF
Power
—
ON Green
Configuration mode
Lockout mode
Run mode
Flashing Red
OFF
Transmit/Receive Tx/Rx
Safety Output SO1, SO2, SO3
Initiation Mode
Power ON
Power OFF
OFF
ON Red
Status (Safety Controller Mode)
Indicates Safety Controller Status
OFF
Transmitting or receiving data (a link is established with
the PC)
Not transmitting or receiving data
ON Green
Safety Output ON
ON Red
Safety Output OFF
Flashing Red
Safety Output fault detected
Flashing Green
Safety Output waiting for Reset
Flashing Green
☛ The OBI functions are detailed in Chapter 6.
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4.7.2
Installation
PC Interface
The Safety Controller can also be configured using a Windows®based computer and the SC22-3 PC Interface (PCI) program
(screen 2). This user-friendly interface utilises icons and circuit symbols to simplify the selection of device properties during configuration. The configuration wiring and Ladder Logic Diagrams are
automatically created as the configuration progresses.
The PCI can be used to create a configuration, save it and send it as
described above, and also monitor the function of a Safety Controller
using the live display, as well as monitor the fault log for troubleshooting purposes. The PCI functions are covered in more detail in
Chapter 5.
Once a configuration is created, it can be:
• Stored to a computer file for archiving and future use
or
• E-mailed to a remote location as an attachment
or
• Can be sent directly to any SC22-3 Safety Controller or to the
plug-in external memory card
Toolbar
I/O Properties
Documents
Screen 2
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Installation
4.7.3
SC22-3 Safety Controller
4.8 EDM, OSSD SAFETY OUTPUT & FSD
CONNECTION
Defining Safeguarding Application
Risk Assessment
This includes:
4.8.1
• Determining required devices
• Determining required level of safety
4.7.4
4.8.1.1 Single channel Monitoring
For connection information refer to figure 26 on page 83.
Building the Configuration
This includes:
• Selecting Safety Input types and circuit connections
• Mapping each input to one or more Safety Outputs, or to other
Input Devices
• Setting optional Safety Output ON or OFF time delays
• Selecting Non-Safety Input types and circuit connections, if
required
• Assigning status output signals, if required
• Creating Configuration Name, Author’s name, Power-up mode
and Monitored System Reset
4.7.5
EDM
4.8.1.2 Dual channel Monitoring
For connection information refer to figure 27 on page 83.
4.8.1.3 No monitoring
If No monitoring is desired, simply do not select either Single channel
or the Dual channel option. If the Safety Controller does not use
the EDM function in Category 3 or Category 4 applications, the
user must ensure that any single failure or accumulation of failures of the external devices does not result in a hazardous condition and that successive machine cycles are prevented.
Confirming Configuration
This includes:
• Via Safety Controller, verifying that desired configuration is valid
• As User, confirming that configuration is what is expected
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4.8.2
Installation
FSD Interfacing Connections
FSDs can take many forms, though the most common are forcedguided (mechanically linked) relays or Interfacing Modules. The mechanical linkage between the contacts allows the device to be monitored by the external device monitoring circuit for certain failures.
Dependent on the application, the use of FSDs can facilitate controlling voltage and current that differs from the OSSD Outputs of the
Safety Controller. FSDs can also be used to control an additional
number of hazards by creating multiple safety stop circuits.
4.8.2.1 Safety (Protective) Stop Circuits
A safety stop allows for an orderly cessation of motion or hazardous
situation for Safeguarding purposes, which results in a stop of motion
and removal of power from the MPCEs (assuming this does not create additional hazards). A safety stop circuit typically comprises of a
minimum of two N.O. contacts from forced-guided (mechanically
linked) relays, which are monitored to detect certain failures such that
the loss of the safety function does not occur (i.e. EDM). Such a circuit can be described as a “safe switching point.”
Typically, safety stop circuits are a series connection of at least two
N.O. contacts coming from two separate, positive-guided relays,
each of them controlled by one separate Safety Output of the Safety
Controller. The safety function relies on the use of Redundant contacts to control a single hazard, so that if one contact fails ON, the
second contact arrests the hazard and prevents the next cycle from
occurring.
Interfacing safety stop circuits must be wired so that the safety function can not be suspended, overridden, or defeated, unless accomplished in a manner at the same or greater degree of safety as the
machine’s safety-related control system that includes the Safety
Controller.
The N.O. Outputs from an interfacing module (see block 3.2.2 on
page 21 for models) are a series connection of Redundant contacts
that form safety stop circuits and can be used in either Single channel
or Dual channel control methods (see figure 14 on page 19).
Dual channel Control
Dual channel (or Dual channel) control has the ability to electrically
extend the safe switching point beyond the FSD contacts. With proper monitoring (i.e., EDM), this method of interfacing is capable of detecting certain failures in the control wiring between the safety stop
circuit and the MPCEs. These failures include a short-circuit of Single
channel to a secondary source of energy or voltage, or the loss of the
switching action of one of the FSD Outputs. The result could lead to
the loss of redundancy or a complete loss of safety if not detected
and corrected.
The possibility of a wiring failure increases:
Single channel Control
Single channel (or Single channel) control, as mentioned, uses a series connection of FSD contacts to form a safe switching point. After
this point in the machine’s safety-related control system, failures can
occur that would result in the loss of the safety function (e.g. a shortcircuit to a secondary source of energy or voltage).
Thus, this method of interfacing should only be used in installations
where FSD safety stop circuits and the MPCEs are physically located
within the same control panel, adjacent to each other and are directly
connected to each other; or where the possibility of such a failure can
be excluded. If this can not be achieved, then Dual channel control
should be used.
Methods to exclude the possibility of these failures include but are not
limited to:
• Physically separating interconnecting control wires from each
other and from secondary sources of power
• Routing interconnecting control wires in separate conduit, runs, or
channels
• Routing interconnecting control wires with low voltage or neutral
that can not result in energizing the hazard
• Locating all elements (modules, switches, devices under control,
etc.) within the same control panel, adjacent to each other and
directly connected with short wiring
• 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
4.8.2.2 Safety Controller Connection to Interface Modules
For Safety Controller connection to Interface Modules refer to
figure 29 on page 84, figure 30 on page 84 and figure 31 on
page 85.
4.8.3
DC Common Wire Installation
Current through loads will create a voltage drop due to the line resistance RL of the DC common wire. The higher the DC common wire resistance (e.g. too small a wire cross sectional area or bad electrical
connection), the higher the voltage created on this wire resistance. If
this voltage exceeds 0,6 V, a Safety Output that has been switchedOFF, might appear to be shorted to + voltage. This would create a
fault in the Controller and the Output would turn OFF or remain OFF,
resulting in a Lockout (see Fault Code 1.2 page 75).
To prevent this happening, all DC common wiring from the loads
connected to the Safety Outputs should always be heavy wired
(larger cross sectional area) and as short as possible to minimise resistance (see figure 32 on page 85).
• As the physical distance between the FSD safety stop circuits and
the MPCEs increases
• As the length or the routing of the interconnection wiring increases
or
• If the FSD safety stop circuits and the MPCEs are located in different enclosures
Thus, Dual channel control with EDM monitoring should be used in
any installation where the FSDs are located remotely from the
MPCEs.
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Installation
SC22-3 Safety Controller
4.9 STATUS OUTPUTS
4.9.1
Status Output Signal Convention
Two signal conventions are selectable for the status Outputs. The default convention provides a 24 V 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. If
the above conditions are not true, the signal output would show 0 V.
Signal Convention 2 is the reverse of Signal Convention 1, as shown
in table 10 below.
Table 10 Signal Convention Breakdown
Mapped Status Output(s) State
Signal Convention 1
24 V dc = Run (Default)
Signal Convention 2
0 V dc = Run
Input Run
Input Stop
24 V dc
0 V dc
0 V dc
24 V dc
Output Run
Output Stop
24 V dc
0 V dc
0 V dc
24 V dc
System in Lockout
System in Run mode
24 V dc
0 V dc
0 V dc
24 V dc
I/O fault exists
No I/O fault exists
24 V dc
0 V dc
0 V dc
24 V dc
System Reset required
System Reset not required
24 V dc
0 V dc
0 V dc
24 V dc
Output Reset required
Output Reset not required
24 V dc
0 V dc
0 V dc
24 V dc
Input is muted
No mute
24 V dc
0 V dc
0 V dc
24 V dc
Tracked Function
4.10 COMMISSIONING CHECKOUT
After power is connected to the Safety Controller, the EDM has been
properly configured, and the Safety Outputs have been connected to
the machine to be guarded, the operation of the Safety Controller with
the guarded machine must be verified before the combined system
may be put into service. To do this, a qualified person as specified in
block 1.8.2 on page 4 must perform the Commissioning Checkout
procedure detailed in block 8.2.5 on page 69.
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Installation
4.11 SOFTWARE INSTALLATION
4.11.1 PCI Software Installation
4.11.1.1 System Requirements
The following are the system requirements for running the PCI
software:
System Requirements
®
Operating System
Windows XP, Windows 2000 &
Windows Vista (PCI Software
Version 1.1 and newer)
Hard drive space
100MB (plus up to 280 MB for
Microsoft. NET2.0, if not already
installed)
USB port
USB 1.1 or 2.0 type A port
Installed Software
Microsoft .NET 2.0, included and
installed with PC-GUI software,
if Adobe® Reader® for Windows®
7.0 or newer version not already
on your computer.
4.11.1.2 Installing the Software
☛ PCI software may be installed from CD (supplied with Safety
Controller) or alternatively, downloaded from the Banner Sales
Force website (https://www.bannersalesforce.com/menu.php).
Instructions for getting started are also supplied with the Safety
Controller in the form of a Quick Start Guide.
1)
Insert CD into computer CD drive.
2)
To install: Run setup.exe, or click Install Software on launch
menu.
3)
Restart computer for maximum functionality.
4)
Remove CD from drive
On PC restart, the Banner Safety Controller icon
which starts
the program appears on the PC desktop.
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Intentionally left blank
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Operating Instructions — PCI
5 OPERATING INSTRUCTIONS - PCI
5.1 WORKING WITH THE PCI PROGRAM
The SC22-3 Safety Controller PCI is the primary tool for creating and
managing configuration files for the Safety Controller. It is also used
to retrieve, display and store both I/O and system status and fault information.
The following information details the steps needed to create a sample
configuration, using the Safety Controller’s PCI. The configuration is
used to define the Safety Input and Non-Safety Input devices to be
connected to the Safety Controller. It is also used to establish relationships between those Safety Input/Non-Safety Input devices and
the Safety Controller Safety Outputs.
5.1.1
Installing PCI Software
Refer to block 4.11.1 on page 35.
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Operating Instructions — PCI
5.1.2
SC22-3 Safety Controller
Starting PCI Program
Proceed as follows:
1)
From the PC Desktop, Double-click on Banner Safety Controller
icon
.
or alternatively
From the Start Menu, click on:
<Start> <All Programs> <Banner Engineering> <Banner Safety
Controller>
2)
Read and understand warning on Start-up page of program and click OK.
A new un-named file is created as shown in screen 3 on page 38.
!
5.1.2.1 Diagrams & Summary
Clicking on each of the three support documents, Wiring Diagram,
Ladder Logic Diagram and Configuration Summary, if opened at this
point, show the following information (screen 3 refers):
Index to screen
1. Ladder Logic Diagram
2. Configuration Summary
3. Wiring Diagram
• Wiring Diagram shows its numbered terminals without any logic
circuit elements in place. The only terminal configured by default is
the System Reset (SR) terminal
S1 thru’ S22 for Input Devices (both safety and non-safety)
A1 for +24 V dc and A2 for 0V dc
O1 through O10 for Controller and I/O status indication
SO1 (1A and 1B), SO2 (2A and 2B) and SO3 (3A and 3B)
for connections to the Safety Outputs
SR, the Controller’s System Reset terminal (shown with a
push button symbol)
• Ladder Logic Diagram shows the vertical lines representing +24 V
and 0 V dc and the System Reset circuit
• Configuration Summary shows only some default system
settings
3
1
2
Screen 3
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5.1.3
Operating Instructions — PCI
Configuration Tools
Screen 4 gives a breakdown of the tool bar and is used for creating
and managing configuration files. In particular, the Live Display button permits the PCI to display real time Run mode data from a working Safety Controller via the USB connection.
1
10
2
3
11
4
5
6
7
12
9
8
Index to screen
1. Send, receive & confirm buttons
appear in colour when a powered
Safety Controller or programming tool
is connected to the PC
2. Access live display
3. Add Safety Input to configuration
4. Add Non-Safety Input to configuration
5.
6.
7.
8.
Access Safety Output settings
Access status output settings
Access system settings
Ladder Logic Diagram
9. Configuration Summary
10. I/O Properties - Double-click to
access property settings
11. Documents Section
12. Wiring Diagram
Screen 4
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Operating Instructions — PCI
5.1.4
1)
SC22-3 Safety Controller
Creating a New Configuration
Double-click on Banner Safety Controller icon
Name details are now also shown on the main screen (screen 7 on
page 40).
.
At this stage the Configuration Name and Author’s name can be filled
in as well as the system settings.
2)
Double-click System Settings icon
. Screen 5 on
page 40 is shown.
Screen 7
5.1.5
Screen 5
3)
Fill in field for Configuration Name file using up to 16 alphanumeric characters.
4)
Fill in field for Author’s name box (up to 10 characters).
5)
Keep or change the default system settings:
Power-up mode:
Automatic, Manual, or Normal
(default), see block 2.5.3 on
page 14
Mute on Power-up:
Checked ON or unchecked OFF
(default), see block 2.5.3 on
page 14
Monitored System Reset: Unchecked OFF or Checked ON
(default), block 1.10 on page 5
Adding Safety Input & Non-Safety Input
Devices
Table 11 on page 40 shows the Safety Input and Non-Safety Input
devices that can be configured with the SC22-3 Safety Controller.
Table 11 Safety Input & Non-Safety Input Configurable Devices
Safety Inputs
•
•
•
•
•
•
•
•
•
•
•
Emergency Stop button
Rope Pull
Gate Switch (interlock)
Optical Sensor – single-/multiplebeam sensors, safety light curtain,
area scanners, etc.
Two-Hand Control device
Safety Mat
Protective Stop – miscellaneous
device
Enabling Device
Mute Sensor
Bypass Switch
EDM
Non-Safety Input
• Manual Reset switch
• ON/OFF switch
• Mute Enable switch
Refer to appendix A2 for more information about each of the Safety
Input device types.
Screen 6
6)
40
When complete, click OK (screen 6 on page 40).
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Operating Instructions — PCI
To Add Safety Input:
1)
5.1.6.1
Click Add Safety Input icon
.Screen 8 is shown.
1)
Adding Emergency Stop
From Add Safety Input menu (screen 8 on page 41) click on an
appropriate icon
and click OK (or double-click on
the icon). Screen 10 on page 41 is shown.
Screen 8
Screen 8 on page 41 displays the Safety Input device types the Safety Controller can accommodate.
2)
Click on appropriate icon to select desired device and click OK
(or double-click on the icon).
To Add Non-Safety Input:
3)
Screen 10
If the default settings are NOT to be used, proceed as follows:
2)
Add Name: e.g. ES01.
☛ Any Safety Input device can be renamed during the configuration
Click Add Non-Safety Input icon
process.
. Screen 9 on
3)
Select appropriate Circuit Type for the designated device: e.g.
Dual channel, 4 terminal.
The selected Circuit Type appears in the Safety Input terminals diagram with automatically assigned terminal numbers. The terminal
numbers can be reassigned using the drop-down menu(s). The plus
signs at S1 and S3 (see screen 10 on page 41) designate that these
terminals supply the +24 V dc source for the device contacts.
page 41 is shown.
☛ For more information about safety circuit integrity levels and the
capabilities of each Circuit Type see appendix A2.
Set Reset Logic: e.g. Manual.
From drop down menu(s), select Input terminals: e.g. S1, S2, S3
and S4 (use the drop-down terminal number fields to change the
terminal assignment, if needed).
6) Set Mapped to: Check or uncheck boxes to map each Safety Input to one or more Safety Outputs, e.g. SO1, SO2, and SO3 (at
least one must be selected).
7) If the default settings are NOT to be used, click on:
Advanced Settings
Check/Uncheck box Enable startup test
Set Simultaneity:
Set Closed-open debounce time:
Set Open-closed debounce time:
4)
5)
Screen 9
5.1.6
Selecting Safety Inputs
For background and properties breakdown refer to block 1.9 on
page 4 and block 4.5 on page 25.
8)
On completion click OK to exit.
Once a Safety Input is selected, the Properties menu for that device
is shown. This menu presents the properties that must be established
for each type of Safety Input.
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Operating Instructions — PCI
SC22-3 Safety Controller
Because a Manual Reset signal was chosen for the E-stop button,
when OK is selected and the ES01 Properties menu closes, the
RS01 Properties Manual Reset screen appears automatically
(screen 11 on page 42) to add a Manual Reset Input Device for that
device. Any Safety Input which keeps the default Manual Reset Logic
setting requires a Manual Reset for any Safety Output Mapped to that
device. A separate Manual Reset may be assigned for each Safety
Output.
☛ If the Safety Input is a Muting Sensor Pair or a Bypass Switch,
those Inputs should be Mapped to at least one of the other Safety
Inputs.
If the default settings are NOT to be used, proceed as follows:
9)
Name: e.g. RS01.
10) Select appropriate Circuit Type: e.g. Single channel, 2 terminal.
11) From drop down menu(s), select Input terminals: e.g. S21 and
S22.
12) Check/Uncheck Mapped to: e.g. SO1, SO2 and SO3.
Screen 13
13) Check/Uncheck Monitored Reset.
14) On completion click OK to exit.
Screen 11
As the properties are selected, the Wiring Diagram also begins to
populate (screen 12 on page 42) with the selected Safety Input(s) as
does the Ladder Logic Diagram (screen 13 on page 42) and Configuration Summary (screen 14 on page 42).
Screen 14
Screen 12
42
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5.1.6.2
1)
Operating Instructions — PCI
Adding Gate Switch
5.1.6.3
From Add Safety Input menu (screen 8 on page 41) click on an
appropriate icon
1)
and click OK (or double-click on the
Adding Optical Sensor
From Add Safety Input menu (screen 8 on page 41) click on an
appropriate icon
icon). Screen 15 on page 43 is shown.
and click OK (or double-click on the
icon). Screen 16 on page 43 is shown.
Screen 16
If the default settings are NOT to be used, proceed as follows:
Screen 15
If the default settings are NOT to be used, proceed as follows:
2)
Add Name: e.g. OS01.
3)
Select appropriate Circuit Type: Dual Channel, PNP.
2)
Add Name: e.g. GS01.
4)
Set Reset Logic: e.g. Automatic.
3)
Select appropriate Circuit Type: Single channel, 2 terminal.
5)
4)
Set Reset Logic: e.g. Manual.
From drop down menu(s), select Input terminals: e.g. S11 and
S12.
5)
From drop down menu(s), select Input terminals: e.g. S5, S6.
6)
Set Mapped to: e.g. SO1 and SO2.
6)
Set Mapped to: e.g. SO1 and SO2.
7)
7)
If the default settings are NOT to be used, click on:
Advanced Settings
Check/Uncheck box Enable startup test
Set Simultaneity:
Set Closed-open debounce time:
Set Open-closed debounce time:
If the default settings are NOT to be used, click on:
Advanced Settings
Check/Uncheck box Enable startup test
Set Simultaneity:
Set Closed-open debounce time:
Set Open-closed debounce time:
8)
On completion click OK to exit.
8)
On completion click OK to exit.
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Operating Instructions — PCI
5.1.6.4
1)
SC22-3 Safety Controller
Adding Two-Hand Control
5.1.6.5
From Add Safety Input menu (screen 8 on page 41) click on an
appropriate icon
1)
and click OK (or double-click on
Adding Muting Sensor Pair
From Add Safety Input menu (screen 8 on page 41) click on an
appropriate icon
the icon). Screen 17 on page 44 is shown.
and click OK (or double-click on the
icon). Screen 18 on page 44 is shown.
Screen 17
Screen 18
If the default settings are NOT to be used, proceed as follows:
If the default settings are NOT to be used, proceed as follows:
2)
Add Name: e.g. THC01.
2)
Add Name: e.g. M1+M2.
3)
Select appropriate Circuit Type: 2X Complementary, PNP
switch.
3)
Select appropriate Circuit Type: Dual channel, 4 terminal.
4)
4)
From drop down menu(s), select Input terminals: e.g. S7, S8, S9
and S10.
From drop down menu(s), select Input terminals: e.g. S13, S14,
S15 and S16.
5)
Set Mapped to: e.g. OS01.
5)
Set Mapped to: e.g. SO3.
6)
6)
If the default settings are NOT to be used, click on:
Advanced Settings
Set Closed-open debounce time:
Set Open-closed debounce time:
If the default settings are NOT to be used, click on:
Advanced Settings
Set Closed-open debounce time:
Set Open-closed debounce time:
7)
On completion click OK to exit.
7)
On completion click OK to exit.
☛ The Reset Logic is set to Automatic for Two-Hand Control devices. There are no other reset options.
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5.1.6.6
1)
Operating Instructions — PCI
Adding External Device Monitoring
From Add Safety Input menu (screen 8 on page 41) click on an
appropriate icon
and click OK (or double-click on the
icon). Screen 19 on page 45 is shown.
Screen 21
Screen 19
If the default settings are NOT to be used, proceed as follows:
2)
Add Name: e.g. EDM01.
3)
Select appropriate Circuit Type: Single channel, 1 terminal.
4)
From drop down menu(s), select Input terminals: e.g. S17.
5)
Set Mapped to: e.g. SO1.
6)
On completion click OK to exit.
7)
Add two more External Device Monitoring Safety Inputs, one for
each Safety Output as shown in screen 20 on page 45 and
screen 21 on page 45, as follows:
• Name them EDM02 and EDM03
• Use Circuit Types Single channel, 1 terminal for each
• Assign Input terminals S18 to EDM02 and S19 to EDM03
Mapped to SO2 for EDM02 and to SO3 for EDM03
Screen 20
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Operating Instructions — PCI
5.1.7
SC22-3 Safety Controller
Add Non-Safety Input devices
5.1.7.2 Adding Mute Enable Switch
1) From Add Non-Safety Input menu (screen 8 on page 41) click
For properties breakdown refer to block 4.6 on page 28.
Once a Non-Safety Input device is selected the Properties menu for
that device is shown (screen 22 on page 46). This menu presents the
properties that must be established for each type of Non-Safety Input. The user-defined properties, depending on the device, include:
on an appropriate icon
and click OK (or double-click
on icon) as shown in screen 23 on page 46.
• Name — The Name (or circuit designation) of each specific device
(not device type)
• Circuit Type — A list of the types of contact or solid-state circuits
that can be used for that device type
• Mapped to — Establishes relationships between Non-Safety Input
devices and Outputs
5.1.7.1
1)
Adding ON/OFF Switch
From Add Non-Safety Input menu (screen 8 on page 41) click
on an appropriate icon
and click OK (or double-click
Screen 23
on icon) as shown in screen 22 on page 46.
If the default settings are not used, proceed as follows:
2)
Add Name: e.g. ME01.
☛ Any Non-Safety Input device can be renamed during the configuration process.
3) Select appropriate Circuit Type: Single channel, 1 terminal.
The selected Circuit Type appears in the Wiring Diagram with automatically assigned terminal numbers.
4)
From drop down menu(s), select Input terminals: e.g. S21.
☛ See appendix A2 for more information about safety circuit integrity levels and the capabilities of each Circuit Type.
Screen 22
5)
Mapped to: Check or uncheck boxes to map each Non-Safety
Input to one or more Safety Output (at least one must be selected).
6)
On completion click OK to exit.
If the default settings are not used, proceed as follows:
5.1.8
2)
The Safety Output(s) are assigned individually for each safety output.
Add Name: e.g. ON01.
☛ Any Non-Safety Input device can be renamed during the configuration process.
3) Select appropriate Circuit Type: for the designated device.
The selected Circuit Type appears in the Wiring Diagram with automatically assigned terminal numbers.
☛ See appendix A2 for more information about safety circuit integrity levels and the capabilities of each Circuit Type.
4)
From drop down menu(s), select Input terminals: e.g. S20.
5)
Set Mapped to: e.g. SO1.
6)
If default settings are NOT to be used:
Advanced Settings
Set Closed-open debounce time:
Set Open-closed debounce time:
7)
On completion click OK to exit.
1)
Assigning Safety Output(s)
Click Safety Output icon
. Screen 24 is shown.
2)
3)
4)
From drop-down menu select Safety Output: e.g. SO1.
Type in Name: e.g. SO1.
Select Delay Type: None, On-Delay or Off-Delay (for info refer
to block 2.5.1.3 on page 13).
5) On completion click OK to exit.
Screen 24
46
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SC22-3 Safety Controller
5.1.9
Operating Instructions — PCI
Configuring Status Outputs
The Safety Controller has 10 configurable Status Outputs (for more
info refer to block 2.5.2 on page 14 and block 4.9.1 on page 34).
1)
Click Status Output icon
. Screen 25 is shown.
Screen 27
14) On completion click OK to exit.
The Wiring Diagram should be as shown in Screen 28.
Screen 25
2)
From drop-down menu select Status Output: e.g. O1.
3)
type in Name: e.g. ESO1.
4)
Select a Function: Track Input (for info refer to block 2.5.2 on
page 14 and block 4.9.1 on page 34).
5)
Select a Source: e.g. ESO1.
6)
Select a Signal Convention...: e.g. 24V dc = Run. Screen 26 is
shown.
Screen 28
The Ladder Logic Diagram should be as shown in screen 29.
Screen 26
7)
On completion click OK to exit.
Add an additional Status Output
8)
Click Status Output icon
. Screen 27 is shown.
9)
From drop-down menu select Status Output: e.g. O2.
10) type in Name: e.g. Need Reset.
11) Select a Function: Output waiting for reset.
12) Select a Source: e.g. SO1.
13) Select a Signal Convention...: e.g. 24V dc = Run. Screen 27 is
shown.
Screen 29
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Operating Instructions — PCI
SC22-3 Safety Controller
5.1.10 Confirming Configuration
The new configuration must be confirmed before it can be used in a
Safeguarding application and the SC22-3 Safety Controller has to be
connected to the PC via the USB cable.
Wait a few seconds for Configuration Validation process to complete.
The Configuration Verification screen then appears (see screen 30).
The confirmation process has two parts:
Configuration Validation The Safety Controller receives and automatically checks a copy of the configuration to ensure that all safety critical settings are appropriate.
Configuration Verification The Safety Controller sends a copy of the
configuration back to the PCI for the final, manual confirmation check
process.
5.1.10.1 Configuration Validation
To confirm a configuration CFG1, follow the steps below:
1)
Save configuration file to the PC.
Click on File > Save.
Name configuration file e.g. CFG1 and select a file location on
your computer.
Click Save.
2)
Using USB cable connect SC22-3 Safety Controller to PC (see
block 4.3.2 on page 24).
3)
Apply 24V dc power to Safety Controller.
4)
Check that Receive, Send and Confirm buttons (
Screen 30
9)
Verify that properties in right-hand column match those in lefthand column. For each device, as you determine that its properties are correct, either click on Confirm or click in corresponding
checkbox. A check mark appears in box and section compresses to a list, as shown in screen 31.
) in
the PCI tool bar go active by changing from gray scale to full colour.
5)
Click on Confirm
button.
☛ The Controller used during the confirmation process may have
an existing (either factory default or user-defined) configuration.
Any configuration already loaded in the Controller is overwritten
(and therefore lost) during this confirmation process. It is the user’s responsibility to save existing configurations, as required.
6)
At Save Configuration pop-up menu, select Yes to save configuration or No to proceed to overwrite Controller’s existing configuration.
7)
At Confirm Configuration pop-up menu (screen 31), enter password (factory default is 0000) and click OK.
8)
At pop-up warning message asking whether to continue, select
Yes.
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INSTRUCTION MANUAL - EUROPEAN VERSION
SC22-3 Safety Controller
Operating Instructions — PCI
5.1.10.2 Editing Configuration
If the columns do not match, or a different circuit is required:
5.1.13 Receiving a Configuration from SC22-3
Safety Controller
1) Select Edit for device to be changed (screen 30 refers).
The Properties menu for the device opens (e.g. screen 15).
To receive a SC22-3 Safety Controller configuration and display it in
the PCI:
2)
Make necessary change(s).
1)
Connect SC22-3 Safety Controller to PC.
3)
On completion click OK to exit.
2)
At PC double-click on Banner Safety Controller program icon.
4)
At message asking whether any other devices are to be edited
or to continue with confirmation process, click required selection.
☛ If any device properties are changed while in the Manual Verifi-
3)
Apply a 24V dc power supply to Controller.
cation stage of the confirmation, the Controller proceeds to revalidate the code.
If the columns match, and no further changes are required:
4)
From tool bar click on Receive button
5)
5) At screen 30 select Confirm for each device.
The verification screen (screen 31) shows the summary that is created after each property has been verified.
If configuration is not already confirmed, Confirm Configuration
as shown in screen 31.
5.1.14 Sending a Configuration to the SC22-3
Safety Controller
To review a confirmed device property:
To send a configuration from the PCI to a SC22-3 Safety Controller:
6)
1)
Using USB cable, connect SC22-3 Safety Controller to PC.
2)
Apply a 24V dc power to the Controller.
3)
At PC double-click on Banner Safety Controller program icon.
4)
From tool bar click on Send button
At screen 31, un-check checkbox and Device properties pop-up
menu re-appears. Perform Edits as necessary.
7) On completion of Manual Verification, click OK to exit.
On completion of verification process, the Confirm Configuration popup menu (screen 31) is again displayed.
8)
Click on Close.
9) Perform a System Reset (see block 5.1.11 on page 49).
The Controller activates the new configuration and functions as per
the new parameters.
5.1.11 System Reset
Under certain conditions the Safety Controller requires a System Reset for the following reasons:
• To recover from certain conditions (e.g. Lockouts)
Both confirmed and unconfirmed configurations can be sent to or received from the XM Card. Proceed as follows:
1)
Using USB cable, connect SC-XMP Programming Tool to PC.
2)
Insert XM Card into SC-XMP Programming Tool (figure 18 on
page 24 refers).
3)
At PC double-click on Banner Safety Controller program icon
To perform a System Reset, either:
.
Provide a 24V dc signal on System Reset input (SR) (screen 28
refers).
or
4)
5.1.12 Editing an Existing Configuration
To edit an existing configuration:
.
At PC double-click on Banner Safety Controller program icon
5.1.16 Sending a Configuration to the XM Card
Both confirmed and unconfirmed configurations can be sent to or received from the XM Card. Proceed as follows:
1)
Using USB cable connect SC-XMP Programming Tool to PC
(figure 18 on page 24 refers).
2)
Insert XM Card into SC-XMP Programming Tool (figure 19 on
page 24).
3)
At PC double-click on Banner Safety Controller program icon
.
2)
From menu click on File then Open
A message appears when the operation is complete.
2) Cycle power.
When the configuration is successfully confirmed, the Controller
switches to Run mode.
1)
.
5.1.15 Opening a Configuration from the XM Card
• To place the Controller into Run mode after it has been configured
1)
.
From menu, click on File, then Open or click
icon to
browse for configuration file to be changed. Make changes as
described in block 5.1 on page 37.
.
4)
From menu, click on File, Open or click
icon to
browse for configuration file.
5) From menu click on File then Send to XM Card.
A message appears when the operation is complete.
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Operating Instructions — PCI
SC22-3 Safety Controller
5.1.17 Locking the XM Card
5.1.19 Exporting Documents
! CAUTION
IT IS IMPORTANT TO NOTE THAT THIS OPERATION CANNOT BE UNDONE. ONCE THE
XM Card IS LOCKED, ANOTHER CONFIGURATION CAN NEVER BE STORED ON IT.
The configuration documents (Wiring Diagram, Ladder Logic Diagram and Configuration Summary) can be saved as either .pdf or .dxf
files (see Screen 33). To export a configuration file:
This operation is useful when the XM Card and its configuration are
used on another Banner Safety Controller or for storing and archiving
a configuration.
To lock the XM Card so that the stored configuration cannot be
changed:
1)
Insert XM Card into SC-XMP Programming Tool (figure 18 on
page 24).
2)
Verify that correct file is stored on XM Card.
3) From menu, click on, Lock XM Card (upper left of tool bar).
A message appears when the operation is complete.
5.1.18 Changing Password Using PCI
1)
Using USB cable, connect PC to Banner Safety Controller
(figure 19 on page 24).
Screen 33
2)
Ensure power supply to Safety Controller is ON (power LED
green
).
3)
At PC double-click on Banner Safety Controller program icon
.
4)
From menu click on File then Change Safety Controller Password. Screen 32 is shown.
1)
At PC double-click on Banner Safety Controller program icon
.
2)
Open configuration file to be saved.
3)
From menu click on File then Export.
4)
Select the configuration document to be exported.
5)
Verify file name is correct and select Save As type file option
(.pdf or .dxf) as required.
6)
Select Done.
5.1.20 Printing Options
To print a configuration file:
1)
At PC double-click on Banner Safety Controller program icon
.
1)
Screen 32
5) Fill in fields as appropriate. Click OK.
The Entering Configuration Mode screen is shown, saying, “Are you
sure you want to do this? All safety Outputs will be turned off.”
Clicking Yes, all safety Outputs turn OFF, together with the machine
or system the Safety Controller is monitoring.
6)
Clicking Yes. Screen 32 re-shown.
7)
Clicking Close. The password is now changed.
8)
Record password for safekeeping.
Open configuration file to be printed.
2)
From menu click on File then Print.
3)
Select configuration document (Wiring Diagram, Ladder Logic
Diagram and Configuration Summary) as required.
4)
When Page Setup menu appears, select page and printer choices then click OK.
☛ Wiring Diagrams, Ladder Logic Diagrams and Configuration
Summaries typically fit the page better when “landscape” is selected. Other documents fit better on “portrait.”
☛ If the password becomes lost, contact Corporate Office as listed
on page 121.
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Operating Instructions — PCI
5.1.21 Accessing Fault Log
5.1.23 Live Display
To access the Controller’s internal Fault Log using the PCI:
To access live Controller information from the PCI:
1)
Using USB cable, connect PC to Banner Safety Controller
(figure 19 on page 24).
1)
Using USB cable, connect PC to Banner Safety Controller
(figure 19 on page 24).
2)
Apply a 24V dc power supply to Controller.
2)
Apply a 24V dc power supply to the Controller.
3)
Click on View menu in the PCI tool bar.
3)
From Tool bar click on Live Display button
4) Select Fault Log.
Screen 34 is shown and displays any I/O or system faults detected
by the Safety Controller.
or open
View and select Live Display.
The Live Display screen is shown.
Screen 34
5.1.22 Scheduled Fault Log Capture
Controller I/O and system fault information can be recorded to a computer file. To set up a recording period to capture fault data from a
Safety Controller, via the Fault Log menu.
1)
Using USB cable, connect PC to Banner Safety Controller
(figure 19 on page 24).
2)
Apply a 24V dc power supply to Safety Controller.
3)
Click on View menu.
4)
Select Fault Log.
5)
Select Edit button. Screen 35 is shown.
Screen 36
Screen 35
6)
Using drop-down fields set Start and End times.
7)
Click on Browse for File location.
8) Click OK.
The fault data is stored as an Excel file to this file location.
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Operating Instructions — PCI
SC22-3 Safety Controller
Intentionally left blank
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SC22-3 Safety Controller
Operating Instructions — OBI
6 OPERATING INSTRUCTIONS - OBI
For an overview of the OBI, refer to block 2.11 on page 16. The
SC22-3 Safety Controller OBI is a tool for creating and managing
configuration files for the Safety Controller, using the built-in features
of the Controller itself. The OBI is also used to retrieve, display and
store both I/O, system status and fault information.
☛ To Enter Run mode a password is NOT required. To Enter Configuration Mode specifically a password IS required.
6.1 RUN MODE
A breakdown of the Run mode is shown in figure 22 on page 53.
The following information details the steps needed to create a sample
configuration, using the Safety Controller’s OBI. The configuration is
used to define the Safety Input devices to be connected to the Safety
Controller and to establish relationships between those Safety Input
devices and the Controller Safety Outputs.
Run Mode
Configuration
Mode
Fault
Diagnostics
ESC ➝
ESC ➝
Clear Fault
Log
OK ➝
View Fault
Log
OK ➝
OK ➝
View Current
Faults
Model Number
Configuration
Summary
(block 6.3)
Terminal
Assignments
software and
hardware versions
Set Display
Contrast
ESC ➝
OK ➝
ESC ➝
System Menu
Input/Output
Mapping
Status Output
Settings
View Response
Times
Enter Password
(block 6.2.1)
Figure 22 SC22-3 Safety Controller OBI Run Mode Options
To enter SC22-3 Safety Controller Run mode:
6.1.1
1)
Connect SC22-3 Safety Controller to safety system as appropriate.
1)
From System Menu (screen 38) select Fault Diagnostics.
Screen 39 is shown.
2)
Connect a 24 V dc power supply to SC22-3 Safety Controller.
2)
At screen 39, use this screen to View
Current Faults, View Fault Log, or
Clear Fault Log. For more information
refer to block 8.3.3.3 on page 78.
Controller boots up to initial screen 37.
Fault Diagnostics Screen
Screen 39
Screen 37
3)
From Run mode, press OK to view
System Menu (screen 38).
This menu provides the ability to read
Fault Diagnostics information, enter ConScreen 38
figuration Mode to create or edit a configuration, read the Configuration Summary, read the Safety Controller
Model Number, and Set Display Contrast itself.
4)
Using up/down arrow buttons, highlight selection required then
press OK to select.
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Operating Instructions — OBI
6.1.2
SC22-3 Safety Controller
Configuration Summary
The Configuration Summary provides viewing only screens to review:
• Input Device Terminal Assignments for each device in the current
configuration
• Input/Output Mapping relationships between Input Devices and
between Input Devices and Safety Outputs
• Current Status Output Settings (to change the settings, see OUTPUTS/SYSTEM SETTINGS on page 61)
• Safety Output Response Times for each input mapped to the output (see block 6.1.2.4 on page 54)
1)
6.1.2.3 Status Output Settings
This option is used for displaying the configured Status Outputs. Proceed as follows:
1)
At screen 49, scroll down menu and
choose Status Output Settings then
press OK. Screen 50 then shows Status Output Settings for first input.
2)
Screen 49
Use left/right arrow buttons to view
Status Output Settings for other Inputs (screen 51 and screen 52). On completion, press either OK
or ESC to exit.
At screen 40, scroll down menu and
choose Configuration Summary then
press OK. Screen 41 is shown.
Screen 40
Screen 50
6.1.2.1 Terminal Assignments
For overview refer to block 4.5.4 on page 27.
Screen 51
Screen 52
6.1.2.4 View Response Times
This option allows viewing of the Response Times for each input
mapped to the output. Response Times can be used to calculate Minimum Safety Distances (see appendix A2.4.2 on page 94 for more information). To view this option:
1)
At screen 41, scroll down menu and
choose Terminal Assignments then
press OK. Screen 42 then shows Terminal Assignments for first input.
2)
Use left/right arrow buttons to view
Screen 41
Terminal Assignments for other Inputs
(screen 43 and screen 44). On completion, press either OK or
ESC to exit.
1)
At screen 53, scroll down menu and
choose View Response Times then
press OK. Screen 42 then shows Terminal Assignments for first input.
2)
Use up/down arrow buttons to view
Response Times for Safety Outputs
(screen 54). On completion, scroll
down to < Done > to exit.
Screen 53
Screen 42
Screen 43
Screen 44
Screen 54
6.1.2.2 Input/Output Mapping
For overview refer to block 4.5.6 on page 27.
1)
At screen 45, scroll down menu and
choose Input/Output Mapping then
press OK. Screen 46 then shows Input/Output Mapping for first input.
2)
Screen 45
Use left/right arrow buttons to view Input/Output Mapping for other Inputs
(screen 47 and screen 48). On completion, press either OK or
ESC to exit.
Screen 46
54
Screen 47
Screen 48
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6.1.3
Operating Instructions — OBI
6.2 ENTERING CONFIGURATION MODE
Model # (Number)
Select this screen to see the Controller model number, and software
and hardware versions. This can be useful when an Applications help
call is needed.
1)
From System Menu (screen 38), select Model #. Screen 55 is
shown.
6.2.1
Entering Controller Password
Before the Configuration Mode can be accessed, a password must
be entered. The default password is 0000.
For instructions on changing the password, refer to block 6.3.3.2 on
page 64.
Details of Model # is shown at screen 55.
2)
Using up/down arrows, highlight selection required then press OK to select.
6.1.4
1)
Screen 55
Set Display Contrast
This screen is used to adjust the brightness of the Controller display
screen background and images for ambient conditions.
1)
From System Menu (screen 38), select Set Display Contrast.
Screen 56 is shown.
2)
At screen 56, select this screen to adjust the brightness of the Controller
display screen background and images for ambient conditions.
3)
At screen 57, Using left/right arrow
buttons, select password digit position.
2) Using up/down arrows, select digit
Screen 57
(value) for each position
(choices 0-9).
3) When password is entered, press OK to enter Configuration
mode. Screen 57 is shown.
4) After reading the Caution shown in
screen 58 press OK.
Screen 59 is then shown.
Screen 58
Screen 56
Using left/right arrow buttons adjust
contrast level (left for lighter, right for more saturated). When
contrast is correct, press OK.
6.1.5
Screen 59
Save Configuration
Initial configuration changes are stored in a temporary memory location. To make the configuration changes permanent (save the configuration in non-volatile memory):
1) Select Save Configuration and press OK.
If it is not required to save changes while at Edit Configuration menu:
2) Press ESC push button and select Yes when prompted.
When configuration is saved or if ESC is pressed, display returns to
the Configuration Mode menu.
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Operating Instructions — OBI
SC22-3 Safety Controller
6.3 CONFIGURATION MODE
3)
At screen 60, use this selection to enter following menus:
• Configuration File (to Edit Configuration)
• Confirm Configuration
Screen 60
• System Options
• Exit Configuration Mode
For more information refer to block 8.3.3 on page 74.
The Configuration Mode is used to create or edit a configuration.
A breakdown of the Configuration Mode itself is shown in figure 23 on
page 56.
To enter Configuration Mode:
1) From Run mode display (screen 37), press OK to display main
System Menu (screen 38).
2) At System Menu, press Down arrow button until Configuration
Mode is highlighted on display (screen 38), then press OK.
Screen 60 is shown.
Edit
Configuration
Name
Configuration
(block 6.3.1.1)
Add Input
Delete Input
Edit Input
Status
Outputs
Save
Configuration
(block 6.1.2)
(block 6.1.5)
Safety
Outputs
System
Settings
Terminal
Assignments
Input/Output
Mapping
Status Output
Settings
OK ➝
ESC ➝
(Add Inputs
page 56)
Configuration
Summary
OK ➝
OK ➝
OK ➝
ESC ➝
(OUTPUTS/SYSTEM
SETTINGS on page 61)
ESC ➝
Outputs/System
Settings
Inputs
(Inputs page 56)
ESC ➝
OK ➝
ESC ➝
(block 6.3.1.1)
View Response
Times
Figure 23 SC22-3 Safety Controller OBI Configuration Mode Options
6.3.1
Configuration File
Inputs
1)
From Configuration Mode (screen 59), select Configuration File.
Screen 61 is shown.
The following functions are in the Configuration File menu:
• Edit Configuration
• Erase Configuration
• Send File to XM
• Receive File from XM
6.3.1.1
1)
Edit Configuration
At screen 61, using up/down arrow
buttons, highlight Edit Configuration
required then press OK to select.
Screen 62 is shown.
3)
At screen 63, use up/down arrow buttons to select Inputs. Press OK.
Screen 64 is shown.
From the Inputs menu, Add Input, Delete
Input or Edit Input may be selected as follows:
ADD INPUT
From this menu a Safety Input or Non-Safety Input can be selected.
Safety Inputs
4)
Screen 61
At screen 64, use up/down arrow buttons to select Add Input. Press OK.
Screen 65 is shown.
Screen 64
NAME CONFIGURATION
2)
56
At screen 62, Enter Configuration
Name. Using up/down arrow buttons, select character to be changed
(up to 16 characters, choices A-Z, 09, -, +, or space). Press OK.
Screen 63 is shown.
Screen 63
5)
At screen 65, use up/down arrow buttons to select a Safety Input. Press
OK. Screen 66 is shown.
Screen 65
Screen 62
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Operating Instructions — OBI
Emergency Stop (ES01) Example Menu Breakdown
< Reset logic.. >
For overview refer to block 4.5.4 on page 27.
6)
7)
At screen 66, use left/right arrow
buttons to select a Safety Input, e.g.
EStop. Press OK. Screen 67 is
shown.
At screen 67, Enter Name; use up/
down arrow buttons to select the
character to be changed (up to 16
characters, choices A-Z, 0-9, -, +, or
space). Press OK. Screen 68 is
shown.
16) At screen 74, use up/down arrow buttons to select Reset logic... Press OK.
Screen 75 is shown.
Screen 66
Screen 74
17) At screen 75, Set Reset Logic using
left/right arrow buttons to select Manual from Manual or Auto. Press OK.
Screen 76 is shown.
Screen 67
< Select Circuit Type... >
For overview refer to block 4.5.3 on page 26.
<Advanced Settings...>
8)
18) At screen 76, use up/down arrow buttons to select Advanced Settings....
Press OK. Screen 77 is shown.
At screen 68, use up/down arrow buttons to select Select Circuit Type....
Press OK. Screen 69 is shown.
Screen 76
Screen 68
9)
19) At screen 77, if necessary, choose
from Advanced Settings... using up/
down arrow buttons to make selections for Simultaneity or Debounce
Screen 77
Time (see block 4.5.7 on page 27 for
information on these settings). Press ESC to go back to ES01
Screen 78.
At screen 69, use left/right arrow buttons to select, e.g. Dual channel, 4 terminal. Press OK. Screen 70 is shown.
Screen 69
< Edit Terminals >
10) At screen 70, use up/down arrow buttons to select, Edit Terminals. Press
OK. Screen 71 is shown.
< Saving Settings >
Screen 70
11) At screen 71, to Edit Terminals, use
left/right arrow button to select terminal assignment to be changed. Use
up/down arrow buttons to change terminal assignments. Press OK.
Screen 72 is shown.
Screen 75
This function used for saving the configured parameters. Proceed as
follows:
20) At screen 78, use up/down arrow buttons to scroll down to < Done >. Press
OK. Screen 79 is shown.
Screen 71
Screen 78
< Map Outputs >
21) At screen 79, press OK to return to Inputs screen (Screen 64).
12) At screen 72, use up/down arrow buttons to select Map Outputs. Press OK.
Screen 73 is shown.
Screen 79
Screen 72
13) At screen 73, to Map Outputs, Use
up/down arrow buttons to highlight an
output.
14) Remove or add input mapping by selecting output and pressing OK.
Screen 73
☛ A filled-in circle next to an output indicates the input is mapped
to that output. An open circle indicates the input is not mapped
to that output.
15) Map E-Stop to all three safety Outputs, and using up/down arrow buttons select Save and press OK. Screen 74 is shown.
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Operating Instructions — OBI
SC22-3 Safety Controller
Non-Safety Inputs
Table 12 Breakdown of Additional Safety Input Devices
Function
22) At screen 80, use up/down arrow
buttons to select Non-Safety Input.
Press OK. Screen 81 is shown.
Screen
External Device Monitoring – EDM02
Screen 80
23) At screen 81, use left/right arrow
buttons to select a Non-Safety Input
e.g. ON/OFF Switch. Press OK.
Screen 82 is shown.
24) At screen 82, Enter Name; use up/
down arrow buttons to select the
character to be changed (up to 16
characters, choices A-Z, 0-9, -, +,
or space). Press OK. Screen 68 is
shown.
Circuit Type:
Single channel, 1 terminal
Screen 86
Screen 81
Terminals: S18
Screen 87
Screen 82
☛ The Screens for step 8) thru to step 21) are almost identical.
Mapped to: SO2
25) Repeat step 8) thru to step 21).
Screen 88
ADDING ADDITIONAL SAFETY INPUT DEVICES
The steps required to add other Safety Input devices are similar to
those just completed.
1)
Create following Safety Input devices, with properties as shown
in table 12 on page 58:
Gate Switch, GS01
Two Hand Control, THC01
Reset Input, RS01
Optical Sensor, OS01
External Device Monitors; EDM01, EDM02, and EDM03
Mute Sensor Pair, M1+M2
Table 12 Breakdown of Additional Safety Input Devices
Function
External Device Monitoring – EDM03
Circuit Type:
Single channel, 1 terminal
Screen 89
Terminals: S19
Screen
Screen 90
External Device Monitoring – EDM01
Mapped to: SO3
Circuit Type:
Single channel, 1 terminal
Screen 91
Screen 83
Gate Switch – GS01
Terminals: S17
Screen 84
Circuit Type:
Single channel, 2 terminal
Screen 92
Mapped to: SO1
Screen 85
58
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Operating Instructions — OBI
Table 12 Breakdown of Additional Safety Input Devices
Function
Table 12 Breakdown of Additional Safety Input Devices
Screen
Terminals: S5 & S6
Function
Screen
Mapped to: SO1 & SO2
Screen 93
Mapped to: SO1, SO2
Screen 101
Auto Reset Logic:
Screen 94
Screen 102
Mute Sensor – M1 + M2
Auto Reset Logic:
The next input is different than the previous Inputs added and is
therefore covered in more detail.
Screen 95
1)
After selecting add a Mute Sensor and entering its name, set
Circuit Type and the terminal assignments as follows:
Two-Hand Control – THC01
Circuit Type:
Dual channel, 4 terminal
Circuit Type:
2X Complementary, PNP switch
Screen 103
Screen 96
Edit Terminals:
13, 14, 15 & 16
Terminals:
S7, S8, S9 & S10
Screen 104
Screen 97
Mapped to: SO3
Screen 98
Instead of mapping to an output, Mute Sensor Inputs are
mapped to the Inputs they mute. Only certain types of Input Devices can be muted. The Safety Controller creates a list of the Inputs in the current configuration that can be muted.
2)
From Mute Sensor Properties menu select Map Inputs and
press OK. Screen 105 is shown.
3)
At screen 105, using up/down arrow buttons, select OS01 from list
of Inputs and press OK. The circle
to the left of OS01 fills in to indicate
that mute senor pair M1+M2 is
mapped to OS01.
Optical Sensor – OS01
Circuit Type:
Dual Channel, PNP
Screen 105
☛ In this case, the Mute Sensor pair is being mapped to only
OS01, but the Mute Sensor pair can be mapped to more than
one input.
Screen 99
4)
Select Save and press OK to complete input mapping process.
Edit Terminals: S11 & S12
Screen 100
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Operating Instructions — OBI
SC22-3 Safety Controller
ADDING ADDITIONAL NON-SAFETY INPUT DEVICES
The steps required to add other Non-Safety Input devices are similar
to those just completed.
Table 12 Breakdown of Additional Safety Input Devices
Function
Screen
Set Mute Limit Timers
The Set Mute Limit Timers defines the
maximum amount of time an input can
be muted.
1)
At screen 106, M1+M2 Properties menu, select Set Mute Limit
Timers and press OK.
screen 107 is shown.
1)
Create following Input Devices, with properties as shown in
table 12 on page 58:
• Reset Input, RS01
• Mute Enable
Table 13 Additional Safety Input Device Breakdown
Screen 106
Function
Screen
Reset – RS01
2)
At screen 107, Select Input, and
press OK. Screen 108 is shown.
Circuit Type:
Single channel, 2 terminal
Screen 107
☛ If the box in front of Enable Time
Screen 110
Limit is not checked, highlight it
and then check it by pressing OK
to enable the time limit.
3)
At screen 108, using up/down arrow buttons, select Change
Time... and press OK.
Screen 109 is shown.
Terminals: S21 and S22
Screen 111
Screen 108
4)
5)
At screen 109, change value to 1
minute. Use the left/right arrow
buttons to select the digit to be
changed and the up/down arrow
buttons to change the digit (0-9)
and press OK.
Mapped to:
SO1, SO2, and SO3
Screen 112
Screen 109
Mute Enable – ME01
At screen 108, select <Done>
and press OK.
When all necessary Safety Inputs have been added in turn, press
ESC to exit to screen 63.
Circuit Type:
Single channel, 1 terminal
Screen 113
Terminals: S20
Screen 114
Mapped to:
SO1, SO2, and SO3
Screen 115
When all necessary Non-Safety Inputs have been added in turn,
press ESC to exit to screen 63.
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Operating Instructions — OBI
Outputs/System Settings
STATUS OUTPUTS
This option is used to configure individually the Status Outputs.
SAFETY OUTPUTS
This option is used to edit the Safety Outputs if necessary.
1)
At screen 63, select Outputs/System Settings. Screen 117 is
shown.
2)
At screen 116, using up/down arrow
buttons, select Safety Outputs and
press OK. Screen 117 is shown.
At screen 116, select Status Outputs. Screen 119 is shown.
2)
At screen 119, using left/right arrow
buttons, select each Status Output in
turn to edit (O1 to O10), and press
OK. Screen 120 is shown.
Screen 119
The Status Output properties menu appears and is used to edit the following indications:
Screen 116
3)
1)
At screen 117, select Safety Output to
edit and press OK. Screen 118 is
shown.
Change Name...
Screen 120
Select Function...
Screen 117
Select Source...
Signal Convention...
4)
For further breakdown of these indications refer to figure 24 on
page 61.
At screen 118, edit Change Name...,
Delay Type and Delay Time as necessary. On completion select < Done >.
.
Screen 118
OK ➝
ESC ➝
Status
Outputs
01-010
Unassigned
Track Input
OK ➝
Enter Name
Select
Function...
ESC ➝
Change
Name...
Track Output
Select
Source...
Signal
Convention...
Choice
24V = Input
Active
(Input Dependant)
Track Fault
Status
Waiting fo
Reset
24V = Input
Inactive
Mute Status
Figure 24 Editing OBI Status Outputs - Options
Change Name...
3) At screen 120, scroll down menu to select Change Name... and
press OK. Screen 121 is shown.
4)
At screen 121, using left/right arrow
buttons, move to each character in
turn (up to 10 characters).
5)
At screen 121, using up/down arrow
buttons, change character(s) as necScreen 121
essary (choices A-Z, 0-9, -, +, or
space). Press OK when done.
When the display returns to the Status Output properties menu, the
top line of the display displays the new name.
INSTRUCTION MANUAL - EUROPEAN VERSION
Select Function...
6) At screen 120, scroll down menu to Select Function...
7) Use left/right arrow buttons to select a function, then press OK.
The display returns to the Status Output Properties menu.
Select Source...
8) At screen 120, scroll down menu to choose Select Source... and
press OK.
9) Use the left/right arrow buttons to select device and press OK.
The display returns to the Status Output Properties menu.
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Operating Instructions — OBI
SC22-3 Safety Controller
Signal Convention...
10) At screen 120, scroll down menu to choose Signal Convention...
and press OK.
11) Use left/right arrow buttons to toggle between options and press
OK.
Options are: 24V = Input Active and 24V = Input Inactive (e.g. if
Track Input is selected; see block 4.9.1 on page 34 for more information).
6.3.1.2 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.
1)
Insert the XM Card into Controller’s
XM port as shown.
12) Select <Done> and press OK to save the settings for this output.
The display returns to the Outputs/System Settings menu.
13) Repeat step 1) thru to step 12) to configure additional Status
Outputs in the same way.
14) When last Status Output is configured, press ESC to return to
the Edit Configuration menu.
SYSTEM SETTINGS
This menu is used to set System Reset, Power-up Option and Mute
on Power-up.
System Reset
1)
At screen 122, scroll down menu to
choose System Reset and press OK.
1)
Mute on Power-up
4) At screen 122, scroll down menu to choose Mute on Power-up
and press OK.
Use left/right arrows to toggle between OFF or ON, and press
OK.
Configuration Summary
For detailed instructions refer to block 6.1.2 on page 54.
Save Configuration
While making the configuration changes they are stored in a temporary memory location.
2)
At Controller screen 125, select Receive File from XM and follow prompts
as appropriate.
The Controller prompts to overwrite the
Screen 125
current configuration in the Controller YES/
NO (if not, send the existing configuration to an empty XM Card first).
Answer Yes, then, if one is not already in the port, insert an XM Card
and press OK. If the new configuration is unconfirmed, the Controller
provides the option to confirm it at this time.
6.3.1.4 Erase Configuration
This selection is used to remove the current configuration from the
Safety Controller, so a new configuration can be created (the Controller can hold only one configuration at a time).
☛ To keep the current file, send it to the XM Card (as detailed in
block 6.3.1.2 on page 62) before erasing it from the Controller.
To perform an Erase:
To make the configuration changes permanent:
1)
1)
Insert the XM Card into Controller’s
XM port.
Use left/right arrow buttons to toggle between Monitored or NonMonitored, and press OK.
Power-up Option
3) At screen 122, scroll down menu to choose Power-up Option
and press OK.
Use the left/right arrows to select Normal, Auto, or Manual, and press
OK.
5)
At Controller screen 124, select
Send File to XM and follow prompts
as appropriate.
If XM Card is not empty, the Controller
Screen 124
prompts to overwrite the current configuration on the XM Card YES/NO (if not, send the existing configuration to an empty XM Card first). Answer Yes, then, if one is not
already in the port, insert an XM Card and press OK.
6.3.1.3 Receive File from XM
This selection is used to receive a configuration from the XM card.
Screen 122
2)
2)
At screen 123, select Save Configuration and press OK.
At screen 126, using up/down arrow buttons, highlight Erase Configuration then press OK to select.
Screen 127 is shown.
Screen 126
Screen 123
☛ If it is not required to save the changes while at the Edit Configuration menu, press ESC and select Yes when prompted to exit
without saving changes yes/no.
2)
At screen 127, using up/down arrow
buttons, set default requirements
Yes/No. To exit Press OK.
Screen 127
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6.3.2
Operating Instructions — OBI
Confirm Configuration
6.3.2.2
Confirm Configuration of Outputs
Before configuration can be used in a Safeguarding application, it
must be confirmed. To Confirm Configuration:
1)
From Screen 129 select Confirm Configuration menu, and press
OK. Screen 137 is shown.
1)
2)
At screen 137, select Safety Outputs,
then press OK. Screen 138 is shown.
Select Confirm Configuration and
press OK. Screen 129 is shown.
Screen 137
Screen 128
The safety-critical configurations for the Inputs, Safety Outputs and system settings
must now be reviewed. An unchecked box
in the Confirm Configuration menu indicates the safety-critical settings have not
yet been confirmed. Screen 129 refers.
3)
Confirm Safety Output SO1’s configuration by selecting SO1 and then
press OK.
The next series of menus lists the safetycritical configurations for SO1.
Screen 129
4)
6.3.2.1 Confirm Configuration of Inputs
From Screen 129 Confirm Configuration menu, select Inputs and
press OK. Screen 130 is shown.
1)
Screen 138
Review safety-critical configurations for S01 of this Safety Output at following screens, screen 139, screen 140 and
screen 141 then press OK.
At screen 130, Confirm by selecting
e.g. E-Stop ES01, then press OK.
Screen 131 is shown.
Screen 139
Screen 140
Screen 130
The next series of menus lists the safety-critical configurations for
this input.
2)
Review safety-critical configurations for each setting of this input
at following screens, screen 131, screen 132, screen 133,
screen 134 and screen 135 and then press OK:
Screen 141
5)
Repeat confirmation process for SO2 and SO3.
When all Safety Outputs have been confirmed, Screen 136 is shown.
6)
Screen 131
Screen 132
6.3.2.3
1)
Screen 133
Screen 142
Confirm Configuration of System Settings
From Screen 129 select Confirm Configuration menu, and press
OK. Screen 143 is shown.
2)
At screen 143, select System Settings,
then press OK. Screen 138 is shown.
The next series of menus lists the safetycritical System Settings.
Screen 134
.
3)
Screen 135
3)
To continue Confirm Configuration,
select <Done> and press OK.
Screen 143
Review safety-critical configurations
for System Settings at following screens, screen 144,
screen 145 and screen 146 then press OK.
Repeat confirmation process for each of the Inputs.
When all Inputs have been confirmed,
Screen 136 is shown.
4)
To continue Confirm Configuration,
select <Done> and press OK.
Screen 144
Screen 145
Screen 136
Screen 146
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Operating Instructions — OBI
SC22-3 Safety Controller
6.3.2.4 Final Confirmation Step
When all of the safety-critical configurations settings have been confirmed then and only then can the configuration be used in a Safeguarding application.
☛ If any changes are made to the configuration, the confirmation
process must be repeated.
1)
At screen 147 exit Confirm Configuration menu by selecting < Done > and
pressing OK.
6.3.4
Exit Configuration Mode
This function is used to return to Run mode.
1)
At screen 152, select Exit Configuration Mode.
Controller prompts whether to Confirm
Configuration Yes/No before exiting and
then returns to System Menu.
Screen 152
Screen 147
6.3.3
System Options
This function is used to Edit Password and Set Language.
1)
At screen 148, select System Options. Screen 149 is shown.
Screen 148
6.3.3.1 Edit Password
This function allows the password to be edited to something other
than the default. The password may be unique to each Controller.
The procedure is similar to that used to enter the default password
initially.
1)
At screen 149, select Edit Password.
Screen 150 is shown.
Screen 149
2)
3)
At screen 150, using left/right arrow
buttons, select password digit position. Using up/down arrows select digit (value) for each position (choices 09).
Screen 150
When password is entered, press OK and record the new password in a file for safekeeping and later reference.
6.3.3.2 Set Language
This screen is used to determine what language appears on the display. Choices are:
English
German
Spanish
French
Italian
Portuguese
Japanese
Highlight the correct language to select it, then press OK.
1)
At screen 151, select Edit Password.
2)
Select language as appropriate and
when finished press OK.
☛ Language can also be changed imme-
Screen 151
diately following power-up. A screen
appears automatically, and the language selection can be
changed at that time. If nothing is changed, the screen times out
after 5 seconds and continues to Run mode in the language that
was selected before the Controller was last powered down.
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Operating Instructions — General
7 OPERATING INSTRUCTIONS — GENERAL
7.1 DISPLAYING CONTROLLER INFORMATION — PCI
or alternatively
From the Start Menu, click on:
<Start> <All Programs> <Banner Engineering> <Banner Safety
Controller>
To display real-time Run mode information on the PC:
1)
Referring to block 4.3.2 on page 24, connect Controller to PC,
via USB cable.
2)
From the PC Desktop, Double-click on Banner Safety Controller
icon
3)
Read and understand warning on Start-up page of program and click OK. Screen 153 is shown.
!
.
Screen 153
4)
At screen 153 on page 65, click on icon Live Display button
Screen 154 on page 65 is shown.
The Live Display (screen 154 on page 65) continually updates Run
mode data and displays it as shown. It provides the same information
that can be viewed on the Controller’s LCD. It shows the status of
each safety output and reports on any Input Device or system event
that can cause a safety output to turn OFF.
Screen 154
For further PCI information, refer to chapter 5.
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Operating Instructions — General
SC22-3 Safety Controller
7.2 DISPLAYING CONTROLLER INFORMATION — OBI
7.2.1
Safety Output
Status Message
Run Mode
For a breakdown of the Run mode refer to figure 22 on page 53.
The Controller OBI Run mode example (screen 155 on page 66) displays current information about the Safety Controller, including:
• Configuration Name
• Safety Output status
• input status
• System status
• XM Card OBI status
Configuration Name
Safety Output Status
input Status Cause of
output SO1 Status, or
Required Action
Screen 155
7.2.1.1 Configuration Name
The top line of the display reads either the name of the configuration
stored in the Safety Controller, if it has been Confirmed, or, Configuration not Confirmed if it has not.
7.2.1.2 Safety Output Status
Lines 2, 3, and 4 of screen 155 on page 66 give status of x3 Safety
Outputs. Selected Safety Output is indicated by a small arrowhead as
shown (the arrowhead scrolls through the Safety Outputs that are
OFF, at 2-second intervals). Line 5 of display gives reason for status
of selected Safety Output. Table 14 on page 66 gives a breakdown
of the Safety Output status messages.
☛ Output faults are recoverable via a System Reset (see block 7.4
on page 68).
Line 5 of screen displays Mute Lamp Fault when a Mute Lamp Fault
exists.
Table 14 Safety Output Status Message Breakdown
Safety Output is ON.
ON-Delay
Safety Output turns ON when ON-delay time expires.
Safety Output is OFF. Line 5 of display indicates reason
Safety Output is OFF.
The Safety Output turns OFF when OFF-delay expires.
OFF-Delay
7.2.1.3 Input Status
If a Safety Output is OFF or turning OFF, line 5 of display indicates
information about input that is keeping output OFF.
one input must be displayed.
Press Up arrow button to pause screen on current input.
Press Down arrow button to change last line to next input (Press
Down arrow button repeatedly to quickly cycle through Inputs).
If more than one output is OFF, a small arrowhead indicates
Safety Output to which input messages correspond (see
screen 155 on page 66).
No input information is displayed when a Safety Output is ON, unless
a mapped input is muted, bypassed, or in a fault condition.
Table 15 on page 66 gives a breakdown of the Input Device status
messages.
Table 15 Input Device Status Message Breakdown
Input Device
Status Message
Stop
Test
Line 5 of display indicates reason Safety Output is in an
OFF-delay.
Reset Needed
A Manual Reset operation needs to be performed. Line 5 of
display indicates name of Manual Reset input to press.
Fault
A problem has been detected with Safety Output. See troubleshooting table (block 8.3.3 on page 74) to find additional
information regarding fault. If fault is due to an EDM fault,
line 5 of display indicates name of EDM.
Cause and/or Required Action
Safety Input is in a state that causes Safety Output to turn
OFF.
A start-up test needs to be completed on Safety Input. To
perform test, cycle input (Run-Stop-Run) to turn Safety Output ON.
Deactive
A two-hand control input or an enabling device needs to be
cycled (Run-Stop-Run) before Safety Output turns ON.
Fault
A problem has been detected with an input that controls
output.
Timed Out
Safety Output is in Enable Mode and enabling device active
time limit has expired. Cycle enabling device to turn output
back ON, or turn enabling device OFF and perform a System Reset to exit Enable Mode.
Cause and/or Required Action
ON
OFF
Line 5 of display indicates Enable Mode if a Safety Output
is in Enable Mode.
☛ Line 5 changes to indicate each input when status of more than
Arrowhead designates
Safety Output
Status Message
Enable Mode
Cause and/or Required Action
Line 5 also indicates when a Manual Reset operation needs to be
performed.
selected Safety Output
66
Table 14 Safety Output Status Message Breakdown
7.2.1.4 System Status
Line 5 of screen 156 on page 66 displays
System Reset Needed whenever a System Reset is needed to turn Safety Outputs
ON. However, when a fault condition exists, fault must be corrected before System
Reset operation turns Safety Outputs ON.
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INSTRUCTION MANUAL - EUROPEAN VERSION
SC22-3 Safety Controller
Operating Instructions — General
7.2.1.5 XM Card OBI Status
The status of XM Card is temporarily displayed (screen 157,
screen 158 and screen 159) when it is inserted while Run mode
screen is active. Correct XM Card should be removed or replaced as
necessary.
Screen 157
Screen 158
Screen 159
Table 16 on page 67 gives a breakdown of the XM Card Status Messages.
Table 16 XM Card Status Message Breakdown
XM Card
Message
Cause
XM matches the active
configuration
Configuration stored on XM Card is same as Safety
Controller’s configuration.
XM does not match the
active configuration
Configuration stored on XM Card is different from
Safety Controller’s configuration.
XM has no configuration
The XM Card does not have a configuration stored
in it.
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Operating Instructions — General
SC22-3 Safety Controller
7.3 MANUAL RESET
7.5 RESET SIGNAL REQUIREMENTS
A Manual Reset operation is valid when all Safety Inputs mapped to
the Safety Output are in the Run state when the Manual Reset is performed. See block 1.10 on page 5 for Reset timing requirements.
Both Manual Reset (Latch) and System Reset signals can be configured for Monitored or Non-Monitored operation, as follows:
When a single Manual Reset device is mapped to two or more Safety
Outputs, one of which has an OFF-delay, then the Manual Reset is
not be able to turn ON either Safety Output until the OFF-delay time
has expired.
If a Safety Input device configured for Manual Reset changes from
the Run state to Stop and back to Run, then any Safety Outputs to
which that device is mapped turn OFF and remain OFF until a valid
Manual Reset is performed.
7.4 SYSTEM RESET & LOCKOUT CONDITIONS
7.5.1
Monitored Reset
Requires the Reset signal to transition from low (0V dc) to high (24V
dc) and then back to low. The high state duration must be 0,3 to 2 s.
This is said to be a trailing edge trip event.
7.5.2
Non-Monitored Reset
Requires only that the Reset signal transitions from low (0V dc) to
high (24V dc) and stays high for at least 0,3 seconds. After the Reset,
the Reset signal can be either high or low. This is said to be a leadingedge trip event.
! WARNING
NON-MONITORED RESETS
IF A NON-MONITORED RESET (EITHER LATCH OR SYSTEM RESET) IS CONFIGURED
AND IF ALL OTHER CONDITIONS FOR A RESET ARE IN PLACE, A SHORT FROM THE
RESET TERMINAL TO +24 V WILL TURN ON THE SAFETY OUTPUT(S) IMMEDIATELY.
CHECKING BEFORE RESET
WHEN PERFORMING THE SYSTEM RESET OPERATION, IT IS THE USER’S RESPONSIBILITY TO MAKE SURE THAT ALL POTENTIAL HAZARDS ARE CLEAR AND FREE OF
PEOPLE AND UNWANTED MATERIALS (SUCH AS TOOLS) THAT COULD BE EXPOSED
TO THE HAZARD. FAILURE TO DO SO COULD RESULT IN SERIOUS BODILY INJURY OR
DEATH.
SYSTEM SWITCH LOCATION
THE MANUAL SYSTEM RESET PUSH BUTTON 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). IF ANY AREAS ARE NOT VISIBLE
FROM THE RESET SWITCH(ES), ADDITIONAL MEANS OF SAFEGUARDING MUST BE
PROVIDED. FAILURE TO DO SO COULD RESULT IN SERIOUS BODILY INJURY OR
DEATH.
A System Reset is necessary under the following conditions:
• Recovering from a Lockout condition
• Starting the Controller after a new configuration has been downloaded
• Recovering from an output fault
• Entering Run mode after power-up, when configured for manual
power-up
• Exiting Enable Mode
A System Reset is used to clear Lockout conditions not related to
Safety Inputs. A Lockout condition is a response where the Controller
turns OFF all affected Safety Outputs when a safety-critical fault is
detected. Recovery from this condition requires all faults to be remedied and a System Reset performed. A Lockout will re-occur after a
System Reset unless the fault that caused the Lockout has been corrected.
The Reset device (a button or switch) connects to a dedicated input
terminal on the Safety Controller, labelled SR. The Reset signal type
can be configured to be either Monitored or Non-Monitored (the default setting is Monitored). See block 7.5 on page 68 for Reset timing
requirements.
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Maintenance
8 MAINTENANCE
8.1 PREVENTIVE MAINTENANCE
8.2.4
A Designated Person as specified in block 1.8.1 must also check the
effectiveness of the protective devices as per the device manufacturers’ recommendation each day that the safeguarded machine is in
service.
8.2 SYSTEM CHECKOUT
! WARNING
8.2.5
PERIODIC CHECKOUTS
THE COMMISSIONING, PERIODIC AND DAILY SAFETY SYSTEM CHECKS MUST BE PERFORMED BY APPROPRIATE PERSONNEL AT THE APPROPRIATE TIMES (AS DESCRIBED IN block 8.2.1 on page 69) IN ORDER TO ENSURE THAT THE SAFETY
SYSTEM IS OPERATING AS INTENDED. FAILURE TO PERFORM THESE CHECKS MAY
CREATE A POTENTIALLY DANGEROUS SITUATION WHICH COULD LEAD TO SERIOUS
INJURY OR DEATH.
DO NOT USE MACHINE UNTIL SYSTEM IS WORKING PROPERLY
IF ALL OF THESE CHECKS CANNOT BE VERIFIED, DO NOT ATTEMPT TO USE THE
SAFETY SYSTEM THAT INCLUDES THE SC22-3 SAFETY CONTROLLER AND THE
GUARDED MACHINE UNTIL THE DEFECT OR PROBLEM HAS BEEN CORRECTED (SEE
chapter 8). ATTEMPTS TO USE THE GUARDED MACHINE UNDER SUCH CONDITIONS
COULD RESULT IN SERIOUS BODILY INJURY OR DEATH.
BEFORE APPLYING POWER TO THE MACHINE
VERIFY THAT THE GUARDED AREA IS CLEAR OF PERSONNEL AND UNWANTED MATERIALS (SUCH AS TOOLS) BEFORE APPLYING POWER TO THE GUARDED MACHINE.
FAILURE TO DO SO COULD RESULT IN SERIOUS BODILY INJURY OR DEATH.
8.2.1
Daily Operational Checks
Commissioning Checkout Procedure
For the initial part of the commissioning checkout, the Controller and associated safety systems must be checked without
power being available to the guarded machine. Final interface
connections to the guarded machine cannot take place until
these systems have been checked out.
8.2.5.1 Commissioning Pre-Checks
Verify pre-checks as follows:
1) ❏ Verify power has been removed from machine, and no power
is available to machine controls or actuators.
2) ❏ Referring to figure 25 on page 69, verify that 7-pin connector is
unplugged from SC22-3 Safety Controller to ensure that Safety
Outputs SO1 (A and B), SO2 (A and B) and SO3 (A and B) are
not connected to machine.
Schedule of Check-outs
Verifying the configuration and proper functioning of the Safety Controller includes the verification of each Safety Input 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. Other Inputs mapped to the same Safety Outputs as the
one that is being tested, must be in their ON-state during the test.
A comprehensive test must be used to verify the operation of the
Safety Controller and the functionality of the intended configuration.
The checklist in block 8.2.2 on page 69 is generic and is intended to
assist in developing a customized (configuration-specific) checklist
for each application. This customized checklist must be made available to maintenance personnel for commissioning and periodic
check-outs. A similar, simplified daily checkout checklist should be
made for the operator (or Designated Person as specified in block
1.8.1). It is highly recommended to have copies of the Wiring Diagrams and Ladder Logic Diagrams and the Configuration Summary
available to assist in the checkout procedures.
8.2.2
Commissioning Checkout
A Qualified Person as specified in block 1.8.2 on Page 4 must perform a safety system commissioning procedure before the safeguarded machine application is placed into service and after each
Safety Controller configuration is created or modified.
8.2.3
Periodic (6 Monthly) Checkout
A Qualified Person as specified in block 1.8.2 on Page 4 must also
perform a safety system re-commissioning 6 monthly or at periodic
intervals based on the appropriate local or national regulations.
INSTRUCTION MANUAL - EUROPEAN VERSION
SC22-3
Safety Controller
Power
Status
Tx/Rx
SO1
SO2
SO3
Figure 25 Safety Output Terminal Block
☛ Permanent connections will be made at a later point in this
checkout.
8.2.5.2 Verifying System Operation
The commissioning checkout procedure must be performed by a
Qualified Person as specified in block 1.8.2 on Page 4 (see also
warning on page 69). 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 Appendix A and the appropriate standards).
The commissioning checkout procedure is performed on two occasions:
• When the Controller is first installed to ensure proper installation
• Whenever any maintenance or modification is performed on the
System or on the machinery being guarded by the System, to
ensure continued proper Controller function (see block 8.2.1 on
page 69 for a schedule of required check-outs)
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Maintenance
8.2.5.3
SC22-3 Safety Controller
☛ In all cases, Outputs associated with a Two-Hand Control device
Procedure
1) ❏ Verify that Safety Output leads are isolated (i.e. not shorted together and not shorted to power or ground).
2) ❏ Verify that, if used, EDM connections have been connected to
a +24V dc via the N.C. monitoring contacts of device(s) connected to Safety Outputs as described in block 4.8 on page 32
and figure 28 on page 83, figure 29 on page 84, figure 30 on
page 84 and figure 31 on page 85.
3) ❏ Verify that proper Controller configuration file for required application has been uploaded to SC22-3 Safety Controller.
4) ❏ Verify that SC22-3 Safety Controller has been connected to
Safety Systems only (do not connect to guarded machine at
this stage) in accordance with instructions detailed in this manual and that it complies with safety standards and local wiring
codes.
This procedure allows the Controller and the associated Safety Systems to be checked out before permanent connections are made to
the guarded machine.
8.2.6
7) ❏ Ensure that all other Input Devices are in the active (Run) state.
8.2.6.2
Power-up & Reset Functions
1) ❏ Ensure that no individual is exposed to the hazardous motion/
situation of the guarded machine during the checkout procedure.
2) ❏ Observe the SO status indicators or the messages on the front
panel display to verify whether a safety output is ON or OFF.
3) ❏ Apply power to Safety Controller and all Input Devices that require power, but NOT to guarded machine.
4) ❏ Verify that configuration file (e.g. revision level) is appropriate
for application. At a minimum, have a copy of Configuration
Summary from PC Interface software available for reference
during the checkout procedure.
5) ❏ Verify that status Outputs configured for a monitored mute lamp
(if used) turn ON briefly (i.e. flash) after power-up.
Initial Setup & Commissioning/Periodic
Check-outs
☛ If any of the status Outputs are mapped to functions within the
configuration, monitor the function of each status output as the
associated operation is tested.
1) ❏ Configure machine so that indicators for safety Outputs (SO1,
SO2, and SO3) of Safety Controller and for the associated Output Devices can be observed and verified to operate correctly
and without risk of injury.
Do not apply power to the Safety Controller or to the guarded
machine at this stage.
8.2.6.1
should not turn ON at power-up. Also, Bypass Switches or Enabling Devices in the active (Run) state at power-up will not function until they are seen as OFF first.
Safety System & Safeguarding Device Checkout
1) ❏ Verify that guarded machine is of a type and design compatible
with this Safeguarding system, as described on chapter 2.
2) ❏ Verify installation and perform checkout procedures for the external safety/Safeguarding systems and devices connected to
the SC22-3 Safety Controller Inputs as described by appropriate manuals. Do not proceed until all checkout procedures
are completed successfully and all problems have been
corrected.
SET POWER-UP OPTION CONFIGURATION
☛ Before carrying out step 1, step 2 and step 3 refer to the System
Settings in the Configuration Summary.
1) ❏ If configured for Normal (default), verify that Safety Outputs
associated only with Input Devices configured for Automatic
Reset turn ON.*
2) ❏ If configured for Automatic, verify that all Safety Outputs turn
ON* within 5 seconds (Outputs with a configured ON-delay
may extend this time).
3) ❏ If configured for Manual:
• Verify that all Safety Outputs remain OFF
• Wait at least 10 s after power-up, then perform a System
Reset (for further information on Resets see block 7.3 on
page 68 & block 1.10 on page 5)
• Verify that Safety Outputs turn ON* even if an associated
Non-Safety Input is configured for a Manual Reset
*In all cases, Safety Outputs associated with a Two-Hand Control will
not turn ON at power-up. Enabling Devices and Bypass Switches are
not available at power-up. They must begin in a Stop state (OFF).
3) ❏ Verify that access to any dangerous parts of guarded machine is not
possible from any direction not protected by Safeguarding system,
fixed guarding, or supplementary Safeguarding and that supplementary Safeguarding and fixed guarding as described by appropriate
safety standards are in place and functioning properly.
4) ❏ Verify that all Reset switches are mounted outside and in full
view of guarded area, out of reach of anyone inside guarded
area and that means of preventing inadvertent use is in place.
5) ❏ Examine electrical wiring connections between SC22-3 Safety
Controller’s OSSD Outputs and guarded machine’s control elements to verify that wiring meets requirements stated in
block 4.8 on page 32.
6) ❏ Verify that all Two-Hand Control devices, Enabling Devices,
Mute Sensors and Bypass Switches are in inactive (Stop)
state.
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Maintenance
RESET CONFIGURATION
8.2.6.4
1) ❏ If configured for Automatic Reset, verify that corresponding
1) ❏ While Outputs are ON, individually actuate and re-arm each
E-Stop and/or Rope Pull device one at a time.
• Verify that each associated Safety Output turns OFF with
proper OFF-delay, where applicable
SO1
or
Controller Safety Output indicator shows green SO2
or
indi-
SO3
cating that Safety Output(s) is ON (assuming that other Inputs
configured for Manual Reset are not associated with the Safety
Output; see Manual Reset).
If Controller red status indicator begins to flash
at any
time, refer to block 8.3.3 on page 74 for troubleshooting information.
2) ❏ If configured for Manual Reset,
• Verify that Controller green status LED is flashing
to
indicate that a Reset is being requested, and that message
System Reset Needed appears on the Diagnostic Display. If
Controller red status indicator begins to flash
at any
time, refer to block 8.3.3 on page 74 for troubleshooting information
☛ If a “monitored manual reset” has been configured, perform a reset by closing the Reset input for at least 0,25 s, but not longer
than 2 s, and then reopening the contact. Verify that Controller
green status indicator comes ON steady
.
3) ❏ Verify that all Reset switches are mounted in full view of guarded area but outside it and out of reach of anyone inside guarded area and that means of preventing inadvertent use is in
place.
4) ❏ Actuate each (Non-Safety Input) Manual Reset device to turn
ON remaining Outputs not associated with a Two-Hand Control
device.
5) ❏ Verify that all Safety Outputs not associated with Two-Hand
Control devices are now ON (exception: An output associated
only with an Enabling Device will remain OFF).
If a function or device as detailed in block 8.2.6.3, block 8.2.6.4 or
block 8.2.6.5 is not part of the application, skip that block and
proceed to next relevant check or to block 8.2.6.11 on page 73.
8.2.6.3 Two-Hand Control Functions
1) ❏ Ensure all Inputs are in ON-state associated with Safety Outputs and activate each Two-Hand Control device to turn ON remaining Outputs.
• If both Two-Hand Controls are NOT activated within 0,5 s of
each other, verify that associated Safety Output remains OFF
• Verify that when one hand is removed and replaced, Safety
Output turns OFF and remains OFF
INSTRUCTION MANUAL - EUROPEAN VERSION
E-Stop & Rope Pull Functions
2) ❏ 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 TwoHand Control, verify that Safety Output remains OFF.
If configured for Automatic Reset (assuming that another device is not holding it OFF), verify that Safety Output turns ON.
3) ❏ Apply a Manual Reset and/or activate Two-Hand Control device as necessary to turn Output(s) back ON.
• Verify that each associated safety output turns ON with proper
ON-delay, where applicable
8.2.6.5
Other Stopping Device Functions
1) ❏ Repeat step 1), step 2) and step 3) in block 8.2.6.4 on page 71
for each device type below, as applicable:
❏ Verify operation of all Gate Switches.
❏ Verify operation of all Optical Sensors.
❏ Verify operation of all Safety Mats.
❏ Verify operation of all Protective Stops (i.e. other safety/Safeguarding Devices otherwise not listed).
❏ Verify operation of all ON/OFF Inputs.
If Mute Sensor, Bypass Switch and/or Enabling Device functions
are not used, proceed to block 8.2.6.11 on page 73.
8.2.6.6
Mute Functions
1) ❏ While Outputs are ON, initiate a Mute Cycle by activating Mute
Enable input (if used) and then activate each Mute Sensor of a
Muting Sensor Pair within 3 s.
• Verify that Mute Lamp, if used, turns ON
2) ❏ Generate a stop command from Safeguarding Device that has
been muted.
• Verify that associated Safety Outputs remain ON (Controller
green status indicator remains ON
)
• If a Muting Time Limit (backdoor timer) is associated with the
mute, verify that associated Safety Outputs turn OFF when
Muting Time Limit expires
3) ❏ Repeat step 1) and step 2) for each Muting Sensor Pair.
• Verify proper operation with each Mute Sensor of a Muting
Sensor Pair
4) ❏ Generate a stop command from non-muted one at a time.
• Verify that associated Safety Outputs turn OFF while muted
input is muted.
*The Mute function will end when an associated output turns OFF for
any reason. In order to complete this test with the other non-muted
Safeguarding Devices, a new Mute Cycle must be initiated for each
one.
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Maintenance
8.2.6.7
SC22-3 Safety Controller
8.2.6.9
Mute on Power-Up Option
1) ❏ Turn power OFF to SC22-3 Safety Controller.
• Activate Mute Enable Inputs (if used)
• Activate an appropriate Muting Sensor Pair for starting a Mute
Cycle
• Ensure all Input Devices are in their Run (active) state (not
including Two-Hand Control devices)
• Verify that all Enabling Devices and Bypass Switches are in
Stop (inactive) state
Bypass Switch Function (without Mute)
1) ❏ Verify that when Safety Input to be bypassed is in Stop state:
• Associated Safety Outputs are OFF
2) ❏ Verify that when Bypass Switch is in Run state:
• Associated Safety Outputs turn ON
• Associated Safety Outputs turn OFF when bypass timer
(backdoor timer) expires
2) ❏ Verify proper operation at Power-up.
3) ❏ Verify that when Bypass Switch is in Stop state and goes back
into the Run state:
• Associated Safety Outputs turn ON
3) ❏ If Power-up is configured for Auto:
• Verify that all Safety Outputs turn ON*
• Verify that Output for mute status (if used) turns ON
4) ❏ Generate a stop command from non-bypassed , one at a time:
• Verify that associated Safety Output(s) turns OFF while input
is bypassed
4)
❏ If Power-up is configured for Normal:
• Verify that all Safety Outputs associated with Automatic Reset
devices only or mutable Manual Reset devices turn ON*
• Verify that output for Mute Status (if used) turns ON
5) ❏ If Power-up is configured for Manual:
• Verify that all Safety Outputs remain OFF
• Wait at least 10 s after Power-up and then apply a System
Reset (see block 7.4 on page 68)
• Verify that all Safety Outputs turn ON*
• Verify that output for Mute Status (if used) turns ON
*In all cases, safety Outputs associated with a two-hand control device will not turn ON at power-up. The Mute on Power-Up feature
does not apply to mutable two-hand control devices.
6) ❏ Generate a Stop command from Safeguarding Device that has
been muted.
• Verify that associated Safety Outputs remain ON (i.e. input is
muted) and green status indicator also remains ON
8.2.6.8
Bypass Switch Function (with Mute)
1) ❏ Verify that each Safety Input, if it is both mutable and can be
bypassed, is in Stop state:
• If SC22-3 Safety Controller is still muting, associated Safety
Outputs should remain ON. Even if timer expires and Outputs
turn OFF, go to the next step
2) ❏ Activate one or both Mute Sensors in a Muting Sensor Pair. If
there are two Muting Sensor Pairs, at least one sensor in one
of the pairs must be activated:
• Verify that Mute Lamp, if used, is flashing
8.2.6.10 Enabling Device Function
1) ❏ Verify that all Inputs associated with same output as Enabling
Device are in Run state to turn output(s) ON. Enabling Device
should remain in Stop state:
• Verify that associated Safety Outputs are ON
2) ❏ Verify that when Enabling Device is in Run state:
• Associated Safety Outputs remain ON and LCD displays Enable Mode
3) ❏ Verify that when Enabling Device is in the Stop state:
• Associated Safety Outputs turn OFF
4) ❏ Verify that when Enabling Device is in Run state:
• Associated Safety Outputs turn ON
• Associated Safety Outputs turn OFF when Enabling Device
timer expires
5) ❏ Verify that when Enabling Device is in Stop state and goes back
into Run state:
• Associated Safety Outputs turn ON
6) ❏ Verify that when all E-Stop and Rope Pull Inputs associated
with same Outputs are in Stop state, one at a time (repeat step
for each device, as necessary):
• The associated Safety Outputs turn OFF while in Enable
Mode
7) ❏ Verify that Enabling Device is in Stop state and then apply a
System Reset (see block 7.4 on page 68):
• Verify that LCD no longer displays Enable Mode
• Verify that Safety Controller is back to normal operation
3) ❏ Verify that when Bypass Switch is in Run state:
• Associated Safety Outputs turn ON
• Mute Lamp, if used, is now steady ON
• Associated Safety Outputs turn OFF when Bypass Switch timer expires
4) ❏ Verify that when Bypass Switch is in Stop state and goes back
into the Run state:
• Associated Safety Outputs turn ON
5) ❏ Verify that when all other non-bypassed Inputs associated with
same output are in a Stop state, one at a time:
• Associated Safety Outputs turn OFF while input is bypassed
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Maintenance
8.2.6.11 System (Final) Checkout
DO NOT continue checkout until all problems are corrected.
The operation of the Safety Controller with the guarded machine
must now be verified before the combined system may be put into
service. To do this, a qualified person as specified in block 1.8.2 on
page 4 must perform the following checks.
Remove power from Safety Controller.
1) ❏ Remove power from Safety Controller.
2) ❏ Referring to figure 25 on page 69, refit Safety Output 7-pin connector terminal strip to SC22-3 Safety Controller Safety Outputs SO1 (A and B), SO2 (A and B) and SO3 (A and B) to
enable connection of machine control circuit. This is a permanent connection.
3) ❏ Verify that all wiring complies with EU standards and local wiring codes.
4) ❏ Apply power to guarded machine and verify that machine does
not start up.
5) ❏ Apply power to Safety Controller and apply Resets (block 7.4
on page 68 refers) as necessary to turn safety Outputs ON.
6) ❏ Generate a stop command from each of safety devices or safeguards connected to input terminals of Safety Controller and
verify for each Input Device that:
❏ Safety Outputs and Status Outputs operate as expected (e.g.
On-Delays, Off-Delays, etc.). Use Configuration Summary to
verify operation.
❏ It is not possible for guarded machine to be put into motion.
7) ❏ Initiate machine motion of guarded machine and while it is moving, generate a Stop command from each of safety devices or
safeguards. Do not attempt to insert anything into dangerous
parts of machine. Upon executing stop command, verify that
dangerous parts of machine come to a stop.
8) ❏ Upon Reset of safety device or safeguard and/or Controller,
verify that machine does not automatically restart and that initiation devices must be engaged to restart machine.
9) ❏ Test machine stopping response time, using an instrument designed for that purpose, to verify that it is same or less than
overall system response time specified by machine manufacturer (Corporate Office as listed on page 121 may be able to
recommend a suitable instrument).
If any of these checks fail, do not attempt to use the system until
the reason for the failure(s) is identified and corrected.
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Maintenance
SC22-3 Safety Controller
8.3 CORRECTIVE MAINTENANCE
8.3.3
8.3.1
Depending on the configuration, the Safety Controller is able to detect a number of input, output and system faults, including:
Cleaning
1)
Disconnect power to the Controller.
2)
Using a soft lint free cloth that has been dampened with a mild
detergent and warm water solution, clean polycarbonate enclosure and display as required.
8.3.2
Repairs and Warranty Service
The Controller is designed and tested to be highly resistant to a wide
variety of electrical noise sources that are found in industrial settings.
However, intense electrical noise sources that produce EMI or RFI
beyond these limits may cause a random Trip or Lockout condition.
If random Trips or Lockouts occur, check that:
• Supply voltage is within 24V dc +/- 20%
• Safety Controller’s plug-in terminal blocks are fully inserted
(figure 25 on page 69 refers)
• Wire connections to each individual terminal are secure
• High-voltage noise sources, high-frequency noise sources or any
high-voltage power lines are not routed near Controller or alongside wires that are connected to Controller
• Proper transient suppression is applied across the output loads
(see warning on page 12)
Troubleshooting
• A stuck contact
• An open contact
• A short between channels
• A short to ground
• A short to a voltage source
• A short to another input
• A loose or open connection
• An exceeded operational time limit
• A power drop
When a fault is detected, a message describing the fault is displayed
in the Fault Diagnostics menu. An additional message may also be
displayed to help remedy the fault.
The troubleshooting table 17 on page 75 summarizes the faults and
suggests additional checks to find the cause of the problem. The following blocks describe how to recover from a Lockout and how to access fault information, using either the PCI or the OBI.
The SC22-3 Safety Controller has no internal field-replaceable parts.
If the Controller is not operating properly, please contact Corporate
Office as listed on page 121. In case of a non-recoverable fault, do
not open the housing of the Controller and do not attempt to disassemble the Controller in anyway. Contact Corporate Office as listed
on page 121.
An applications engineer will attempt to remotely troubleshoot the
Controller from the reported description of the problem. If it is concluded that the Controller or a component is defective and must be
returned to Banner, an RMA (Return Merchandise Authorization)
number will be issued, and shipping instructions will be forwarded.
The Controller should be packaged carefully. Damage which occurs
during return shipping is not covered by warranty.
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Maintenance
Table 17 Diagnostic Display Breakdown
Fault Code
Displayed
Message
Initial Check
Further Steps & Checks
0.0
Input Fault
Cycle Input
Input fault detected momentarily.
• Check for unstable input signal
• Turn input OFF to clear the fault indication
1.1
Output Fault
Check for shorts
A Safety Output appears ON at power-up when it should be OFF.
• Check for short to external voltage source
Check for shorts
A Safety Output is sensing a fault to another voltage source.
• Check for short between Safety Outputs
• Check for short to external voltage source
• Check load device compatibility (too much capacitance)
• Check DC common wiring from the loads connected to the Safety Outputs are heavy wired (larger cross
sectional area) and as short as possible to minimise resistance. If necessary use larger cross sectional area
wiring
1.2
Output Fault
1.3 – 1.6
Internal Fault
—
Check for shorts
Internal failure – Contact Banner Corporate Office as listed on page 121.
An overload is detected on the Safety Outputs.
• Check each output terminal for a short to ground or overload condition (a fault on only one output may cause
other Outputs to indicate a fault)
• Verify system power supply rating with system load requirements
1.7
Output Fault
1.8
Internal Fault
2.1
Concurrency Fault
Cycle Input
On a Dual channel input with both Inputs in the Run state, one input went to the Stop state then back to Run.
• Check wiring
• Check input signals
• Consider adjusting Debounce times
2.2
Simultaneity
Fault
Cycle Input
On a Dual channel input, one input went into the Run state but the other input did not follow within 3 seconds.
• Check wiring
• Check input signal timing
Cycle Input
On a Complementary Pair with both Inputs in the Run state, one of the Inputs changed to Stop then back to Run.
• Check wiring
• Check input signals
• Check power supply providing input signals
• Consider adjusting Debounce times
—
Internal failure – Contact Banner Corporate Office as listed on page 121.
2.3 or 2.5
Concurrency Fault
2.4 or 2.6
Simultaneity
Fault
Cycle Input
On a Complementary Pair, one input went into the Run state but the other input did not follow within the time
limit.
• Check wiring
• Check input signal timing
2.7
Internal Fault
Check Terminal xx
Internal failure – Contact Banner Corporate Office as listed on page 121.
Input Fault
Check Terminal xx
Input stuck high.
2.8 – 2.9
• Check for shorts to other Inputs or other voltage source
• Check Input Device compatibility
2.10
Input Fault
Check Terminal xx
Check for short between Inputs.
2.11 – 2.12
Input Fault
Check Terminal xx
Check for short to ground.
2.13
Input Fault
Check Terminal xx
Input stuck low.
• Check for short to ground
2.14
Input Fault
Check Terminal xx
2.15
Open Lead
Check Terminal xx
2.16 – 2.18
Input Fault
Check Terminal xx
2.19
Open Lead
Check Terminal xx
INSTRUCTION MANUAL - EUROPEAN VERSION
Missing test pulses.
• Check for short to other Inputs or other voltage source
Check for open lead.
Missing test pulses.
• Check for short to other Inputs or other voltage source
Check for open lead.
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Maintenance
SC22-3 Safety Controller
Table 17 Diagnostic Display Breakdown
Fault Code
76
Displayed
Message
Initial Check
Further Steps & Checks
2.20
Input Fault
Check Terminal xx
Missing test pulses.
• 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.
3.1
EDMxx Fault
Check Terminal xx
EDM contact open prior to turning ON the Safety Outputs.
• Check for a stuck-ON contactor or relay
• Check for open wire
3.2
EDMxx Fault
Check Terminal xx
EDM contact(s) failed to close within 200 ms after the Safety Outputs turned OFF.
• Check for slow or stuck-ON contactor or relay
• Check for open wire
3.3
EDMxx Fault
Check Terminal xx
EDM contact(s) open prior to turning ON the Safety Outputs.
• Check for stuck-ON contactor or relay
• Check for open wire
3.4
EDMxx Fault
Check Terminal xx
EDM contact pair mismatched for longer than 200 ms.
• Check for slow or stuck-ON contactor or relay
• Check for open wire
3.5
EDMxx Fault
Check Terminal xx
Check for unstable signal on the input.
3.6
EDMxx Fault
Check Terminal xx
Check for short to ground.
3.7
EDMxx Fault
Check Terminal xx
Check for short between Inputs.
4.1
Supply Voltage Low
Check Power Supply
The supply voltage dropped below the rated voltage for longer than 6 ms.
• Check the power supply voltage and current rating
4.2
Internal Fault
—
A configuration parameter has become corrupt. To fix the configuration:
• Replace configuration with backup copy obtained and transferred from PCI or XM Card
• Erase and recreate configuration using OBI
4.3 – 4.11
Internal Fault
—
Internal failure – Contact Banner Corporate Office as listed on page 121.
4.12
Configuration Timeout
Check Configuration
Safety Controller was left in Configuration Mode for more than one hour without pressing any keys.
4.13
Configuration Timeout
Check Configuration
Safety Controller was left in Configuration Mode for more than one hour without receiving any commands from
the PC Interface.
4.14
Configuration Unconfirmed
Check Configuration
Configuration was not confirmed after being edited.
• Confirm configuration using the OBI or the PCI
4.15 – 4.19
Internal Fault
—
4.20
Unassigned
Terminal in
Use
4.21 – 4.32
Internal Fault
• Check for an overload on the Outputs that might cause the power supply to limit the current
Check Terminal xx
—
or
Internal failure – Contact Banner Corporate Office as listed on page 121.
This terminal is not mapped to any device in the present configuration and should not be active.
• Check wiring
Internal failure – Contact Banner Corporate Office as listed on page 121.
5.1
Mute Lamp
Fault
Check Lamp and
Wiring
The monitored Status Output voltage should be low when the lamp is OFF and is sensing a high, indicating an
open circuit in the Mute Lamp.
5.2
Mute Lamp
Fault
Check for shorts
The monitored Status Output voltage should be high when the lamp is ON and is sensing a low, indicating a
short in the mute lamp circuit.
5.3
Internal Fault
—
Internal failure – Contact Banner Corporate Office as listed on page 121.
6.xx
Internal Fault
—
Invalid configuration data. Possible internal failure.
• Try to load a new configuration using the PCI, OBI or XM card
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SC22-3 Safety Controller
Maintenance
8.3.3.1 Recovering from a Lockout
To recover from a Lockout condition perform one or more of the following steps:
1)
At Safety Controller display, perform ON SCREEN fault display
recommendation (e.g. Cycle Input).
2)
Follow recommendations listed in troubleshooting table 17 on
page 75 under Further Steps and Checks.
3)
Perform a System Reset (block 7.4 on page 68 refers).
Cycle power and perform a System Reset (block 7.4 on page 68
refers) if necessary.
If these steps do not remedy the Lockout condition, contact Banner
Corporate Office as listed on page 121.
FAULT LOG — PCI
While the Controller is powered up and connected to the PC, every
fault that occurs is stored in the Fault Log. The PCI displays real-time
fault information via the Fault Log screen shown in screen 160.
To access the Fault Log:
1)
Open PCI program
2)
From Tabular, click on View then Fault Log. Screen 160 is displayed.
4)
Saves the displayed faults to a file
for later reference.
Clears the faults displayed and
gets the latest faults stored in the
Safety Controller’s fault log.
8.3.3.2 Fault Diagnostics via PCI
When diagnosing faults via the PCI:
1)
Ensure PC is connected to SC22-3 Safety Controller via supplied USB cable, supplied SC22-3 Safety Controller software
program is loaded and Safety Controller hardware has been recognised by the PC.
2)
Referring to instructions detailed in block 5.1.2 on page 38,
open PCI program.
3) Referring to block 5.1.23 on page 51, open Live Display screen.
The Live Display screen displays information in real time (see
screen 36 on page 51) as follows:
• Status of each Safety Output
• Which device caused an output to turn OFF if any
• Basic information about Controller model and configuration
Click on this button to generate
an extended record of faults and
save to file
Screen 160
The Fault Log includes the following information about each fault (expand the size of the window as needed to see all the faults).
• Date and time of the fault
• Device name
• General description of the fault, and
• Fault code (for looking up table reference)
Should factory applications assistance be required, additional code
information can be displayed.
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Maintenance
SC22-3 Safety Controller
Fault Log Recording — PCI
To determine the cause of a persistent fault, an extended record of
faults can be compiled and saved to file.
2)
To access this function:
1)
At screen 162, select Fault Diagnostics and press OK. Screen 163 is displayed.
Screen 162
Open Fault Log as previously described.
2)
In Fault Log (screen 160), click Edit button. The Schedule Fault
Log Capture menu screen 161 is then displayed.
In screen 161, the menu settings show that any fault that occurs from
Friday, June 29, 2007 at 11:00 pm until Saturday, June 30, 2007 at
6:00 am will be recorded to a user-designated file for future reference.
☛ The selected start and stop times must be later than the time at
which this selection is made; the fault log capture will not capture
past faults.
At screen 163 the Diagnostic Menu provides three choices:
• View Current Faults
• View Fault Log
• Clear Fault Log
Screen 163
View Current Faults
To view current fault conditions:
3)
Using up/down arrow buttons, select View Current Faults and
press OK.
Screen shows fault conditions that currently exist, one at a time
(screen 164).
4)
Use left/right arrow keys to view all faults (screen 165 and
screen 166) (short-cut: To view current faults when the Run
mode screen is displayed, simply press OK three times).
A breakdown of the View Current Faults, shown in screen 164,
screen 165 and screen 166, is as follows:
Screen 161
8.3.3.3 Fault Diagnostics via OBI
Fault diagnosing the SC22-3 Safety Controller and associated I/O
devices can also be carried out using the OBI.
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 Safety Controller’s display. Further information
about current and past faults can be accessed using the Fault Diagnostics menu.
To access SC22-3 Safety Controller Fault Diagnostics menu:
1)
• Top line indicates which device has the fault
• Second and third lines provide a brief description of the fault
• Fourth line provides a suggestion for correcting the fault
• Fifth line provides the fault code
Use the fault code and information in block 8.3.3 on page 74 and
table 17 on page 75 to obtain more information about the fault and
additional suggestions for correcting it.
5)
Use left/right arrow buttons to access fault information for all
faulty devices.
From Run mode menu press OK. Screen 162 is displayed.
Arrowhead designates location of additional fault screens
Device Name
Fault Description
Suggested Remedy
Fault Code
Screen 164
78
Screen 165
Screen 166
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SC22-3 Safety Controller
Maintenance
View Fault Log
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 Fault Log:
1)
From Diagnostic Menu (screen 163), using up/down arrow buttons, select View Fault Log and press OK.
Screen shows first fault stored in the Fault Log (screen 167).
2)
Use left/right arrow keys to view additional faults in the Fault Log
(screen 168 and screen 169).
• Top line of Fault Log screen indicates which device had the
fault
• Second and third lines provide a brief description of the fault
• Fourth line displays how long ago the fault occurred. For
instance, a time of 01:30:23 indicates fault occurred one hour,
thirty minutes, and 23 seconds previous to the View Fault Log
menu’s appearance on the screen (If a fault is added to the
Fault Log while it is being viewed, the time is displayed as
New Fault. If a fault is older than twenty-four hours, the time is
displayed as > 24 hours)
• Fifth line provides the Fault Code. Use the Fault Code and
information in table 17 on page 75 to obtain more information
about the fault and additional suggestions for correcting it
☛ Removing power from Safety Controller will clear the Fault Log,
in addition to the method described in Clear Fault Log.
Device Name
Fault Description
Time Since Fault
Fault Code
Screen 167
Screen 168
Screen 169
Clear Fault Log
To Clear Fault Log:
1)
From Diagnostic Menu (screen 170),
select Clear Fault Log and press OK.
Screen 171 is displayed.
Screen 170
2)
When fault is cleared, indicated by
screen 171, press OK to return to Diagnostic Menu menu, then press ESC
twice to return to the Run mode menu.
Screen 171
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79
Maintenance
SC22-3 Safety Controller
8.4 SPARE PARTS, SPECIAL TOOLS &
MATERIAL
8.4.1
8.4.1.1 Safety Controller Starter Kit
Kits include SC22-3 Safety Controller:
Spare Parts
This block details Spare Parts information for the SC22-3 Safety
Controller.
• Set of plug-on terminal blocks (screw or cage-clamp type, depending on model)
• USB A/B cable (for direct connection between PC and Controller,
included with some kits)
• External non-volatile memory card (XM card, with write-on label on
reverse side)
• XM card programming tool (included with some models)
• CD (includes software interface, on-line manual and configuration
tutorials)
• Quick Start Guide
Table 18 on page 80 gives information on the kits.
Table 18 Kit & Accessory Information for SC22-3 Safety Controller
Type No.
Description
Order Part
No.
Safety Controller Starter Kit
SC22-3-S
Screw terminals, XM card
30 772 59
SC22-3-C
Clamp terminals, XM card
30 779 13
SC22-3-SU1
Screw terminals, XM card, XM card
programming tool and USB A/B cable
included
30 779 14
SC22-3-CU1
Clamp terminals, XM card, XM card
programming tool and USB A/B cable
included
30 779 15
Replacement Parts/Accessories
SC-XM1
External memory card (XM card)
30 761 77
SC-XM1-5
Bulk pack of 5 XM memory cards
TBA*
SC-XMP
USB programming tool for XM card
30 777 08
SC-TS1
Screw terminal blocks (1 set for 1 Safety
Controller)
30 778 12
SC-TC1
Cage clamp terminal blocks (1 set for 1
Safety Controller)
30 778 13
SC-TC1SCUSB1
USB A/B cable
–
CD including PCI program and instruction
manual
TBA*
134534
*To be annotated
80
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INSTRUCTION MANUAL - EUROPEAN VERSION
SC22-3 Safety Controller
8.4.1.2
Maintenance
Interface Modules
SC-IM9 series
SC-IM9 series Interface Modules are for use only with the SC22-3 Safety Controller and have:
• Dry contacts for use with higher ac/dc voltage and current with a 10 A output
• DIN-mount housing
• Removable (plug-in) terminal blocks for OSSD Outputs (screw terminal block supplied)
• Measures approx. 72 mm H, 170 mm D, and 45 mm, 90 mm, or 140 mm W depending on model
☛ EDM is required to be wired separately to the N.C. contacts to comply with ISO 13849-1 categories control reliability (see block 4.8 on
page 32).
Table 19 on page 81 gives information on the various modules.
Table 19 Interface Modules Series SC-IM9
Type No.
Description
SC-IM9A
For use with x1
SC22-3 Safety Controller
Safety Output
SC-IM9B
For use with x2
SC22-3 Safety Controller
Safety Outputs
SC-IM9C
For use with x 3SC22-3
Safety Outputs
Inputs
(Safety Controller
Outputs)
Supply
Voltage
x2 (SO1)
24V dc
(Controller
supplied)
Output
Rating
Safety Outputs
EDM
Contacts
Order Part
No
30 778 14
x3 N.O.
x4 (SO1 and SO2)
Total of 6
(x3 N.O. as per output)
x6 (SO1, SO2 & SO3)
Total of 9
(x3 N.O. as per output)
10 amps
x1 N.C. as
per
Output (2
contacts
in series)
30 778 15
30 778 23
IM-T-9 series
IM-T-9 series interface modules have:
• 6A output
• 22,5 mm DIN-mount housing
• Removable (plug-in) terminal blocks
• Low current rating of 1 V ac/dc @ 5 mA
• High current rating of 250 V ac/dc @ 6A
☛ EDM is required to be wired separately to the N.C. contacts to comply with ISO 13849-1 categories control reliability (see block 4.8 on
page 32).
Table 20 on page 81 gives information on the various modules.
Table 20 Interface Modules Series IM-T-9
Type No.
Supply Voltage
Inputs
24V dc
x2 (Dual channel
connection)
IM-T-9A
IM-T-11A
Safety Outputs
Output Rating
EDM Contacts
6A
x2 N.C.
Aux. Outputs
Order Part No
—
30 614 25
x1 N.C.
30 614 24
x3 N.O.
x2 N.O.
8.4.1.3 Mechanically Linked Contactors
Provides an additional 10 A or 16 A carrying capability to any safety system. If used, two contactors as per safety output pair (e.g. 2 x SO1)
are required. The N.C. contacts are to be used in an EDM circuit (see figure 28 on page 83).
Table 21 on page 81 gives information on the various versions.
Table 21 Mechanically Linked Contactors
Type No.
Supply Voltage
Inputs
24V dc
x2 (Dual channel
connection)
11-BG00-31-D-024
11-BF16C01-024
INSTRUCTION MANUAL - EUROPEAN VERSION
Outputs
Output Rating
Order Part No
x3 N.O.
10 A
30 696 82
16 A
30 696 87
+
x1 N.C.
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Maintenance
8.4.2
SC22-3 Safety Controller
Documentation
Table 22 on page 82 details the documentation applicable to the
SC22-3 Safety Controller.
Table 22 Documentation Order Numbers
Order
Part No.
82
Description
135369
Instruction Manual (European version UK English)
135453
Instruction Manual (European version French)
135454
Instruction Manual (European version German)
135455
Instruction Manual (European version Italian)
133485
Quick Start Guide (English)
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SC22-3 Safety Controller
Appendix 1
A1 WIRING DIAGRAMS
Safety Input
Safety Input
+24 VDC
EDM EDM
EDM
SC22-3
MPCE 1
SC22-3
MPCE 1
SO 1
SO 1
MPCE 2
MPCE 2
MPCE1
MPCE1
MPCE2
Dual channel EDM used to monitor
both MPCE feedback signals. If the
channels are not in the same state, the
system goes into a Lockout condition.
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.
+24 VDC
Figure 27 Dual channel EDM Connection
Figure 26 Single channel EDM Connection
! WARNINGS
REFER TO USE OF TRANSIENT SUPPRESSORS warning on
page 12.
Safety Stop Circuit
SC22
SO1
1A
SO2
1B
2A
SO3
2B
3A
REFER TO OSSD INTERFACING warning on page 12.
REFER TO SHOCK HAZARD warning on page 3.
REFER TO PROPER WIRING warning on page 12.
Dual channel
Single channel
Input Terminals
This figure is generic in nature and represents all three
EDM options:
3B
FSD
3A
3B
• Safety Output SO1 is shown with NO EDM configured (typically used with self-monitored devices)
Dual channel
Single channel
Safety Stop Circuit
• Safety Output SO2 is shown with Dual channel
EDM configured
+24 VDC
• Safety Output SO3 is shown with Single channel
EDM configured
Any particular Safety Controller configuration may use any
combination of external device monitoring options,
depending on the application.
See also block 1.18 on page 6 on EDM and block 4.8.2 on
page 33 on interfacing safety stop circuits.
FSD
2A
2B
+24 VDC
FSD
1A
1B
Figure 28 Generic Connection Showing Single channel, Dual channel, & No EDM options
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Appendix 1
SC22-3 Safety Controller
Machine Control
! WARNINGS
REFER TO USE OF TRANSIENT SUPPRESSORS warning on
page 12.
SC-IM9A
REFER TO OSSD INTERFACING warning on page 12.
REFER TO SHOCK HAZARD warning on page 3.
REFER TO PROPER WIRING warning on page 12.
Input Terminals
13
21
33
43
A1
14
22
34
44
A2
SC22
SO1
1A
SO2
1B
2A
SO3
2B
3A
3B
A2
(To
SO
The SC-IM9A Interface Module is shown as Single channel
1A
)
EDM connection. The SC-IM9B and SC-IM9C modules are
connected in the same manner using individual Single
Supplied
Terminal
Block
13
21
33
43
A1
14
22
34
44
A2
(To
SO
1B
)
channel EDM circuits (terminals 21/22 on each pair of contactors).
For interfacing safety stop circuits, see also block 1.18 on
page 6 on EDM and block 4.8.2 on page 33.
x3 wires
* Installation of transient (arc) suppressors across the coils of
MPCE1, MPCE2 & MPCE3 is recommended (see warning on
page 12)
*
MPCE
1
MPCE
2
*
MPCE
3
*
+24V dc
0 VDC
Figure 29 Single channel EDM Connection to SC-IM9A Interface Module
! WARNINGS
REFER TO USE OF TRANSIENT SUPPRESSORS warning on
page 12.
Input Terminals
SC22
SO1
1A
SO2
1B
2A
REFER TO OSSD INTERFACING warning on page 12.
SO3
2B
3A
3B
0 VDC
A2
The IM-T-9A interface module is shown as Dual channel
EDM connection. The IM-T-11A module is connected in a
similar manner.
IM-T-9A
S1
S3
* Installation of transient (arc)
suppressors across the coils of
MPCE1, MPCE2 & MPCE3 is
recommended (see warning on
page 12)
K2
+24 VDC
REFER TO SHOCK HAZARD warning on page 3.
REFER TO PROPER WIRING warning on page 12.
Depending on the application, each Safety Output requires
a separate and individually wired IM-T-..A module.
For interfacing safety stop circuits, see also block 1.18 on
page 6 on EDM and block 4.8.2 on page 33.
K1
S4
S2
Y3
Y4
Y1
Y2
13
14
23
24
33
34
MPCE
1
Machine
Control
*
MPCE
2
*
Feedback (optional)
Figure 30 Dual channel EDM Connection to IM-T-9A Interface Module
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SC22-3 Safety Controller
Appendix 1
! WARNINGS
REFER TO USE OF TRANSIENT SUPPRESSORS warning on
Input Terminals
SC22
SO1
1A
SO2
1B
2A
page 12.
REFER TO OSSD INTERFACING warning on page 12.
SO3
2B
3A
3B
0 VDC
A2
REFER TO SHOCK HAZARD warning on page 3.
REFER TO PROPER WIRING warning on page 12.
The IM-T-9A interface module depicted in this figure is
shown in Single channel EDM connection. The IM-T-11A
module is connected in a similar manner.
IM-T-9A
S1
S3
K2
* Installation of transient (arc)
suppressors across the coils of
MPCE1, MPCE2 & MPCE3 is
recommended (see warning on
page 12)
+24 VDC
Machine
Control
Depending on the application, each Safety Output requires
a separate and individually wired IM-T-..A module.
See also block 1.18 on page 6 on EDM and block 4.8.2 on
page 33 on interfacing safety stop circuits.
K1
S4
S2
Y3
Y4
Y1
Y2
13
14
23
24
33
34
MPCE
1
*
MPCE
2
*
Feedback (optional)
Figure 31 Single channel EDM Connection to IM-T-9A Interface Module
SC22-3 Safety Controller
Power Supply
0 V +24 V dc
+24 V dc 0 V
SO1
SO2
SO3
x6 Output Loads
DC Common Line/Wire Resistance RL
I1
Itot.
I2
I3
I4
I5
I6
Figure 32 DC Common Wire Installation
+24V dc
+24v dc
Open
Open
Open
Open
Open
Figure 34 Category 3 Circuit - Gate Switch
Figure 33 Category 2 Circuit - Gate Switch
INSTRUCTION MANUAL - EUROPEAN VERSION
Open
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Appendix 1
SC22-3 Safety Controller
Open
Figure 35 Category 4 Circuit - Gate Switch
Figure 36 Category 2 Circuit E-Stop
Figure 37 Category 3 Circuit E-Stop
Figure 38 Category 4 Circuit E-Stop
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SC22-3 Safety Controller
Appendix 2
A2 INPUT DEVICE & SAFETY CATEGORY REFERENCE
A2.1 SAFETY CIRCUIT INTEGRITY & ISO 13849-1 (EN954-1) SAFETY CIRCUIT PRINCIPLES
A2.1.1 Safety Circuit Integrity Levels
! WARNINGS
SAFETY CATEGORIES
THE LEVEL OF SAFETY CIRCUIT INTEGRITY CAN BE GREATLY IMPACTED BY THE DESIGN AND INSTALLATION OF THE SAFETY DEVICES AND THE MEANS OF INTERFACING
OF THOSE DEVICES. A RISK ASSESSMENT MUST BE PERFORMED TO DETERMINE THE
APPROPRIATE SAFETY CIRCUIT INTEGRITY LEVEL OR SAFETY CATEGORY AS DESCRIBED BY ISO 13849-1 (EN 954-1) TO ENSURE THAT THE EXPECTED RISK REDUCTION IS ACHIEVED AND THAT ALL RELEVANT REGULATIONS ARE COMPLIED
WITH.
INPUT DEVICES WITH SOLID STATE OUTPUTS
THE SAFETY CONTROLLER WILL NOT DETECT SHORTS BETWEEN INPUTS OR FROM
AN INPUT TO +24 V 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 +24 V).
CATEGORY 2 OR CATEGORY 3 INPUT SHORTS
DETECTION OF A SHORT BETWEEN TWO INPUT CHANNELS (CONTACT INPUTS, BUT
NOT COMPLEMENTARY CONTACTS), IF THEY ARE SUPPLIED THROUGH THE SAME
SOURCE (E.G. THE SAME TERMINAL FROM THE CONTROLLER IN A DUAL CHANNEL,
3 TERMINALS CONNECTION, OR FROM AN EXTERNAL 24 V SUPPLY) IS NOT POSSIBLE, IF THE TWO CONTACTS ARE CLOSED.
SUCH A SHORT CAN BE DETECTED ONLY WHEN BOTH OF THE CONTACTS ARE OPEN
AND THE SHORT IS PRESENT FOR AT LEAST 2 SECONDS.
Safety circuits involve the safety-related functions of a machine that
minimize the level of risk of harm. These safety-related functions can
prevent initiation, or they can stop or remove a hazard. The failure of
a safety-related function or its associated safety circuit usually results
in an increased risk of harm.
The integrity of a safety circuit depends on several factors, including
fault tolerance, risk reduction, reliable and well-tried components,
well-tried safety principles, and other design considerations.
Depending on the level of risk associated with the machine or its operation, an appropriate level of safety circuit performance (i.e., integrity) must be incorporated into its design. Standards for Europe that
detail safety performance levels include ISO 13849-1 (EN954-1)
Safety-Related Parts of a Control System.
INSTRUCTION MANUAL - EUROPEAN VERSION
Safety circuits in International and European standards have been
segmented into categories, depending on their ability to maintain
their integrity in the event of a failure. The most recognized standard
that details safety circuit integrity levels is ISO 13849-1 (EN954-1),
which establishes five levels: Categories B, 1, 2, 3, and the most
stringent, Category 4.
The typical level of Safety Circuit Integrity is known as Control Reliability. Control Reliability typically incorporates Redundant control and
self-checking circuitry and has been loosely equated to ISO 13849-1
Categories 3 and 4.
If the requirements described by ISO 13849-1 are to be implemented
in Europe, a Risk Assessment must first be performed to determine
the appropriate category, in order to ensure that the expected risk reduction is achieved. This Risk Assessment must also take into account national regulations such as European “C” level standards, to
ensure that the minimum level of performance that has been mandated is complied with.
The following blocks (appendix A2.2 thru’ to appendix A2.11) deal
only with Category 2, Category 3, and Category 4 applications, as
described by ISO 13849-1 (2006). Table 23 on page 88 provides a
breakdown of the possible Safety Categories that can be achieved
for each device type, depending on the selected circuit option.
For further information refer to the remaining part of appendix A2 as
well as the appropriate standards.
A2.1.2 Fault Exclusion
An important concept within the category requirements of
ISO 13849-1 is the Probability of the Occurrence of the Failure which
can be decreased using a technique termed Fault Exclusion. The rationale assumes that the possibility of certain well-defined failure(s)
can be reduced to a point where the resulting fault(s) can be, for the
most part, disregarded i.e., excluded.
Fault Exclusion is a tool a designer can use during the development
of the safety-related part of the control system and the risk assessment process. Fault Exclusion allows the designer to design out the
possibility of various failures and justify it through the risk assessment process to meet the intent requirements of Category 2,
Category 3 or Category 4. See ISO 13849-1/-2 for further information.
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Appendix 2
SC22-3 Safety Controller
Table 23 Input Devices, Circuit Options, & their Potential Safety Categories
Circuit Symbol Examples
E-Stop
Gate
Switch
Optical
Sensor
TwoHand
Control
Rope
Pull
Protective
Stop
Safety
Mat
Enabling
Device
Bypass
Switch
Mute
Sensor
Cat. 2
Cat. 2
Cat. 2
—
Cat. 2
Cat. 2
—
—
—
—
Cat. 3
Cat. 2
Cat. 3
Cat. 2
Cat. 3
Type IIIa
Cat. 1
Type IIIb
Cat. 3
Cat. 3
Cat. 2
Cat. 3
—
Cat. 2
Cat. 3
Cat. 2
Cat. 3
Cat. 2
Cat. 3
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Type IIIa
Cat. 1
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Type IIIa
Cat. 1
Type IIIb
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
Cat. 2
Cat. 3
Cat. 4
—
Cat. 3
Cat. 4
—
Type IIIc
Cat. 4
—
—
—
Cat. 3
Cat. 4
Cat. 4
—
—
Cat. 3
Cat. 4
—
Type IIIc
Cat. 4
—
—
—
Cat. 3
Cat. 4
Cat. 4
—
—
—
—
—
—
—
Cat. 2
Cat. 3
—
—
—
24V
24V
ON
ON
24V
ON
OFF
24V
ON
OFF
ON
OFF
☛ Category B or Category 1 is assumed when not using safety-rated devices.
All safety Input Device contacts are shown in the ON/active state (e.g. E-Stop in the armed state, safety gate in the closed state, light screen in the clear state, etc.)
Category B/Category 1, Category 2, Category 3 and Category 4 are as per ISO 13849-1 (EN 954-1), except for two-hand control.
Two-hand categories are as per ISO 13851.
88
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INSTRUCTION MANUAL - EUROPEAN VERSION
SC22-3 Safety Controller
Appendix 2
A2.2 PROTECTIVE STOPS (SAFETY)
A2.2.2.3 Dual Channel, PNP
A Protective Stop (Safety) is designed for the connection of
miscellaneous devices (not otherwise listed on the Add Safety Input screen) that could include Safeguarding Devices
(protective) and complementary equipment. This Stop function is a
type of interruption of operation that allows an orderly cessation of
motion for Safeguarding purposes. The function can be either automatically or manually activated and Reset either manually or automatically.
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating, installation
and the fault detection (e.g. short circuit) capabilities of the Output
Device. The SC22-3 Safety Controller does not provide short circuit
detection in this configuration.
A2.2.1 Requirements
A2.2.2.4 Dual channel, 4 terminal
The required Safety Circuit Integrity level is determined by a Risk Assessment and will indicate the level of control performance that is acceptable (e.g. Category 4, Control Reliability) (see appendix A2.1 on
page 87 and appendix A2.1.1 on page 87). The Protective Stop circuit must control the safeguarded hazard by causing a Stop of the
hazardous situation(s) and removing power from the machine actuators. This is typically functional Stop Category 0 or Category 1 as described by IEC60204-1.
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements, depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit
between channels or to another source of power.
The user must follow the device manufacturer’s installation, operation, and maintenance instructions and all relevant regulations. If there is any question about the device(s) that are to be
connected to the SC22-3 Safety Controller, call Banner Corporate Office as listed on page 121 for assistance.
A2.2.2 Connection Options
☛ All figures show the Input Device in the OFF (Stop) state.
A2.2.2.1 Single channel, 1 terminal - Single channel, 2 terminal
- Single channel, PNP switch
These circuits can typically meet ISO 13849-1 Category 2 requirements, depending on the Safety Rating of the Output Device(s). At a
minimum, a safety-rated device must be used to achieve a
Category 2. The Single channel, 1 terminal and the Single channel,
PNP switch device circuits can not detect a short circuit to another
source of power. Single channel, 2 terminal connection uses pulse
monitoring and can detect a short circuit to another source of power.
Fault Exclusion must be used to achieve a higher level of Safety Circuit Integrity.
24V
OFF
OFF
OFF
A2.2.2.5 Complementary, 2 terminals - Complementary, 3 terminals
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit
between channels. In the actuated condition (e.g. S1 Open / S2
Close, see circuit below), a short across the closed contact can 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 block 4.5 on page 25).
24V
A2.2.2.6 Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit
between channels. In the actuated condition (e.g. S1 OFF /S2 ON below) a short across the closed contact can 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 block 4.5 on page 25).
OFF
ON
A2.2.2.2 Dual channel, 2 terminals - Dual channel, 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
Output Device(s). Dual channel, 3 terminals connection uses pulse
monitoring and can detect a short circuit to another source of power.
Both Dual channel, 2 terminals and Dual channel, 3 terminals connection can detect a short between channels when the contacts are
open if the short is present longer than 2 seconds.
24V
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89
Appendix 2
SC22-3 Safety Controller
A2.3 GATE SWITCHES (or INTERLOCKED
GUARD)
A2.3.2.1 Positive-Opening Safety Interlocking Switches
The SC22-3 Safety Controller Safety Inputs may be used
to monitor electrically interlocked guards or gates.
A2.3.1 Safety Circuit Integrity Levels
Requirements vary widely for the level of Control Reliability or Safety
Category as per ISO 13849-1 (EN954-1) in the application of interlocked guards. While Banner always recommends the highest level
of safety in any application, it is the responsibility of the user to safely
install, operate and maintain each safety system and comply with all
relevant laws and regulations.
The safety performance (integrity) must reduce the risk from identified hazards as determined by the machine’s Risk Assessment. See
appendix A2.1 for guidance if the requirements as described by
ISO 13849-1 are to be implemented.
In addition to the requirements stated in this appendix A2.3.1, the design and installation of the interlocking device should comply with
ISO 14119.
A2.3.2 Requirements
The following general requirements and considerations apply to the
installation of interlocked guards and gates for the purpose of Safeguarding. In addition, the user must refer to the relevant regulations
to be sure to comply with all necessary requirements.
Hazards guarded by the interlocked guard must be prevented from
operating until the guard is closed. A Stop command must be issued
to the guarded machine if the guard opens while the hazard is
present. Closing the guard must not, by itself, initiate hazardous motion. A separate procedure must be required to initiate the motion.
The safety switches must not be used as a mechanical or end-of-travel stop.
The guard must be located an adequate distance from the danger
zone (so that the hazard has time to stop before the guard is opened
sufficiently to provide access to the hazard) and it must open either
laterally or away from the hazard; not into the safeguarded area. The
guard also should not be able to close by itself and activate the interlocking circuitry. In addition, the installation must prevent personnel
from reaching over, under, around or through the guard to the hazard.
Any openings in the guard must not allow access to the hazard (see
EN 294, ISO 14120 or the appropriate standard). The guard must be
strong enough to contain hazards within the guarded area, which
may be ejected, dropped or emitted by the machine.
Safety interlock switches must satisfy several requirements. Each
switch must provide electrically isolated contacts; at minimum, one
normally closed (N.C.) contact from each individually mounted
switch. The contacts must be of Positive-Opening (direct-opening)
design, as described by IEC 60947-5-1, with one or more normally
closed contacts rated for safety. Positive-Opening operation causes
the switch to be forced open, without the use of springs, when the
switch actuator is disengaged or moved from its home position (see
the Banner Safety Catalogue for examples).
In addition, the switches must be mounted in a Positive Mode to
move/disengage the actuator from its home position and open the
NC contact when the guard Opens.
A2.3.2.2 Magnetically Operated Safety Interlocking Switches
In higher levels of safety performance, the design of a Dual channel
magnetic switch typically uses Complementary Switching, in which
one channel is Open and one channel is Closed at all times. This provides Redundancy (two contacts) and Diversity (different principles of
operation) to minimize the possibility of the loss of the switching function due to common mode failures (e.g. secondary magnetic fields).
The circuitry or the Safety Controller that is monitoring the magnetic
switch will detect and respond to a failure that results in the loss of
the Complementary state (e.g. a short circuit between the channels,
or a short circuit to other sources of power).
Coded and non-coded Magnetic Switches affect the ability of the
switch to be defeated and to withstand common mode failures. Noncoded switches are easily defeated by the presence of a simple magnetic field and should be mounted in a concealed position. A coded
Magnetic Switch that uses alternating magnetic poles should be used
in applications that require higher levels of safety performance.
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.
The safety interlocking switches and actuators must be designed and
installed so that they cannot be easily defeated. They must be mounted securely so that their physical position cannot shift, using reliable
fasteners that require a tool to remove them.
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Appendix 2
A2.3.2.3 Monitoring Series-Connected Safety Interlocking
Switches
When monitoring two individually mounted Safety Interlocking
Switches (as shown in figure 33 on page 85), a faulty switch will be
detected if it fails to switch as the guard Opens. In this case, the Controller will de-energize its Safety Outputs (OSSDs on page 117) and
disable its Reset function until the input requirements are met (i.e. the
faulty switch is replaced). However, when multiple Safety Interlocking
Switches are series-connected, the failure of one switch in the system may be masked or not be detected at all (refer to figure 34 on
page 85 and figure 35 on page 86).
Series-connected Safety Interlocking Switch circuits may not meet
ISO 13849 (EN954-1) Safety Category 4 requirements because of
the potential of an inappropriate Reset or a potential loss of the Safety Stop Signal. This is due to the typical inability to fault exclude the
failure of the Safety Interlocking Switch. A multiple connection of this
type should not be used in applications where loss of the Safety Stop
Signal or an inappropriate Reset can lead to serious injury or death.
The following two scenarios assume two Positive-Opening Safety Interlocking Switches on each guard, both connected in series to Safety Interlocking Switches of a second guard:
Scenario 1 Masking of a Failure
If a guard is opened but a Safety Interlocking Switch fails to open, the
Redundant Safety Interlocking Switch will Open and cause the Controller to de-energize its Outputs. If the faulty guard is then closed,
both Controller input channels also close but, because one channel
did not open, the Controller will not Reset. However, if the faulty
switch is not replaced and a second good guard is cycled (opening
and then closing both of the Controller’s input channels), the Controller considers the failure to be corrected. With the input requirements
apparently satisfied, the Controller allows a Reset. This system is no
longer Redundant and if the second switch fails, may result in an unsafe condition (i.e. the accumulation of faults resulting in loss of the
safety function).
Scenario 2 Non-Detection of a Failure
If a good guard is opened, the Safety Controller de-energizes its Outputs (a normal response) but if a faulty guard is then opened and
closed before the good guard is re-closed, the faulty guard is not detected. This system also is no longer Redundant and may result in a
loss of safety if the second safety switch fails to switch when needed.
This check must be performed and all faults must be cleared, at a
minimum, during periodic check-outs. If the application can not exclude these types of failures and such a failure could result in serious
injury or death, then the series connection of safety switches must not
be used.
A2.3.2.4 Series Connection & Safety Circuit Integrity Considerations
A2.3.2.5 Category 2
A Single-Channel interlocked guard application typically provides a
Category 2 level of circuit performance because a short circuit could
cause loss of 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 faults
that can result in loss of the safety function. For circuit diagram refer
to figure 33 on page 85.
A2.3.2.6 Category 3
A Dual-Channel connection 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. However, a short circuit between input channels
or Safety Outputs may not be detected. It should be noted that an accumulation of faults may cause 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 catastrophic/common mode failures that could result in the loss of safety function. For
circuit diagram refer to figure 34 on page 85.
A2.3.2.7 Category 4
The self-monitoring Safety Inputs can be interfaced to achieve a
Category 4 level of safety. 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 catastrophic/common mode failures that could result in loss of the safety
function. For circuit diagram refer to figure 35 on page 86.
The systems in either scenario do not inherently comply with the
safety standard requirements of detecting single faults and preventing the next cycle. In multiple-guard systems using series-connected
safety switches, it is important to periodically check the functional integrity of each interlocked guard individually. Operators, maintenance personnel, and others associated with the operation of the
machine must be trained to recognize such failures and be instructed
to correct them immediately.
Each safeguard should be Opened and Closed separately while verifying that the Controller Outputs operate correctly throughout the
check procedure. Each safeguard closure should be followed with a
Manual Reset, if needed. If a contact set fails, the Controller will not
enable its Reset function. If the Controller does not Reset, a switch
may have failed. That switch must be immediately replaced.
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Appendix 2
SC22-3 Safety Controller
A2.3.3 Gate Switch (or Interlocked Guard) Connection Options
☛ All layouts are shown with the Gate Switch (guard) in the
Closed, or Open state. The safety contact is considered to
be the N.C. contact that is of a Positive-Opening design (un-
A2.3.3.3 Dual Channel, PNP
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating, installation, and the fault detection (e.g. short circuit) capabilities of the device(s). The SC22-3 Safety Controller does not provide short circuit
detection in this configuration.
less otherwise noted), normally marked with the
ON
ON
symbol.
A2.3.3.1 Single channel, 1 terminal - Single channel, 2 terminal
- Single channel, PNP switch
These circuits can typically meet ISO 13849-1 Category 2 requirements, depending on the design and installation of the switch. At a
minimum, the switch must be a safety-rated device to achieve a
Category 2 level. The Single channel, 1 terminal and the Single channel, PNP switch can not detect a short circuit to another source of
power. Single channel, 2 terminal connection uses pulse monitoring
and can detect a short circuit to another source of power. Fault Exclusion must be used to achieve a higher level of safety circuit integrity.
A2.3.3.4 Dual channel, 4 terminal
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements, depending on the design and installation of
the switch(es). This circuit can detect a short circuit between channels or to another source of power.
Two switches
individually mounted
on a single guard is
typically a Category 4
application. A series
connection of switches
on multiple guards is
typically a Category 3
application.
24V
A2.3.3.2 Dual channel, 2 terminals - Dual channel, 3 terminals
This circuit typically can meet ISO 13849-1 Category 2 or Category 3
requirements, depending on the design and installation of the
switch(es). Dual channel, 3 terminals connection uses pulse monitoring and can detect a short circuit to another source of power. Both
Dual channel, 2 terminals and Dual channel, 3 terminals connections
can detect a short between channels if the contacts are open longer
than 2 seconds.
24V
24V
A single switch
mounted on a single
guard is typically a
Category 2 application.
24V
Two switches
individually mounted
on a single guard is
typically a Category 3
application.
One switch mounted
on a single guard is
typically a Category 2
application.
A2.3.3.5 Complementary, 2 terminals - Complementary, 3 terminals
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the design and installation of
the switch(es). 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. In this situation, the Response Time could be longer than specified, based on the (selected) Debounce Time (see block 4.5 on
page 25).
24V
24V
A single coded magnetic switch mounted on a
single guard can meet Category 3, or
Category 4 depending on installation and the
frequency of exercising the guard (ClosedOpen-Closed).
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Appendix 2
A2.3.3.6 Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements, depending on the design and installation of
the switch(es). This circuit can detect a short circuit between channels. 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. In this situation, the Response Time could be
longer than specified, based on the (selected) Debounce Time (see
block 4.5 on page 25).
ON
OFF
A2.3.3.7 2X Complementary, 4 terminals - 2X Complementary,
5 terminals
This circuit can meet ISO 13849-1 Category 4 requirements, depending on the design and installation of the switches. 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. In this situation, the Response Time could be longer than specified, based on
the (selected) Debounce Time, (see block 4.5 on page 25).
24V
24V
A two-coded magnetic
switch mounted on a
single guard can meet
Category 4.
A2.3.3.8 2X Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 4 requirements depending on the design and installation of the device(s). This circuit can detect a short circuit between channels. 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. In this situation, the Response Time could be longer than specified, based on the
(selected) Debounce Time (see block 4.5 on page 25).
ON
OFF
ON
OFF
ON
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OFF
ON
OFF
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Appendix 2
SC22-3 Safety Controller
A2.4 OPTICAL SENSORS
The SC22-3 Safety Controller Safety Inputs Optical Sensor devices that use light as a means of detection.
A2.4.1 Safety Circuit Integrity Levels
Requirements vary widely for the level of Control Reliability or Safety
Category as per ISO 13849-1 (EN954-1) in the application of Optical
Safeguarding. While Banner Engineering always recommends the
highest level of safety in any application, it is the responsibility of the
user to safely install, operate and maintain each safety system and
comply with all manufacturer instructions and all relevant laws and
regulations.
The safety performance (integrity) must reduce the risk from identified hazards as determined by the machine’s Risk Assessment. See
appendix A2.1 for guidance if the requirements as described by
ISO 13849-1 (EN954-1) are to be implemented. In addition to the requirements stated in this appendix A2.4.1, the design and installation
of the Optical Safeguarding device should comply with IEC 61496 (all
parts).
A2.4.2 Requirements
! 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.
When used as Safeguarding, these devices are described by
IEC 61496-1/-2/-3 as Active Opto-Electronic Protective Device
(AOPD) and Active Opto-Electronic Protective Device Responsive to
Diffuse Reflection (AOPDDR).
AOPDs include Safety Light Screens and Safety Point & Grid Systems (multiple-/single-beam devices). These devices are described
as meeting Type 2 or Type 4 design requirements. A Type 2 device
is allowed to be used in a Category 2 application as per
ISO 13849-1 and a Type 4 device can be used in a Category 4 application. AOPDDRs can also be area or laser scanners. The primary
designation for these devices is a Type 3, for use in up to Category 3
applications.
Optical Safety Devices also must be placed at an appropriate Minimum Safety Distance, according to applicable standards.
The applicable standards should be referred to and also to Manufacturers documentation specific to the device for the appropriate calculations.
94
A2.4.3 Minimum Safety Distance
☛ The following information is only applicable to Œ certified
installations.
For the purpose of the Minimum Safety Distance calculation, the
Safety Controller default Response Time is 0,010 seconds, plus any
additional Closed-open debounce time. If the Debounce Time is adjusted, the time in excess of 6 ms (= default Closed-open debounce
time) must be added to the stated response (refer to Specifications,
block 3.2.1 on page 20). For quick access to a Controller’s specific
Response Times see also block 6.1.2.4 on page 54.
Calculation of Minimum Safety Distance takes into account several
factors, including a calculated human speed, the total system stopping time (which itself has several components), and the additional
distance based on the intrusion of the hand or object towards the
danger zone prior to actuation of the safety device.
As an example, the Minimum Safety Distance for Safety Light
Screens that are classified as Type 2 or Type 4 devices, can be calculated using the general formula as specified in ISO 13855 (EN 999)
and detailed as follows:
General Formula
S = K x T + C where:
S = Minimum Safety Distance in millimetres; from danger
zone to centre line of detection zone (see Detection
Zone on page 117). Minimum allowable safety distance
is 100 mm (175 mm for non-industrial applications) regardless of calculated value.
K = Recommended hand-speed constant (in mm) derived
from data on approach speeds of the body or parts of the
body as stated in ISO 13855
T = Overall response time of machine; that is, time between
physical initiation of safety device and machine coming
to a stop or risk being removed. This can be broken
down into two parts: Ts and Tr where T = Ts + Tr
Ts = Response Time of machine measured between application of stop signal from Safety Light Screen and machine
coming to a stop or risk being removed (including stop
times of all relevant control elements measured at maximum machine velocity, e.g. Interface Modules). Ts is
usually measured by a stop-time measuring device
☛ If the specified machine stop time is used, it is recommended
that at least 20% be added as a safety factor to account for
clutch/brake system deterioration.
Tr = Response Time of Safety Light Screen
C
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= Additional distance in millimetres, based on intrusion of
hand or object towards danger zone prior to actuation of
safety device. C is calculated using the formula as follows: C = 8 x(d-14) where d is the resolution of the device
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SC22-3 Safety Controller
Appendix 2
☛ This measurement must take into account the slower of the two
MPCE (see MPCE on page 117) channels, and response time of
all devices or controls (such as interface modules) that react to
stop machine. If all devices are not included, the calculated Minimum Safety Distance (S) will be too short and serious injury
could result.
User should consider all factors, including physical ability of operator, when determining value of K to be used.
Access to danger zone by reaching over or round the Safety
Light Screen(s) shall be prevented using values stated in
ISO 13852.
A2.4.4 Generic Connection
☛ In appendix A2.4.4 the optical sensor is shown actuated in
the N.O. or OFF state.
A2.4.4.1 Single channel, 1 terminal - Single channel, 2 terminal
- Single channel, PNP switch
These circuits can typically meet ISO 13849-1 Category 2 requirements, depending on the Safety Rating of the Input Device(s). At a
minimum, a safety-rated device must be used to achieve a
Category 2 level of safety. The Single channel, 1 terminal and the
Single channel, PNP switch can not detect a short circuit to another
source of power. Single channel, 2 terminal connection uses pulse
monitoring and can detect a short circuit to another source of power.
Fault Exclusion must be used to achieve higher level of
Safety Circuit Integrity.
A2.4.4.4 Complementary, 2 terminals - Complementary, 3 terminals
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Input Device. This circuit can detect a short circuit between channels. In the actuated condition (e.g. S1 Open /S2 Closed
below) a short across the closed contact can cause the Response
Time to increase based on the Debounce Time. In this situation, the
Response Time could be longer as specified, based on the (selected)
Debounce Time (see block 4.5 on page 25).
24V
A2.4.4.5 Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Input Device. This circuit can detect a short circuit between channels. In the actuated condition (e.g. S1 OFF / S2 ON
below) a short across the closed contact can cause the Response
Time to increase based on the Debounce Time. In this situation, the
Response Time could be longer as specified based on the (selected)
Debounce Time (see block 4.5 on page 25).
OFF
ON
OFF
24V
A2.4.4.2 Dual channel, 2 terminals - Dual channel, 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
Input Device(s). Dual channel, 3 terminals connection uses pulse
monitoring and can detect a short circuit to another source of power.
Both Dual channel, 2 terminals and Dual channel, 3 terminals connection can detect a short between channels when the contacts are
open if the short is present longer than 2 seconds.
24V
A2.4.4.3 Dual Channel, PNP
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements, depending on the Safety Rating, installation, and the fault detection (e.g. short circuit) capabilities of the Input
Device. The SC22-3 Safety Controller does not provide short circuit
detection in this configuration.
OFF
OFF
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Appendix 2
SC22-3 Safety Controller
A2.5 TWO-HAND CONTROL
! WARNINGS
POINT-OF-OPERATION GUARDING
WHEN PROPERLY INSTALLED, THE TWO-HAND CONTROL DEVICE PROVIDES PROTECTION ONLY FOR THE HANDS OF THE MACHINE OPERATOR. IT MAY BE NECESSARY TO INSTALL ADDITIONAL SAFEGUARDING, SUCH AS SAFETY LIGHT SCREENS
AND/OR FIXED GUARDS, TO PROTECT PERSONNEL FROM HAZARDOUS MACHINERY.
FAILURE TO PROPERLY GUARD HAZARDOUS MACHINERY CAN RESULT IN A DANGEROUS CONDITION WHICH COULD LEAD TO SERIOUS INJURY OR DEATH.
! CAUTIONS
HAND CONTROLS
THE ENVIRONMENT IN WHICH HAND CONTROLS ARE INSTALLED MUST NOT ADVERSELY AFFECT THE MEANS OF ACTUATION. SEVERE CONTAMINATION OR OTHER
ENVIRONMENTAL INFLUENCES MAY CAUSE SLOW RESPONSE OR FALSE ON CONDITIONS OF MECHANICAL OR ERGONOMIC BUTTONS. THIS MAY RESULT IN EXPOSURE
TO A HAZARD.
INSTALL HAND CONTROLS TO PREVENT ACCIDENTAL ACTUATION
TOTAL PROTECTION FROM DEFEAT OF THE TWO-HAND CONTROL SYSTEM IS NOT
POSSIBLE. HOWEVER, THE USER IS REQUIRED BY EUROPEAN REGULATIONS TO AR-
• 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. mounting
position, rings, guards or shields)
• Minimizing the possibility of defeat (e.g. hand controls must be far
enough apart so that they cannot be operated by the use of one
arm — typically, not less than 550 mm in a straight line, as per
ISO 13851
• The functional reliability and installation of external logic devices
• Proper electrical installation as per IEC 60204
When used in single-cycle or single-stroke mode, the machine control must provide an anti-repeat feature so that the operator must release the Two-Hand Control actuators after each machine cycle,
before a new cycle can be initiated. In addition to the anti-repeat of
the machine control, the SC22-3 Safety Controller input(s) can also
be used to halt a machine cycle and help in providing Anti-Repeat
Control (see Caution)
RANGE AND PROTECT HAND CONTROLS TO MINIMIZE POSSIBILITY OF DEFEAT OR
ACCIDENTAL ACTUATION.
MACHINE CONTROL MUST PROVIDE ANTI-REPEAT CONTROL
APPROPRIATE ANTI-REPEAT CONTROL MUST BE PROVIDED BY THE MACHINE CONTROL AND IS REQUIRED BY INTERNATIONAL STANDARDS FOR SINGLE-STROKE OR
SINGLE CYCLE MACHINES.
The SC22-3 Safety Controller may be used as an initiation device for most powered machinery when machine
cycling is controlled by a machine operator.
Using a Two-Hand Control system makes the operator, in effect, a
“hostage” while the hazard is present, thus limiting or preventing exposure to the hazard. The Two-Hand Control actuators must be located so that hazardous motion is completed or stopped before the
Operator can release one or both of the buttons and reach the hazard
(see appendix A2.5.1 Minimum Safety Distance).
The SC22-3 Safety Controller Safety Inputs used to monitor the actuation of the hand controls for Two-Hand Control comply with the
functionality of Type III requirements of IEC60204-1 and ISO 13851
for two-hand control, which include:
• Concurrent actuation by both hands within a 500 ms time frame
• Where this time limit is exceeded, both hand controls must be
released before operation is initiated
• Continuous actuation during hazardous condition
• Cessation of hazardous condition if either hand control was
released
• Release and re-actuation of both hand controls to re-initiate the
hazardous motion or condition (i.e. Anti-Tie Down)
• The appropriate performance level of the safety-related function
(e.g. Control Reliability, Category or SIL) as determined by a Risk
Assessment
The level of safety achieved (e.g. ISO 13849-1 Category) depend in
part on the circuit type selected. See appendix A2.5.2.
The installation of the hand controls must consider:
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Appendix 2
A2.5.1 Minimum Safety Distance
Example Minimum Safety Distance (S) Calculation
The following example illustrates the use of the formula to calcu-
! WARNING
late the Minimum Safety Distance:
LOCATION OF TOUCH BUTTON CONTROLS
HAND CONTROLS MUST BE MOUNTED A SAFE DISTANCE FROM MOVING MACHINE
PARTS. IT MUST NOT BE POSSIBLE FOR THE OPERATOR OR OTHER NON-COMPETENT
PERSONS TO RELOCATE THEM. FAILURE TO ESTABLISH AND MAINTAIN THE REQUIRED SAFETY DISTANCE COULD RESULT IN SERIOUS INJURY OR DEATH.
☛ The following information is only applicable to Œ certified
installations.
ISO 13855 – Safety of Machinery – The positioning of protective
equipment in respect of approach speeds of parts of the human body.
Both hand controls must be located far enough away from the nearest hazard point that the operator cannot reach the hazard with a
hand or other body part before the hazardous motion ceases. If no
appropriate Type C standard exists then the Minimum Safety Distance shall be calculated using the general formula.
General Formula
S = K x T + C where:
S is the minimum safety distance in millimetres, from the danger
zone to the detection point, line or plane;
K is a constant in millimetres per second, derived from data on approach speeds of the body or part of the body: K = 1600 mm per
second;
T is the overall response time in seconds;
C is an additional distance in millimetres, based on intrusion towards the danger zone prior to actuation; C = 250 mm.
Where machine specific European standards specify a different distance than the safety distance calculated using this standard then
the greater of the distances shall be used as the minimum safety
distance.
☛ Overall response time is the time between the physical initiation
of the safety device and the machine coming to a stop or the risk
being removed. The overall response time comprises a minimum
of two phases:
T = T1 + T2 where:
K = 1600 mm per second
T1 = 0,055 seconds
T2 = 0,50 seconds (measured by a stop-time measuring device)
C = 250 mm
S = K x T + C (where T = T1 + T2)
= 1600 x (0,055 + 0,50) + 250
= 1138 mm
In this example, both hand controls must be located no closer than
1138 mm from the nearest hazard point.
A2.5.2 Connection Options
☛ The device is shown Not Actuated or in the OFF state. See
ISO 13851 for a complete explanation of Type designations
and ISO 13849-1 Category requirements.
A2.5.2.1 Dual channel, 2 terminals - Dual channel, 3 terminals Dual channel, 4 terminal
The circuit layouts below are of 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. A Type IIIb and Category 3 can
be achieved if redundant contacts from each hand control are used
in each channel, i.e. two each in series, as shown in Layout D below,
or with a Dual channel, 3 terminals connection that uses pulse monitoring and can detect a short circuit to another source of power. Both
Dual channel, 2 terminals and Dual channel, 3 terminals connections
can detect a short between channels when the contacts are open if
the short is present longer than 2 seconds. The Dual channel, 4 terminal circuit can detect a short circuit between channels or to another
source of power (Layout C).
24V
A.
B.
T1 is the maximum response time of the safety device between the
physical initiation of the sensing function and the output signal
switching devices being in the OFF state.
The DUO-TOUCH with STB Buttons (AT-FM-10K Safety Module interfaced with STB Touch Buttons) has an output response time of
55 ms.
T2 is the response time of the machine, that is the time required to
stop the machine or remove the risk after receiving the output signal from the safety device.
24V
D.
C.
A2.5.2.2 Dual Channel, PNP
The layout below 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 SC22-3 Safety Controller does not
provide short circuit detection between channels in this configuration.
☛ If the risk from encroachment of the body or part of the body to-
OFF
OFF
wards the danger zone is eliminated while the device is being actuated, e.g. by adequate shielding, then C may be zero, with a
Minimum Safety Distance for S of 100 mm.
See example of Minimum Safety Distance calculation opposite.
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SC22-3 Safety Controller
A2.5.2.3 2X Complementary, 4 terminals - 2X Complementary,
5 terminals
The layout below is of a Type IIIc Two-Hand Control circuit as described by ISO 13851, and typically can meet ISO 13849-1
(EN 954-1) Category 4 requirements. In the actuated condition
(e.g. S1 Open / S2 Closed below) a short across the closed contact
can cause the Response Time to increase based on the Debounce
Time. In this situation, the Response Time could be longer as specified, based on the (selected) Debounce Time (see block 4.5 on
page 25).
☛ Select this option if using Banner Self-Checking Touch Button
models STBVR81…
24V
A2.5.2.4 2X Complementary, PNP switch
The layout below is a Type IIIc Two-Hand Control circuit as described
by ISO 13851 and typically can meet ISO 13849-1 (EN 954-1)
Category 4 requirements. In the actuated condition (e.g. S1 Open /
S2 Closed below), a short across the closed contact can 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 block 4.5 on page 25).
☛ Select this option if using Banner Self-Checking Touch Buttons
models STBVP6…
OFF
98
ON
OFF
ON
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Appendix 2
A2.6 SAFETY MATS (SAFETY EDGES)
A2.6.1.1 Safety Mat System Design & 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
Safety Mat’s sensing surface (less than 100 ms to 200 ms, depending
on the relevant standard).
! WARNING
APPLICATION OF SAFETY MATS
REQUIREMENTS VARY WIDELY FOR THE LEVEL OF CONTROL RELIABILITY OR
ISO 13849-1 (EN954-1) CATEGORY IN THE APPLICATION OF SAFETY MATS. IT IS
THE RESPONSIBILITY OF THE USER TO SAFELY INSTALL, OPERATE, AND MAINTAIN
EACH SAFETY MAT (OR SAFETY EDGE) SYSTEM PER THE MANUFACTURER’S RECOMMENDATIONS AND COMPLY WITH ALL RELEVANT LAWS AND REGULATIONS.
DO NOT USE A SAFETY MAT 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 CERTAIN FAILURES (E.G. LOSS OF POWER TO THE
CONTROLLER) CAN RESULT IN A ‘FALSE’ ENABLE SIGNAL.
The SC22-3 Safety Controller may be used to monitor pressure-sensitive Safety Mats and Safety Edges (sensors).
The purpose of the Safety Mat input of the Safety Controller is to verify the proper operation of 4-wire Presence-Sensing Safety Mats
(sensors). Multiple Safety Mats may be switched in series to one
Controller (see appendix A2.6.2).
☛ The Controller is not designed to monitor 2-wire mats, bumpers,
or edges (with or without sensing resistors).
The function is to monitor the contacts (Contact Plates) and the wiring
of one or more Safety Mat(s) for failures and prevent the machine
from restarting if a failure is detected. A Reset routine after the operator steps off the Safety Mat can be provided by the Safety Controller,
or, if the Controller is used in Automatic Reset mode, the Reset/Restart function must be provided by the machine control system. This
prevents the controlled machinery from restarting automatically after
the Safety Mat is cleared.
A2.6.1 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 information contained in ISO 13856-1. The user must review all relevant applicable regulations and standards and must ensure that the
Controller and any associated sensors are in full compliance.
INSTRUCTION MANUAL - EUROPEAN VERSION
For a Safety Mat system, the minimum object sensitivity of the sensor
must detect, at minimum, a 30 kg weight on an 80 mm diameter circular disk test piece, anywhere on the Safety 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 permitted (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; i.e. the effects on the sensor
of liquids and other substance contamination which could be expected, must be taken into account (e.g. 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 of a lifetime non-slip design, or
alternatively, the possibility of not meeting the expected operating
conditions should be minimised.
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.
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A2.6.2 Connection Options
Pressure-Sensitive Safety 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 relevant
requirements of ISO 13849-1(EN 954-1).
The SC22-3 Safety Controller is designed to monitor 4-wire Safety
Mats but is not compatible with two-wire devices (mats, sensing edges, etc., with two wires and a ‘sensing’ resistor).
This circuit typically can meet ISO 13849-1 Category 2 or Category 3
requirements depending on the Safety Rating and installation of the
Safety Mat(s) or other sensor(s). This circuit can detect a short circuit
between channels or to another source of power.
Each sensor must be installed to minimize tripping hazards (particularly towards the machine hazard). A tripping hazard may exist when
the difference in height of an adjacent horizontal surface is 4 mm or
more. Tripping hazards must be minimized at joints, junctions and
edges, and when additional coverings are used. Methods include a
ground-flush (recessed in floor so it is flush with surrounding floor area) installation of the sensor, or a ramp that does not exceed 20°
from horizontal. Use contrasting colours or markings to identify
ramps and edges.
The Safety Mat system must be sized and positioned so that persons
cannot enter the hazardous area without being detected and can not
reach the hazard before the hazardous conditions have ceased. Additional guards or Safeguarding Devices may be required to ensure
that exposure to the hazard(s) is not possible by reaching over, under
or around the device’s sensing surface.
A Safety Mat installation must take into account the possibility of easily stepping over the sensing surface and not being detected. International standards require a minimum depth of field of the sensor
surface (the smallest distance between the edge of the mat and hazard) to be from 750 mm to 1200 mm, depending on the application
and the relevant standard. The possibility of stepping on machine
supports or other physical objects to bypass or climb over the sensor
also must be prevented.
A2.6.3 Installation
The mounting surface quality and preparation for the sensor must
meet the requirements stated by the sensor’s manufacturer. Irregularities in the floor (or other mounting surfaces) may impair the function of the sensor and therefore should be reduced to an acceptable
minimum.
The mounting surface should be level and clean. The collection of fluids under or around the sensor should be avoided. The risk of failure
due to build-up of dirt, turning-chips, or other material under the sensor(s) or the associated hardware must be prevented. Special consideration should be given to joints between sensors to ensure that
foreign material does not migrate under or into the sensor.
Any damage (e.g. cuts, tears, wear, or punctures) to the outer insulating jacket of the interconnect cable (in the presence of fluids) or to
any part of the exterior of the sensor must be immediately repaired or
replaced. Ingress of material (including dirt particles, insects, fluid,
moisture or machine waste metal turnings) which may be present
near the Safety Mat can cause the sensor to corrode or to lose its
sensitivity.
Each sensor must be routinely inspected and tested per the manufacturer’s recommendations. Care must be taken not to exceed operational specifications (e.g. the maximum number of switching
operations).
Each sensor must be securely mounted to prevent inadvertent movement (creeping) or unauthorized removal. Methods include, but are
not limited to, secured edging or trim, tamper-resistant or one-way
fasteners, and recessed flooring or mounting surface, in addition to
the size and weight of large mats.
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Appendix 2
A2.6.4 Minimum Safety Distance
☛ The following information is only applicable to Œ certified
installations.
As a stand-alone safeguard, the sensor must be installed at the Minimum Safety Distance so that the exterior edge of the sensing surface
is at or beyond the safety distance, unless solely used to prevent
start/restart or solely used for a clearance Safeguarding Device.
If an individual can cross completely over the sensor and no longer
be detected, supplementary Safeguarding Devices or other means
should be used to prevent unexpected start-up and exposure to a
hazard. At a minimum, the Safety Mat system (or the machine control) must be manually Reset and requires re-initiation of the normal
actuating means prior to the start or re-start of the machine cycle.
The Minimum Safety Distance required for an application depends
upon several factors, including the speed of the hand (or individual),
the total System Stopping Time (which includes several response
time components) and the Depth Penetration Factor. The user must
refer to the relevant standard to determine the appropriate distance
or means to ensure that individuals can not be exposed to the hazard(s).
The Minimum Safety Distance calculated is the minimum horizontal
distance from the outer edge of the Safety Mat sensor mat detection
zone to the closest part of the hazard. The general formula for ground
level mounted Safety Mats is as specified in ISO 13855 (EN 999).
General Formula
S = [1600 x (t1 + t2)] + (1200 – 0,4H)
S is the Minimum Safety Distance in mm in a horizontal plane
from the Danger Zone to the detecting edge of the device furthest
from the Danger Zone
1600 is a minimum speed constant based on the movement of the
hand/arm only and the body being stationary
1600 mm/s
t1 is the maximum time between the actuation of the sensing function and the output signal switching devices being in the OFF state
t2 is the maximum Response Time of the machine, i.e. the time
required to stop the machine or remove the risks after receiving the
output signal from the protective equipment
1200 is the depth penetration factor which is the maximum travel
towards the hazard within the Safety Mat area that may occur before a stop is signalled
1200 mm
H is the distance above the reference plane, e.g. floor, in millimetres
S
1600(t1 + t2)
(1200 – 0,4H)
Hazardous
Zone or
Area
Safety Mat
Figure 39 Determining Minimum Safety Distance (S) for the Safety Mat
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SC22-3 Safety Controller
A2.7 E-STOPS
A2.7.2 Requirements
! WARNINGS
E-STOP FUNCTIONS
DO NOT MUTE OR BYPASS ANY E-STOP DEVICE. IEC 60204-1 REQUIRE THAT THE
E-STOP FUNCTION REMAIN ACTIVE AT ALL TIMES. MUTING OR BYPASSING THE
SAFETY OUTPUTS WILL RENDER THE EMERGENCY STOP FUNCTION INEFFECTIVE.
THE SC22-3 SAFETY CONTROLLER E-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.
RESET ROUTINE REQUIRED
INTERNATIONAL STANDARDS REQUIRE THAT A RESET ROUTINE BE PERFORMED AFTER RETURNING THE E-STOP SWITCH TO ITS CLOSED-CONTACT POSITION (WHEN
ARMING THE E-STOP SWITCH). WHEN AUTOMATIC RESET IS USED, AN ALTERNATE
MEANS MUST BE ESTABLISHED TO REQUIRE A RESET ROUTINE, AFTER THE E-STOP
SWITCH IS ARMED. ALLOWING THE MACHINE TO RESTART AS SOON AS THE E-STOP
SWITCH IS ARMED CREATES AN UNSAFE CONDITION WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.
The SC22-3 Safety Controller safety Inputs may be used to
monitor E-Stop push buttons.
A2.7.1 Safety Circuit Integrity Levels
Requirements vary widely for the level of Control Reliability or Safety
Category as per ISO 13849-1 (EN954-1) in the application of
E-Stops. While Banner Engineering always recommends the highest
level of safety in any application, it is the responsibility of the user to
safely install, operate and maintain each safety system and comply
with all manufacturer instructions and all relevant laws and regulations.
The E-Stop switch must provide one or two contacts for safety which
are closed when the switch is armed as shown in figure 36, figure 37
and figure 38. Once activated, the E-Stop switch must open all its
safety-rated contacts, and must require a deliberate action (such as
twisting, pulling, or unlocking) to return to the closed-contact, armed
position. The switch must be a Positive-Opening (or Direct-Opening)
type, as described by IEC 60947-5-1. A mechanical force applied to
such a button (or switch) is transmitted directly to the contacts, forcing them open. This ensures that the switch contacts will open whenever the switch is activated.
Standards IEC 60204-1 and ISO 13850 specify additional E-Stop
switch device requirements which include the following:
• E-Stop push buttons shall be located at each operator control station and at other operating stations where emergency shutdown is
required
• Stop and E-Stop push buttons shall be continuously operable and
readily accessible from all control and operating stations where
located. Do not mute or bypass E-Stop buttons
• Actuators of E-Stop devices shall be coloured red. The background immediately around the device actuator shall be coloured
yellow. The actuator of a push-button-operated device shall be of
the palm or mushroom-head type
• The E-Stop actuator shall be a self-latching type
☛ Some applications may have additional requirements. The user
must comply with all relevant regulations.
The safety performance (integrity) must reduce the risk from identified hazards as determined by the machine’s Risk Assessment. See
appendix A2.1 for guidance if the requirements as described by
ISO 13849-1 (EN954-1) are to be implemented.
In addition to the requirements stated in this appendix A2.7.1, the design and installation of the E-Stop device should comply with ISO
13850.
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Appendix 2
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 catastrophic
failures that could result in the loss of the safety function.
A2.7.2.1 Safety Circuit Integrity Levels & Multiple E-Stop
Buttons
! WARNINGS
A2.7.2.4 Category 4
MULTIPLE E-STOP SWITCHES
WHENEVER TWO OR MORE E-STOP SWITCHES ARE CONNECTED TO THE SAME CONTROLLER:
• CONTACTS OF THE CORRESPONDING POLE OF EACH SWITCH MUST BE CONNECTED TOGETHER IN SERIES. NEVER CONNECT THE CONTACTS OF MULTIPLE
E-STOP SWITCHES IN PARALLEL TO ONE CONTROLLER. SUCH A PARALLEL
The self-monitoring Safety Inputs can be interfaced to achieve a
Category 4 application. 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
catastrophic failures or faults that could result in the loss of the safety
function. For circuit diagram refer to figure 38 on page 86.
CONNECTION DEFEATS THE SWITCH CONTACT MONITORING ABILITY OF THE
CONTROLLER AND CREATES AN UNSAFE CONDITION WHICH COULD RESULT IN
SERIOUS INJURY OR DEATH
• EACH SWITCH MUST BE INDIVIDUALLY ACTUATED (ENGAGED), THEN RE-ARMED
AND THE CONTROLLER RESET. THIS ALLOWS THE CONTROLLER TO CHECK
EACH SWITCH AND ITS WIRING TO DETECT FAULTS
FAILURE TO TEST EACH SWITCH INDIVIDUALLY IN THIS MANNER COULD RESULT IN
UNDETECTED FAULTS AND CREATE AN UNSAFE CONDITION WHICH COULD RESULT
IN SERIOUS INJURY OR DEATH. THIS CHECK MUST BE PERFORMED DURING PERIODIC
CHECK-OUTS.
As part of the required Risk Assessment for the machine, IEC 602041 states that the safety performance (integrity) must reduce the risk
from identified hazards as determined by the Risk Assessment. See
appendix A2.1 on page 87 for guidance if the requirements as described by ISO 13849-1 (EN954-1) are to be implemented.
In addition to the requirements stated above, the design and the installation of the E-Stop device (e.g. switch, button or Rope Pull) must
be such that the possibility of a catastrophic failure of the device resulting in the loss of the safety function must be excluded (designed
out). The device must comply with ISO 13850 requirements such that
the fault exclusions of ISO 13849-2 are applicable. Electromechanical devices that have contacts designed in accordance to
IEC 60947-5-1 Annex K and that are installed per manufacturer’s instructions are expected to open when the E-Stop device is actuated.
A2.7.2.2 Category 2
A Single channel E-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. For circuit diagram refer to figure 36 on page 86.
A2.7.2.3 Category 3
A Dual channel connection 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 the E-Stop button, the opening of the second
channel, and the monitoring function of the Safety Inputs. However,
a short circuit between input channels or Safety Outputs may not be
detected. It should be noted that an accumulation of faults may cause
the loss of the safety function. For circuit diagram refer to figure 37 on
page 86.
INSTRUCTION MANUAL - EUROPEAN VERSION
A2.7.3 Connection Options
☛ The device is shown in the Armed or Run state.
A2.7.3.1 Single channel, 1 terminal - Single channel, 2 terminal
- Single channel, PNP switch
These circuits can typically meet ISO 13849-1 Category 2 requirements, depending on the design and installation of the switch. At a
minimum, the switch must be a safety-rated device in order to
achieve Category 2. The Single channel, 1 terminal and the Single
channel, PNP switch can not detect a short circuit to another source
of power. Single channel, 2 terminal connection uses pulse monitoring and can detect a short circuit to another source of power. Fault
Exclusion must be used to achieve higher level of Safety Circuit Integrity.
24V
A2.7.3.2 Dual channel, 2 terminals - Dual channel, 3 terminals
This circuit typically can meets ISO 13849-1 Category 3 requirements, depending on the design and installation of the switch. Dual
channel, 3 terminals connection uses pulse monitoring and can detect a short circuit to another source of power. Both Dual channel, 2
terminals and Dual channel, 3 terminals connection can detect a
short between channels when the contacts are open if the short is
present longer than 2 seconds.
24V
A2.7.3.3 Dual Channel, PNP
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements, depending on the Safety Rating, installation, and the fault detection (e.g. short circuit) capabilities of the
switch. The SC22-3 Safety Controller does not provide short circuit
detection in this configuration.
ON
ON
A2.7.3.4 Dual channel, 4 terminal
This circuit can meet ISO 13849-1 Category 4 requirements, depending on the design and installation of the switch. This circuit can detect a short
circuit between channels or to another source of
power.
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A2.8 ROPE PULLS (CABLE)
Rope Pull (Cable Pull) E-Stop switches use steel wire
rope and provide emergency stop actuation continuously
over a distance, such as along a conveyor.
Rope Pull E-Stop switches have many of the same requirements as
E-Stop push buttons, such as Positive-Opening (or Direct-Opening)
operation, as described by IEC 60947-5-1. See appendix A2.7 on
page 102 on E-Stop push buttons for additional applicable information.
It is recommended to use Rope Pull E-Stop switches that have the
capability not only to react to a pull in any direction, but also to slack
or a break of the rope. Typically, this is accomplished by separate
contacts within the switch. When the rope is properly tensioned, both
contacts of the switch are closed. When the rope is pulled, the Positive-Break contacts open. If the rope breaks or goes slack, the second set of contacts opens. See appendix A2.8.2 on page 104 for
connection options.
Some Rope Pull E-Stop switches provide a latching function that requires a Manual Reset after actuation. If using a switch that does not
provide a Latch function after the rope is released, a separate Latch
circuit is required, which can be provided by the SC22-3 Safety Controller.
A2.8.2 Connection Options
☛ The device is shown in the Armed or Run state.
A2.8.2.1 Single channel, 1 terminal - Single channel, 2 terminal
- Single channel, PNP switch
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 Single channel, 1 terminal and the Single channel, PNP
switch can not detect a short circuit to another source of power. Single channel, 2 terminal connection uses pulse monitoring and can detect a short circuit to another source of power. Fault Exclusion must
be used to achieve higher level of Safety Circuit Integrity.
24V
A2.8.2.2 Dual channel, 2 terminals - Dual channel, 3 terminals
This circuit typically can meet ISO 13849-1 Category 3 requirements,
depending on the Safety Rating and installation of the Output Device(s). Dual channel, 3 terminals connection uses pulse monitoring
and can detect a short circuit to another source of power. Both Dual
channel, 2 terminals and Dual channel, 3 terminals connection can
detect a short between channels when the contacts are open if the
short is present longer than 2 seconds.
A2.8.1 Installation Guidelines
24V
When installing Rope Pull E-Stop switches observe the following
guidelines:
• The wire rope should be easily accessible and visible along its
entire length. Markers or flags may be fixed on the rope to
increase its visibility
• Mounting points, including support points, must be rigid
• The rope should be free of friction at all supports. Pulleys are recommended
• Use pulleys when routing the rope around a corner, or whenever
direction is changed, even slightly
• Never run rope through conduit or other tubing
• Never attach weights to the rope
• Temperature affects rope tension. The rope expands (lengthens)
when temperature increases, and contracts (shrinks) when temperature decreases. Significant temperature variations require frequent checks of the tension adjustment
• Do not exceed the manufacturer’s recommended maximum rope
length
• Mount the switch securely on a solid, stationary surface
• The anchor point for rope must be solid and stationary, and be
able to withstand the constant tension of the rope
A2.8.2.3 Dual Channel, PNP
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements, depending on the Safety Rating, installation, and the fault detection (e.g. short circuit) capabilities of the Output Device. The SC22-3 Safety Controller does not provide short
circuit detection in this configuration.
ON
ON
A2.8.2.4 Dual channel, 4 terminal
This circuit can meet ISO 13849-1 Category 4 requirements, depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit between channels or to
another source of power.
O
• Each Rope Pull E-Stop installation should be tested and inspected
for proper operation at suitable intervals as determined by the
user’s risk assessment, based upon severity of the operating environment and the frequency of switch actuations
• Pulleys and other moving parts associated with the rope should be
periodically lubricated
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A2.8.2.5 Complementary, 2 terminals - Complementary, 3 terminals
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit
between channels. In the actuated condition (e.g. S1 Closed /S2
Open below) a short across the closed contact can 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 block 4.5 on page 25).
24V
A2.8.2.6 Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit
between channels. In the actuated condition (e.g. S1 ON /S2 OFF below) a short across the closed contact can 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 block 4.5 on page 25).
ON
OFF
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A2.9 ENABLING DEVICE (PENDANTS)
If more than one individual is to be safeguarded by the use of Ena-
An Enabling Device is a manually operated control that, when
continuously actuated, allows a machine cycle to be initiated
in conjunction with a start control. Standards that cover the design
and application of Enabling Devices include:
bling Devices, each individual must have their own device. Each En-
ISO 12100-1/-2
IEC 60204-1
A2.9.1 Installation Guidelines
Depending on the application, the use of the Enabling Device may require supervision and allow only limited machine operation when the
individual actuating the device is exposed to a hazardous situation.
When the Enabling Device is in use, the control of machine motion
must be prevented from other sources that would override the function of the Enabling Device. Simply actuating the Enabling Device
should not create a hazard.
An Enabling Device allows a hazardous situation when continuously
actuated in one position only. In any other position, the hazard must
be eliminated and the start function be inhibited.
Since an individual’s reaction to an emergency situation may be either to release or to tighten the grip, many standards require the use
of three-position devices:
• Position 1 - The OFF function of the switch (actuator is not operated)
• Position 2 - The enabling function (actuator is operated in its midpoint)
• Position 3 - The OFF function of the switch (actuator is operated
past its midpoint)
Release of, or compression past, the midpoint-enabled position
(position 2) of the Enabling Device must initiate an immediate stop-
abling Device must be concurrently operated before machine motion
can be initiated.
The means to return the machine to production mode must be located outside the hazardous area, where it can not be reached from
within that area and is guarded against unintended operation. In addition, the Reset switch operator must have full view of the entire
guarded area and verify that the area is clear of individuals during the
Reset procedure.
A2.9.2 Connection Options
☛ The device is shown in the Actuated Position or Stop state.
A2.9.2.1 Dual channel, 2 terminals - Dual channel, 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
Enabling Device(s). Dual channel, 3 terminals connection uses pulse
monitoring and can detect a short circuit to another source of power.
Both Dual channel, 2 terminals and Dual channel, 3 terminals connection can detect a short between channels when the contacts are
open if the short is present longer than 2 seconds.
24V
A2.9.2.2 Dual Channel, PNP
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating, installation, and the fault detection (e.g. short circuit) capabilities of the Enabling Device. The SC22-3 Safety Controller does not provide short
circuit detection in this configuration.
2 PNP
OFF
OFF
ping of hazardous motion or situations. It is required that the Enabling
Device be released and re-actuated before machine motion can be
re-initiated.
If allowed, for two-position types, the positions are as follows:
• Position 1 - The OFF function of the switch (actuator is not operated)
• Position 2 - The enabling function (actuator is operated)
The stop function must be either a functional stop Category 0 or a
Category 1. The design and installation of the Enabling Device must
consider the ergonomic issues (force, posture, etc.) of sustained activation. A visual means of indicating that the device is active may be
required.
A2.9.2.3 Dual channel, 4 terminal
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements, depending on the Safety Rating and the installation of the enabling device. This circuit can detect a short circuit
between channels or to another source of power.
☛ Only trained and qualified individuals (see block 1.8.2 on
page 4) are allowed to operate the Enabling Device if it is bypassing other safeguards.
Safe work procedures must include, but are not limited to, the use of
the Enabling Device, the associated hazards, and the task requiring
the use of the Enabling Device.
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A2.9.2.4 Complementary, 2 terminals - Complementary, 3 terminals
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit
between channels. In the actuated condition (e.g. S1 Open / S2
Closed) a short across the closed contact can cause the Response
Time to increase based on the Debounce Time. In this situation, the
Response Time could be longer as specified, based on the (selected)
Debounce Time (see block 4.5 on page 25).
24V
A2.9.2.5 Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Output 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. In this situation, the Response Time could be longer as specified, based on the (selected)
Debounce Time (see block 4.5 on page 25).
OFF
ON
A2.9.2.6 2X Complementary, 4 terminals - 2X Complementary,
5 terminals
This circuit can meet ISO 13849-1 Category 3 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
guard closed condition (e.g. S1 Open / S2 Closed) a short across the
closed contact can 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
block 4.5 on page 25).
24V
A2.9.2.7 2X Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 3 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. In this situation, the Response Time could be longer
than specified, based on the (selected) Debounce Time (see
block 4.5 on page 25).
OFF
ON
S1
S2
OFF
ON
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SC22-3 Safety Controller
A2.10 BYPASS SWITCH (BYPASSING
SAFEGUARDS)
A2.10.1.1 Safe Working Procedures and Training
The SC22-3 Safety Controller may be used to monitor
switches that initiate the Bypassing of a Safeguarding
Device.
Bypassing or Overriding a Safeguarding Device is the manual interruption or suspension of the normal function of a Safeguard under supervisory control. It is typically accomplished by selecting a bypass
mode of operation using a key switch to facilitate machine setup, web
alignment/adjustments, robot teach, and process troubleshooting.
A2.10.1 Requirements
Requirements to bypass a Safeguarding Device includes*:
• The bypass function must be temporary
• The means of selecting or enabling the bypass must be capable of
being supervised
• Automatic machine operation must be prevented by limiting range
of motion, speed, or power (e.g., only used in inch, jog, or slowspeed modes). Bypass mode must not be used for production
• Supplementary Safeguarding must be provided. Personnel must
not be exposed to hazards
• The means of bypassing must be within full view of the safeguard
to be bypassed
• Initiation of motion should only be through a hold-to-run type of
control
• All E-Stops must remain active
• The means of bypassing must be employed at the same level of
reliability as the safeguard
• Visual indication that the Safeguarding Device has been bypassed
must be provided and be readily observable from the location of
the safeguard
• Personnel must be trained in the use of the safeguard and in the
use of the bypass
• Risk assessment and risk reduction (per the relevant standard)
must be accomplished
• The Reset, actuation, clearing, or enabling of the Safeguarding
Device must not initiate hazardous motion or create a hazardous
situation
* This summary was derived from the following and other sources:
ISO 13849-1 (EN954-1) and IEC60204-1
Bypassing a Safeguarding Device should not be confused with Muting which is the temporary, automatic suspension of the Safeguarding function of a Safeguarding Device during a non-hazardous
portion of the machine cycle. Muting allows for material to be manually or automatically fed into a machine or process without issuing a
stop command. Another term commonly confused with bypassing is
Blanking, which desensitizes a portion of the sensing field of an Optical Safety Device (e.g. disabling one or more beams of a Safety
Light Screen so that a specific beam break is ignored).
The user must also address the possibility that an individual could bypass the Safeguarding device and then either fail to reinstate the
Safeguarding or fail to notify other personnel of the bypassed condition of the Safeguarding device; both cases could result in an unsafe
condition. One possible method to prevent this is to develop a safe
work procedure and ensure personnel are trained and correctly follow the procedure.
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.
A2.10.1.2 Lockout/Tagout
☛ There is no specific European Standard covering Lockout/Tagout. This subject is covered in US standards
OSHA 29CFR1910.147 “The control of hazardous energy (Lockout/Tagout)” or ANSI 2244.1 “Lockout/Tagout of Energy
Sources”
The intention is to prevent machine operation when the machine is
temporarily down or being repaired. Inadvertent start-ups have
caused injuries and deaths. This approach ensures that power is cut
to a machine by physically locking the power switch in the OFF position. In addition, a tag is added to the switch that identifies the process underway and the personnel involved.
If Lockout/Tagout is to be implemented for machine maintenance and
servicing situations in which the unexpected energisation, start up, or
release of stored energy could cause injury, the above quoted standard(s) must be adhered to. The user must refer to these standard(s)
to ensure that bypassing a Safeguarding Device does not conflict
with the requirements that are contained within these standard(s).
A2.10.2 Connection Options
☛ The device(s) is shown not actuated or in the OFF state.
A2.10.2.1 Dual channel, 2 terminals - Dual channel, 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
Bypass Switch(es). Dual channel, 3 terminals connection uses pulse
monitoring and can detect a short circuit to another source of power.
Both Dual channel, 2 terminals and Dual channel, 3 terminals connection can detect a short between channels when the contacts are
open if the short is present longer than 2 seconds.
24V
A2.10.2.2 Dual Channel, PNP
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating, installation, and the fault detection (e.g. short circuit) capabilities of the Bypass Switch(es). The SC22-3 Safety Controller does not provide
short circuit detection in this configuration.
2 PNP
OFF
OFF
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A2.10.2.3 Dual channel, 4 terminal
A2.10.2.7 2X Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Bypass Switch(es). This circuit can detect a short circuit between channels or to another source of power.
This circuit can meet ISO 13849-1 Category 4 requirements depending on the design and installation of the Bypass Switch(es). 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. In this situation, the Response Time could be longer than specified, based on the (selected) Debounce Time (see block 4.5 on
page 25).
A2.10.2.4 Complementary, 2 terminals - Complementary, 3 terminals
OFF
ON
OFF
ON
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Bypass Switch(es). This circuit can detect a short circuit between channels. In the actuated condition (e.g., S1 Open /S2
Closed, as shown below) a short across the closed contact can cause
the Response Time to increase based on the Debounce Time. In this
situation, the Response Time could be longer as specified, based on
the (selected) Debounce Time (see block 4.5 on page 25).
24V
A2.10.2.5 Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Bypass Switch(es). 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. In this situation, the Response Time could be longer as specified, based on the (selected)
Debounce Time (see block 4.5 on page 25).
OFF
ON
A2.10.2.6 2X Complementary, 4 terminals - 2X Complementary,
5 terminals
This circuit can meet ISO 13849-1 Category 4 requirements depending on the design and installation of the Bypass Switch(es). This circuit can detect a short circuit between channels. In the guard closed
condition (e.g. S1 Open / S2 Closed) a short across the closed contact can 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
block 4.5 on page 25).
24V
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SC22-3 Safety Controller
A2.11 MUTE SENSOR (PAIR)
A2.11.2 Requirements
A2.11.1 Muting Function
! WARNINGS
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 AS PER ISO 13855.
MUTE INPUTS MUST BE REDUNDANT
IT IS NOT ACCEPTABLE TO USE A SINGLE SWITCH, DEVICE, OR RELAY WITH TWO
N.O. CONTACTS FOR THE MUTE INPUTS. THIS SINGLE DEVICE, WITH MULTIPLE OUTPUTS, MAY FAIL SO THAT THE SYSTEM IS MUTED AT AN INAPPROPRIATE TIME. THIS
MAY RESULT IN A HAZARDOUS SITUATION.
The user is required to arrange, install, and operate the
safety system so as to protect personnel and minimize the
possibility of defeating the safeguard.
To mute the primary safeguard appropriately, the design of a Muting
System must:
• Identify the non-hazardous portion of the machine cycle
• Involve the selection of the proper Mute Devices
• Include proper mounting and installation of those devices
The SC22-3 Safety Controller can monitor and respond to redundant
signals that initiate the mute. The mute then suspends the Safeguarding function by ignoring the state of the Input Device that the
muting function has been assigned to; e.g. this allows an object or
person to pass through the defined area of a Safety Light Screen
without generating a stop command (this should not be confused with
Blanking, which disables one or more beams in a Safety Light
Screen, resulting in larger resolution).
The mute may be triggered by a variety of external devices. This feature provides a variety of options (see appendix A2.11.2 on
page 110) to tailor the System to the requirements of a specific application.
A pair of Mute Devices must be triggered simultaneously (within
3 seconds of one another). This reduces the chance of common
mode failures or defeat.
110
The beginning and end of a Mute Cycle must be triggered by Outputs
from either pair of Mute Devices, depending on the application. The
Mute Device pairs both must have N.O. contacts, or have PNP Outputs, both of which fulfil the Mute Device requirements, described below. These contacts must Close (Conduct) when the switch is
actuated to initiate the mute, and must Open (Non-Conducting) when
the switch is not actuated and in a power OFF condition.
The Controller monitors the Mute Devices to verify that their Outputs
turn ON within 3 seconds of each other. If the Inputs do not meet this
Simultaneity requirement, a mute condition can not occur.
Several types and combinations of Mute Devices can be used, including, but not limited to:
• Limit Switches
• Photoelectric Sensors
• Positive-Opening Safety Switches
• Inductive Proximity Sensors
• Whisker Switches
See appendix A2.11.2.1 on page 110 for further information.
A2.11.2.1 General
The Mute Devices (typically sensors or switches) must, at a minimum, comply with the following requirements:
• There must be a minimum of two independent hard-wired Mute
Devices
• The Mute Devices must either both have N.O. contacts, PNP Outputs (both of which must fulfil the input requirements listed in the
specifications (block 3.2.1 on page 20)) or Complementary
Switching action. At least one of these contacts must Close when
the switch is actuated, and must Open (or Non-Conducting) when
the switch is not actuated or in a power OFF condition
• The activation of the Inputs to the muting function must be from
separate sources. These sources must be mounted separately in
order to prevent an unsafe muting condition resulting from misadjustment, misalignment, or a single common mode failure
(e.g. physical damage to the mounting surface could cause both
Mute Devices to be knocked out of alignment, resulting in false
muting input signals). Only one of these sources may pass
through, or be affected by, a programmable logic controller or similar device
• The Mute Devices must be installed so that they can not be easily
defeated or bypassed
• The Mute Devices must be mounted so that their physical position
and alignment can not be easily changed
• It must not be possible for environmental conditions to initiate a
mute condition (e.g. extreme airborne contamination)
• The Mute Devices must not be set to use any delay or other timing
functions unless:
- such functions are accomplished so that no single component
failure prevents the removal of the hazard
- subsequent machine cycles are prevented until the failure is
corrected and
- no hazard is created by extending the muted period)
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Appendix 2
A2.11.3 Connection Options
A2.11.2.2 Examples of Muting Sensors and Switches
! WARNINGS
AVOID HAZARDOUS INSTALLATIONS
TWO OR FOUR INDEPENDENT POSITION SWITCHES (AT M1–M2 OR M3–M4) MUST
BE PROPERLY ADJUSTED OR POSITIONED SO THAT THEY CLOSE ONLY AFTER THE
HAZARD NO LONGER EXISTS, AND OPEN AGAIN WHEN THE CYCLE IS COMPLETE OR
THE HAZARD IS AGAIN PRESENT. IF IMPROPERLY ADJUSTED OR POSITIONED, INJURY
OR DEATH COULD RESULT.
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.
Photoelectric Sensors (Opposed Mode)
Opposed Mode sensors, which initiate the muted condition when the
beam path is blocked, should be configured for Dark Operate (DO)
and have Open (Non-Conducting) output contacts in a power OFF
condition. Both the Emitter and Receiver from each pair should be
powered from the same source to reduce the possibility of common
mode failures.
Photoelectric Sensors (Polarized Retroreflective Mode)
The user must ensure that False Proxing (activation due to shiny or
reflective surfaces) is not possible. Banner LP sensors with Linear
Polarization can greatly reduce or eliminate this effect.
Use a sensor configured for Light Operate (LO or N.O.) if initiating a
mute when the retro reflective target or tape is detected (e.g. Home
Position). Use a sensor configured for Dark Operate (DO or N.C.)
when a blocked beam path initiates the muted condition (e.g. entry/
exit). Both situations must have open (Non-Conducting) output contacts in a power OFF condition.
Positive-Opening Safety Switches
Two (or four) independent switches, each with a minimum of one
Closed safety contact to initiate the mute cycle, are typically used. An
application using a single switch with a single actuator and two
Closed contacts could result in an unsafe situation.
Inductive Proximity Sensors
Typically, Inductive Proximity Sensors are used to initiate a Mute Cycle when a metal surface is detected. Due to excessive leakage current causing false ON conditions, two-wire sensors are not to be
used. Only three- or four-wire sensors that have digital PNP or hardcontact Outputs that are separate from the input power should be
used.
The Controller provides configuration options for the Mute Devices.
One or two pairs of Mute Devices (typically sensors or switches) must
be used; these pairs are designated M1-M2 and M3-M4. In the circuit
diagrams below, it is assumed that each contact or output is being
generated by an individual device for Category 3 and Category 4.
A2.11.3.1 Dual channel, 2 terminals - Dual channel, 3 terminals
This circuit typically can meet ISO 13849-1 Category 2 or Category 3
requirements depending on the installation of the Mute Devices. To
meet Category 4 requirements, user/installer must design out or otherwise eliminate the possibility of a short circuit between input channels (see section appendix A2.1.2 on page 87). Dual channel, 3
terminals connection use pulse monitoring and can detect a short circuit to another source of power. Both Dual channel, 2 terminals and
Dual channel, 3 terminals connection can detect a short between
channels when the contacts are Open if the short is present longer
than 2 seconds.
24V
A2.11.3.2 Dual Channel, PNP
This circuit can meet ISO 13849-1 Category 2 or Category 3 requirements depending on the installation and the fault detection (e.g. short
circuit) capabilities of the Mute Device. To meet Category 4 requirements, user/installer must design out or otherwise eliminate the possibility of a short circuit between input channels (see section
appendix A2.1.2 on page 87). The SC22-3 Safety Controller does not
provide short circuit detection in this configuration.
2 PNP
OFF
OFF
A2.11.3.3 Dual channel, 4 terminal
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 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.
A2.11.3.4 Complementary, 2 terminals - Complementary, 3 terminals
This circuit can meet ISO 13849-1 Category 2, Category 3 or
Category 4 requirements depending on the Safety Rating and the installation of the Output Device. This circuit can detect a short circuit
between channels. The Complementary, 3 terminals connection can
detect a short circuit to another source of power, when the contact is
closed.
24V
A2.11.3.5 Complementary, PNP switch
This circuit can meet ISO 13849-1 Category 2, Category 3 or
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stallation of the Output Device. This circuit can detect a short circuit
between channels.
OFF
! WARNING
ON
A2.11.4 Mute Enable (ME)
The Mute Enable input is a non-safety-rated input. When the input is
Closed, the Controller will allow a mute condition to occur. Opening
this input while the System is muted will have no effect.
Typical uses for Mute Enable include:
• To allow the machine control logic to create a “window” for Muting
to begin;
to inhibit Muting from occurring or
to reduce the chance of unauthorized or unintended Bypassing or
defeat of the safety system.
A2.11.4.1 Simultaneity Timer Reset Function
The Mute Enable input can also be used to Reset the Simultaneity
Timer of the Mute Inputs. If one input is active for longer than three
seconds before the second input becomes active, the Simultaneity
Timer will prevent a Mute Cycle from occurring. This could be due to
a normal stoppage of an assembly line that may result in blocking one
Mute Device and the Simultaneity Timer running out.
If the ME input is cycled (Closed-Open-Closed) while one Mute Input
is active, the Simultaneity Timer is Reset and if the second Mute Input
becomes active within three seconds, a normal Mute Cycle begins.
The timing requirement for the Closed-Open-Closed is similar to the
Manual Reset function. Initially, the input needs to be active (Closed)
for longer than 0,25 second, then open for longer than 0,25 second,
but not longer than 2 seconds, and then must Reclose to Reset the
Simultaneity Timer. The function can Reset the timer only once per
Mute Cycle (i.e. all Mute Inputs M1–M4 must open before another
Reset can occur).
A2.11.5 Mute Lamp Output (ML)
! CAUTION
a
MUTE STATUS MUST BE READILY OBSERVED
Indication that the safety device is muted should be provided and be
readily observable.
Failure of this indication should be detectable and prevent the next mute,
or operation of the indicator should be verified at suitable intervals.
Lamp monitoring must be selected if the application requires compliance
with IEC 61496.
Some applications require that a lamp (or other means) be used to
indicate when the safety device (e.g. Safety Light Screen) is muted;
the Controller provides for this through the Status Outputs. If a monitored output signal is required (see caution above), Status Outputs
O9 and O10 can be configured for a Monitored Output. The Monitored Output will prevent the initiation of a mute after an indicator failure is detected. If the application requires compliance with
IEC 61496, Lamp Monitoring must be selected and the lamp used
must meet applicable requirements.
112
A2.11.6 Muting Time Limit (Backdoor Timer)
a
MUTING TIME LIMIT
AN INFINITE TIME FOR THE BACKDOOR TIMER (I.E. DISABLING) SHOULD BE SELECTED ONLY IF THE POSSIBILITY OF AN INAPPROPRIATE OR UNINTENDED MUTE CYCLE
IS MINIMIZED, AS DETERMINED AND ALLOWED BY THE MACHINE’S RISK ASSESSMENT. IT IS THE USER’S RESPONSIBILITY TO ENSURE THAT THIS DOES NOT CREATE
A HAZARDOUS SITUATION.
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 Mute 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.
The timer begins when the second Mute Device makes the Simultaneity requirement (within 3 seconds of the first device), and will allow
a mute to continue for the predetermined time. After the timer expires,
the mute ends – no matter what the signals from the Mute Devices
indicate. If the input device being muted is in an OFF state, the
mapped OSSD Outputs will turn OFF and must be manually reset (if
the input device is configured for manual reset).
A2.11.7 Mute on Power-up
! WARNING
a
MUTE ON POWER-UP
THE Mute on Power-up FUNCTION SHOULD BE USED ONLY IN APPLICATIONS
WHERE:
• MUTING THE SYSTEM (M1 AND M2 CLOSED) WHEN POWER IS APPLIED IS
REQUIRED AND
• USING IT MUST NOT, IN ANY SITUATION, EXPOSE PERSONNEL TO ANY HAZARD
If selected, the Mute on Power-up function will initiate a mute when
power is applied, the Mute Enable input is Closed (if configured), the
safety device Inputs are active (Closed), and either M1-M2 or M3-M4
(but not all four) are Closed.
If Automatic Reset is configured, the Controller allows 2 seconds for
the Input Devices to become active (Closed) to accommodate systems that may not be immediately active at power-up.
If Manual Reset is configured, the first valid Reset after the Output
Device is active (Closed) will result in a Mute Cycle if all other conditions are satisfied.
A2.11.8 Corner Mirrors, Optical Safety Systems &
Muting
Mirrors are typically used with Safety Light Screens, Single Beam
Safety Systems and Multiple Beam Safety Systems to guard multiple
sides of a hazardous area. If the Safety Light Screen is muted, the
Safeguarding function is suspended on all sides. It must not be possible for an individual to enter the guarded area without being detected and a Stop command issued to the machine control. This
supplementary Safeguarding is normally provided by an additional
device(s) that remains active while the Primary Safeguard is muted.
Therefore, mirrors are typically not allowed for muting applications.
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Appendix 2
A2.11.9 Multiple Presence Sensing Safety Devices
! WARNING
a
GUARDING MULTIPLE AREAS
DO NOT SAFEGUARD MULTIPLE AREAS, WITH MIRRORS OR MULTIPLE SENSING
FIELDS, IF PERSONNEL CAN ENTER THE HAZARDOUS AREA WHILE THE SYSTEM IS
MUTED, AND NOT BE DETECTED BY SUPPLEMENTAL SAFEGUARDING THAT WILL ISSUE A STOP COMMAND TO THE MACHINE.
Muting multiple Presence Sensing Safety Devices (PSSDs) or a
PSSD with multiple sensing fields is not recommended unless it is not
possible for an individual to enter the guarded area without being detected and a stop command issued to the machine control.
As with the use of corner mirrors (see appendix A2.11.8), if multiple
sensing fields are muted the possibility exists that personnel could
move through a muted area or access point to enter the safeguarded
area without being detected.
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.
A2.11.10 Mute Timing Sequences
Figure 40, figure 41 and figure 42 detail typical Mute Timing sequences.
Power
Safety Light Screen
Mute Enable
Mute Sensor 1
<3 s
Mute Sensor 2
Backdoor Timer
Maximum
Time
Maximum
Time
Safety Output
Mute Cycle ends due to the
expiration of the Backdoor Timer
Mute Cycle prevented due
to open Mute Enable input
Figure 40 Mute Timing Diagram with Muting Sensor Pair, Mute Enable, Safety Light Screen and Limited
Mute Time with Mutable Safety Device Configured for Automatic Reset
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SC22-3 Safety Controller
Power
Safety Light Screen
Mute Enable
Mute Sensor 1
<3 s
Mute Sensor 2
Mute Sensor 3
<3 s
Mute Sensor 4
Maximum
Time
Backdoor Timer
Maximum
Time
Safety Output
Figure 41 Mute Timing Diagram with four Mute Sensors, Mute Enable, Safety Light Screen & Limited Mute Time
with Safety Light Screen Configured for Automatic Reset
Power
Two-Hand Control Inputs
Mute Enable
Mute Sensor 1
<3 s
<3 s
Mute Sensor 2
Backdoor Timer
Maximum
Time
Maximum
Time
Safety Output
Mute Cycle prevented due
to open Mute Enable input
Figure 42 Mute Timing Diagram with Muting Sensor Pair, Mute Enable, Two-Hand Control & Limited Mute Time
114
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Appendix 3
A3 DECLARATION OF CONFORMITY
A3.1 DECLARATION OF CONFORMITY
Figure 43 Declaration of Conformity
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Appendix 3
SC22-3 Safety Controller
Declaration of Conformity
Declaration of Conformity
Manufacturer:
Address:
Banner Engineering Corp>
9714 10th Ave N.
Minneapolis, MN 55441 USA
Attached Schedule
Safety Controller
Herewith declares that:
- is in conformity with the
provisions of the Machinery
Directive (Directive 98/37/
EEC), and all Essential Health
and Safety Requirements have
been met.
SC22-3
(Safety Controller)
(See attached schedule for list of models
covered by this Declaration of Conformity)
89/336/EEC, 73/23/EEC,
- is in conformity with the
provisions of the following other
EEC Directives:
and that:
- the following (parts/clauses of)
harmonized standards have been
applied:
EU Notified Body:
IEC 61508-Part 1-7:2000
IEC 62061:2005
IEC 61131-2:2003
EN ISO 13849-1:2006
EN 50178:1997
EN 60204-1:2006
EN 574:1996
EN 61496-1:2004 Type 4
IEC 61508/IEC 62061 SIL 3
ISO 13849-1 (Cat. 4, PL e)
EN 574 (Type III C)
Models covered by this Declaration of
Conformity:
SC22-3
TUV Reinland Product Safety GmbH
Certificate:
#968/EL493.00/07
I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and
Standard(s)
R. Eagle / Engineering Manager
Date
Figure 44 Declaration of Conformity - Translation
116
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SC22-3 Safety Controller
Appendix 4
A4 GLOSSARY & ABBREVIATIONS
A4.1 LIST OF ABBREVIATIONS
A4.2 GLOSSARY OF TERMS
AOPD
The following terms are used often in this manual. Where possible,
this manual uses definitions from the U.S. and international product
performance standards that govern the design of the Safety Controller. Additional definitions are available on http://www.bannerengineering.com/iknow.
Active Opto-Electronic Protective Device
AOPDDR Active Opto-Electronic Protective Device Responsive to
Diffuse Reflection
COS
Change of State
EDM
External Device Monitoring
EN
Engineering Norm
ESPE
Electro-sensitive Protective Equipment
FMEA
Failure Mode & Effects Analysis
Automatic Reset: The Safety Input device control operation setting
where the assigned Safety Output will automatically turn on when all
of its associated Input Devices are in the Run state. No Manual Reset
operation is required for the Safety Output to turn on when controlled
only by Safety Input devices configured for Automatic Reset.
FSD
Final Switching Device
☛ When Automatic Reset is selected, the Input Device may be said
HMI
Human Machine Interface
to be configured to run in Trip mode.
Change-of-state: The change of an input signal when it switches
from Run-to-Stop or Stop-to-Run state. Dual channel input signals,
have two possible configurable COS settings describing the signal
disparity limits that can exist between channels before a fault condition is registered; Simultaneity and Concurrent.
IEC
International Electro-technical Commission
IP...
Ingress Protection (Class)
ISO
International Organisation for Standardisation
LCD
Liquid Crystal Display
LED
Light Emitting Diode
ME
Mute Enable
ML
Mute Lamp
MSSI
Mutable Safety Stop Interfaces
MPCE
Machine Primary Control Element
a concern for the application, the user has to ensure that the correct selection was made during the configuration.
Closed-open debounce time: The time required to bridge a jittery
input signal or bouncing of input contacts to prevent nuisance tripping
of the Controller. Adjustable from 6 ms to 100 ms. Default is 50 ms
for mute sensors, 6 ms for other devices.
N.O.
Normally Open
☛ A longer Closed-open debounce time will also affect and in-
N.C.
Normally Closed
OBI
On Board Interface
OSSD
Output Signal Switching Device
PCI
PC Interface
PL
Performance Level
PLC
Programmable Logic Controller
prEN
preliminary European Norm
PSSD
Presence Sensing
PSDI
Presence Sensing Device Initiation
QD
Quick Disconnect
SIL
Safety Integrity Level
SSI
Safety Stop Interface
USB
Universal Serial Bus
VAC
Voltage Alternating Current
V dc
Voltage Direct Current
☛ Simultaneity vs. Concurrency. If Simultaneity is a requirement or
crease the Response Time of the system and/or the Machine response time (see page 118).
Code validation: The configuration code file inspection process automatically performed by the Controller to verify that the configuration
code has not been corrupted or altered in any way.
Concurrent: The setting that permits an indefinite signal disparity
between channels, without going into a fault condition. A fault condition is created if the Stop signal changes back to a Run signal before
its allied signal changes to the Stop state. Both signals must change
from the Stop state to the Run state before the Dual channel device
is considered to be in the Run state.
Control Reliability: A method of ensuring the performance integrity
of a control system. Control circuits are designed and constructed so
that a single failure or fault within the system does not prevent the
normal stopping action from being applied to the machine when required, or does not create unintended machine action, but does prevent initiation of successive machine action until the failure is
corrected.
Designated Person: An individual identified and designated in writing, by the employer, as being appropriately trained to perform a
specified checkout procedure. See designated person as specified in
block 1.8.1 (see also qualified person on page 119).
Detection Zone: The light curtain generated by the System. When
the detection Zone is interrupted by an opaque object of a specified
cross section or larger, a trip condition (or latch condition, depending
on the Controller) results.
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Appendix 4
SC22-3 Safety Controller
Emitter: The light-emitting component of a safety light screen system, consisting of a row of synchronized modulated LEDs. The emitter, together with the receiver (placed opposite), creates a “screen of
light” called the defined area.
E-Stop: Special switch push button positioned in strategic locations
and used for shutting off electrical power and motion in an emergency
to the machine.
External Device Monitoring (EDM): A means by which a safety device (such as a safety light screen) actively monitors the state (or status) of external devices that may be controlled by the safety device.
A lockout of the safety device results if an unsafe state is detected in
the external device. External device(s) may include, but are not limited to: MPCEs, mechanically linked relays/contactors, and safety
modules.
Latch Condition: The response of the Safety Output (e.g. OSSDs)
of a safety light screen system when an object equal to or greater
than the diameter of the specified test piece enters the defined area.
In a Latch condition, Safety Output simultaneously de-energize and
open their contacts. The contacts are held (latched) open until the object is removed from the defined area and a Manual Reset is performed. A latching output is used most often in perimeter guarding
applications (see trip condition on page 119).
Lockout Condition: A Safety Light Screen system condition that is
automatically attained in response to certain failure signals (an internal Lockout). When a Lockout condition occurs, the Safety Light
Screen system’s Safety Output turns OFF, and a Manual Reset is required to return the system to Run mode. Requires the attention of a
qualified person as specified in block 1.8.2 on page 4.
Failure to Danger: A failure which delays or prevents a machine
safety system from arresting dangerous machine motion.
Machine Operator: An individual who performs production work and
who controls operation of the machine.
False Proxing: Sensor activation due to shiny or reflective surfaces.
Machine Primary Control Element (MPCE): An electrically-powered element, external to the safety system, which directly controls
the machine’s normal operating motion in such a way that the element is last (in time) to operate when machine motion is either initiated or arrested.
Final Switching Device (FSD): The component of the machine’s
safety-related control system that interrupts the circuit to the machine
primary control element (MPCE) when the output signal switching device (OSSD) goes to the OFF state.
Fixed or Hard Guarding: Screens, bars, or other mechanical barriers affixed to the frame of the machine intended to prevent entry by
personnel into the hazardous area(s) of a machine, while allowing the
Point-of-Operation to be viewed. The maximum size of openings is
determined by the applicable standard.
FMEA (Failure Mode and Effect Analysis): A testing procedure by
which potential failure modes in a system are analysed to determine
their results or effects on the system. Component failure modes that
produce either no effect or a Lockout condition are permitted; failures
which cause an unsafe condition (a failure to danger) are not. Banner
safety products are extensively FMEA tested.
Forced-Guided Contacts: Relay contacts that are mechanically
linked, so that when the relay coil is energized or de-energized, all of
the linked contacts move together. If one set of contacts in the relay
becomes immobilized, no other contact of the same relay is able to
move. The function of forced-guided contacts is to enable the safety
circuit to check the status of the relay. Forced-guided contacts are
also known as “positive-guided contacts,” “captive contacts,” “locked
contacts,” or “safety relays.”
Machine Response Time: The time between the activation of a machine stopping device and the instant when the dangerous parts of
the machine reach a safe state by being brought to rest.
Manual Reset: The Safety Input device control operation setting
where the assigned Safety Output will turn on only after a manual reset is performed and if the other associated Input Devices are in their
Run state.
☛ When Manual Reset is selected, the Input Device may be said to
be configured to run in Latch mode; meaning that the controlled
output has latched to the OFF state and requires a Manual Reset
to turn back ON. This Reset is sometimes called a Manual Latch
Reset.
Mapped to: Implies a control logic relationship between an input and
an output or between an input and another input, where the state of
the first input determines the state of the output or of the second input.
Minimum Safety Distance: That distance, along the direction of approach, between the outermost position at which the appropriate test
piece is just detected and the nearest dangerous machine part(s).
Hazardous Area: An area that poses an immediate or impending
physical hazard.
Muting: The Automatic suspension of the Safeguarding function of a
safety device during a non-hazardous portion of the machine cycle.
Hazard Point: The closest reachable point of the hazardous area.
OFF State: The Safety Output signal that results when at least one
of its associated Input Device signals changes to the Stop state. In
this Manual, the Safety Output is said to be OFF or in the OFF state
when the signal is 0V dc nominally.
Key System Reset (Manual Reset): A key-operated switch used to
Reset a Safety Light Screen for example, to the ON state following a
Lockout condition. Also refers to the act of using the switch to System
Reset a safety system from a Latch condition.
118
ON State: The Safety Output signal that results when all of its associated Input Device signals change to the Run state. In this Manual,
the Safety Output is said to be ON or in the ON state when the signal
is 24V dc nominally.
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Appendix 4
Open-closed debounce time: The required time to bridge a jittery
input signal or bouncing of input contacts to prevent unwanted start
of the machine. Adjustable from 10ms to 500ms. Default is 50ms.
☛ A longer Open-closed debounce time will also affect the reaction
time of the Controller.
Output Signal Switching Device (OSSD): The Safety Output that is
used to initiate a Stop signal.
Point-of-Operation: the location of a machine where material or a
workpiece is positioned and a machine function is performed upon it.
Positive-Opening Safety Switches: Term used with reference to EStops. A mechanical force applied to such a button (or switch) is
transmitted directly to the contacts, forcing them open without the use
of springs. This ensures that the switch contacts open whenever the
switch is activated even if a contact has welded closed.
Presence-Sensing-Device Initiation (PSDI): An application in
which a presence-sensing device is used to actually start the cycle of
a machine. In a typical situation, an operator manually positions a
part in the machine for the operation. When the operator moves out
of the hazardous area, the presence-sensing device starts the machine (no start switch is used). The machine cycle runs to completion,
and the operator can then insert a new part and start another cycle.
The presence-sensing device continually safeguards the machine.
Single break mode is used when the part is automatically ejected after the machine operation. Double break mode is used when the part
is both inserted (to begin the operation) and removed (after the operation) by the operator.
Qualified Person: An individual who, by possession of a recognized
degree or certificate of professional training, or by extensive knowledge, training, and experience, has successfully demonstrated the
ability to solve problems relating to the subject matter and work. See
qualified person as specified in block 1.8.2 on page 4 (see also designated person on page 117).
Start up test: For certain safety devices, like Safety Light Screens or
Gate Switches, it can be an advantage to test the device on power up
at least one time for proper function. If ‘Start up Test’ has been selected for a Safety Light Screen and it is clear at power up, it would
be necessary to cycle the Safety Light Screen one time (from ON to
OFF and back to ON), even if the Controller has been configured for
auto power up.
Stop State: The input signal monitored by the Controller that, when
detected, causes one or more Safety Outputs to turn OFF. In this
Manual, either the Input Device or device signal is said to be in the
Stop state.
Supplementary Guarding: Additional or fixed guarding, used to
prevent a person from reaching over, under, through or around the
primary safeguard or otherwise accessing the guarded hazard.
System Reset: The term used to describe a Manual Reset operation
required for one or more Safety Outputs to turn ON after Controller
power-up, when configured for manual power-up, and Lockout (fault
detection) situations.
Trip Condition: the response of the Safety Output (e.g. OSSDs) of
a safety light screen system when an object equal to or greater than
the diameter of the specified test piece enters the defined area. In a
Trip condition, the OSSDs simultaneously de-energize. A Trip condition clears (Resets) automatically when the object is removed from
the defined area (see also Latch Condition on page 118).
TUV (Technischer Überwachungsverein): independent testing
and certification organization providing EMC (electromagnetic compatibility) and product safety testing, certification, and quality management systems registration.
Receiver: the light-receiving component of a Safety Light Screen
system, consisting of a row of synchronized photo transistors. The
Receiver, together with the Emitter (placed opposite), creates a
“screen of light” called the defined area.
Reset: The use of a manually operated switch to restore the Safety
Output to the ON state from a lockout or a Latch condition.
Response Time: The time between the physical initiation of the safety device and the machine coming to a stop or the risk being removed.
Run State: 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.
Simultaneity: The setting that permits a signal disparity between
channels within the Input Device for a limited time, without going into
a fault condition. If a signal disparity exists for more than 3 seconds,
then a fault condition occurs.
Single channel: Having only one signal line for a Safety Input or
Safety Output.
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Appendix 4
SC22-3 Safety Controller
Intentionally left blank
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Appendix 5
A5 CUSTOMER INFORMATION
The following is a list of addresses for Banner Representatives and Distributors in Europe:
CORPORATE OFFICES:
Banner Engineering Europe
Park Lane, Culliganlaan 2F
1831 Diegem,
Belgium
GREECE
CZECH REPUBLIC
Turck s.r.o.
2KAPPA LTD
Hradecká 1151
Sofokli Venizelou 13, 54628 Menemeni
CZ-50003 Hradec Králové 3
Tel: 00 30 23 10 77 55 10
Tel.: +420 495 518 766
Fax: 00 30 23 10 77 55 14-15
Fax: +420 495 518 767
email: 2kappa@pel.forthnet.gr
e-mail: turck@turck.cz
http://www.turck.cz
Tel.: +32 2 456 07 80
DENMARK
Fax: +32 2 456 07 89
HUNGARY
Turck Hungary Kft.
Könyves Kalman Krt. 76
e-mail: mail@bannereurope.com
Hans Folsgaard AS
http://www.bannereurope.com
Ejby Industrivej 30
Banner Engineering GmbH
Dk-2600 Glostrup
Martin-Schmeißer-Weg 11
Tel.: +45 43 20 86 00
44227 Dortmund
Fax: +45 43 96 88 55
Tel.: + 49 (0) 231 963 37 30
e-mail: hf@hf.net
Fax: + 49 (0) 231 963 39 38
http://www.hf.net
H-1087 Budapest
Tel.: +36 1 477-0740 or 36-1-313-8221
Fax: +36 1 477-0741
e-mail: turck@turck.hu
http://www.turck.hu
ICELAND
e-mail: info@bannerengineering.de
ESTONIA
http://www.bannerengineering.de
K M Stáhl ehf.
Bíldshöfòa 16
Osaühing «System Test»
110 Reykjavik
Pirita tee 20
Tel.: +354 56 78 939
Intermadox GmbH
EE-10127 Tallinn
Fax: +354 56 78-938
Josef-Moser-Gasse 1
Estonia
e-mail: kalli@kmstal.is
A-1170 Vienna
Tel.: +372 6 405 423
Tel.: +431 48 615870
Fax: +372 6 405 422
Fax: +431 48 6158723
e-mail: systemtest@systemtest.ee
AUSTRIA
IRELAND
Tektron
e-mail: imax.office@intermadox.at
http://www.intermadox.at
FINLAND
Tramore House
Tramore Road
Sarlin Oy Ab
Cork
P.O. Box 750
Tel.: +353 (0)21-431 33 31
MULTIPROX N.V.
SF-00101 Helsinki 10
Fax: +353 (0)21-431 33 71
Lion d'Orweg, 12
Tel.: +358 9 50 44 41
e-mail: sales@tektron.ie
B-9300 Aalst
Fax: +358 9 56 33 227
http://www.tektron.ie
Tel.: +32 53 766 566
e-mail: sales.automation@sarlin.com
Fax: +32 53 783 977
http://www.sarlin.com
BELGIUM
e-mail: mail@multiprox.be
http://www.multiprox.be
FRANCE
ITALY
Turck Banner s.r.l.
Via Adamello, 9
Turck Banner S.A.S.
20010 Bareggio
3, Rue de Courtalin
Milano
Sensomat Ltd.
Magny - Le - Hongre
Tel.: +390 2 90 36 42 91
VH V, App 11
77703 Marne - La - Valleé Cedex 4
Fax: +390 2 90 36 48 38
Dr. Ivan Penakov Str. 15
Tel.: +33 1 60 43 60 70
e-mail: info@turckBanner.it
BG-9300 Dobrich
Fax: +33 1 60 43 10 18
http://www.turckBanner.it
Tel.: +359 58 603 023
e-mail: info@turckBanner.fr
Fax: +359 58 603 033
http://www.turckBanner.fr
BULGARIA
e-mail: info@sensomat.info
http://www.sensomat.info
GERMANY
LATVIA
LASMA Ltd.
Aizkraukles 21-111
Hans Turck GmbH & Co KG
LV-1006 Riga
Witzlebenstrasse 7
Tel.: +371 754 5217
45472 Mülheim an der Ruhr
Fax: +371 754 5217
Tel.: +49 208 49 520
e-mail: inga@lasma.lv
Fax: +49 208 49 52 264
e-mail: turckmh@mail.turck-globe.de
http://www.turck.com
INSTRUCTION MANUAL - EUROPEAN VERSION
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Appendix 5
SC22-3 Safety Controller
LITHUANIA
SWEDEN
ROMANIA
Hidroteka
TURCK Automation Romania SRL
HF Sverige AB
Büro: Taikos 76-4
Str. Iuliu Tetrat nr. 18, Sector 1
Stockholm:
LT-3031 Kaunas
RO-011914 Bucharest
Kanalvägen 10C
Post: P.O. Box 572
Tel: +40 21 230 02 79 or 230 05 94
SE-194 61 Upplands Väsby
LT-3028 Kaunas
Fax: +40 21 231 40 87
Tel.: +46 8 555 409 85
Tel.: +370 37 352195
e-mail: info@turck.ro
Fax: +46 8 590 717 81
Fax: +370 37 351952
http://www.turck.ro
e-mail: hf.sverige@hf.net
e-mail: hidroteka@post.sonexco.com
http://www.hf.net
RUSSIA AND CIS
LUXEMBOURG
Turck Office Minsk
Sogel SA 1
ul. Engelsa, 30
7, Rue de l'Industrie
BY-220030 Minsk
8399 Windhof
Republic of Belarus
Luxemburg
Tel.: +375 172 105957
Tel.: +352 40 05 05 331
Fax: +375 172 275313
Fax: +352 40 05 05 305
e-mail: turck@infonet.by
e-mail: sogel@sogel.lu
http://www.turck.by
Båstad:
Tel.: +46 431 755 60
Fax: +46 431 755 61
e-mail: hf@hf.net
http://www.hf.net
Malmo:
Tel.: +46 040 611 96 70
Fax: +46 040 611 96 85
e-mail: hf@hf.net
http://www.hf.net
Turck Office Moskow
NETHERLANDS/HOLLAND
Volokolamskoe shosse 1 office 606A
SWITZERLAND
Turck B.V.
125080 Moskow
Ruiterlaan 7
Tel.: +7 095 105 00 54
Bachofen AG
NL-8019 BN Zwolle
Fax: +7 095 158 95 72
Ackerstrasse 42
Tel.: +31 38 42 27 750
e-mail: turck@turck.ru
8610 Uster
Tel.: + 41 44 944 11 11
Fax: +31 38 42 27 451
SLOVAK REPUBLIC
e-mail: info@turck.nl
http://www.turck.nl
Fax: + 41 44 944 12 33
e-mail: info@bachofen.ch
MARPEX s.r.o.
http://www.bachofen.ch
Sportovcov 672
NORWAY
018 41 Dubnica nad Váhom
TURKEY
Danyko A.S.
Tel.: +421 42 4426987
P.O. Box 48
Fax: +421 42 4426986
Dacel Muhendislik Elektrik,
N-4891 Grimstad
e-mail: marpex@marpex.sk
Elektronik, San. Ve Tic. Ltd.
Perpa Elektrokent Is Merkezi
Tel.: +47 37 04 02 88
SLOVENIA
Fax: +47 37 04 14 26
A Blok Kat 2 No:38
Okmedani/Istanbul
e-mail: danyko@hf.net
Tipteh d.o.o
http://www.danyko.no
TURKIYE
CESTA V GORICE 40
Tel: 00 90 212 210 76 46
SLO-1111 Ljubljana
Fax:00 90 212 220 50 45
Tel.: +386 1 200 51 50
e-mail: Özer Özkurt <ozkurt@dacel.net
POLAND
Turck Sp. z o.o,
Fax: +386 1 200 51 51
ul Zeromskiego 1
e-mail: info@tipteh.si
PL-50 053 Opole
SPAIN
Tel.: +48-77 443 48 00
Gökhan Elektrik Malzemelri San Tic Ltd. Sti
Perpa Elektrokent Ticaret Merkezi A Blok Kat 8
No: 694
80270 Okmeydani - ISTANBUL
Fax: +48-77 443 48 01
Elion, S.A.
Tel.: +90 212 2213236
e-mail: turck@turck.pl
Farell, 5 - 08014 Barcelona
Fax: +90 212 2213240
http://www.turck.pl
Tel.: + 932 982 035
e-mail: gokhan@gokhanelektrik.com
Fax: + 934 314 133
http//www.gokhanelektrik.com
PORTUGAL
Salmon & Cia Lda.
e-mail: elion@elion.es
UNITED KINGDOM
http://www.elion.es
Rua Cova da Moura, 2-6º
Turck Banner Limited
1399-033 Lisboa
Blenheim House, Hurricane Way,
Tel.: +351 21 39 20 130
Wickford,
Fax: +351 21 39 20 189
Essex, SS11 8YT
e-mail: div8.salmon@mail.telepac.pt
Tel: +44 (0)1268 578888
Fax: +44 (0)1268 763648
e-mail: info@turckBanner.co.uk
http://www.turckBanner.co.uk
122
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Alpha-Numerical Index
Click on an item to go to the information
2006/42/ec 2
24v = input active 61
24v = input inactive 61
2x complementary, 4 terminals - 2x complementary, 5 terminals 107
2x complementary, 4 terminals - 2x complementary, 5 terminals 109
2x complementary, 4 terminals - 2x complementary, 5 terminals 93
2x complementary, 4 terminals - 2x complementary, 5 terminals 98
2x complementary, pnp switch 107
2x complementary, pnp switch 109
2x complementary, pnp switch 93
2x complementary, pnp switch 98
bypass switch function (without mute) 72
bypass switch function 10
bypass switch time limit 10
bypass with mute 10
bypassable 26
C
A
accessing fault codes 29
accessing fault log 51
add an additional status output 47
add input 17
add input 53
add input 56
add input 56
add input 61
add non-safety input devices 46
adding additional non-safety input devices 60
adding additional safety input devices 58
adding emergency stop 41
adding external device monitoring 45
adding gate switch 43
adding mute enable switch 46
adding muting sensor pair 44
adding on/off switch 46
adding optical sensor 43
adding safety input & non-safety input devices 40
adding two-hand control 44
additional logic functions 16
additional safety input device breakdown 60
advanced settings 27
advanced settings used for further configuration of device type (e.g. simultaneity,
closed-open debounce time or open-closed debounce time) 25
all indicators off 30
allow minimum 65 mm clearance for usb cable and 43 mm for xm card insertion 22
aopd active opto-electronic protective device 117
aopddr active opto-electronic protective device responsive to diffuse reflection 117
application of safety mats 99
applications 7
assigning safety output(s) 46
author’s name 15
auto & manual monitored manual reset safety inputs mapped to same safety output
(safety output has no delay) timing logic 7
automatic power-up 15
automatic reset & manual reset inputs mapped to same safety output 7
aux. outputs 81
avoid hazardous installations 111
B
backdoor timer 113
backdoor timer 114
backdoor timer 114
before applying power to the machine 69
breakdown of additional safety input devices 58
building configuration 11
building the configuration 32
bypass switch (bypassing safeguards) 108
bypass switch 10
bypass switch 17
bypass switch 26
bypass switch 28
bypass switch 53
bypass switch 61
bypass switch 88
bypass switch function (with mute) 72
INSTRUCTION MANUAL - EUROPEAN VERSION
category 2 103
category 2 91
category 2 circuit - gate switch 85
category 2 circuit e-stop 86
category 2 or category 3 input shorts 87
category 3 103
category 3 91
category 3 circuit - gate switch 85
category 3 circuit e-stop 86
category 4 103
category 4 91
category 4 circuit - gate switch 86
category 4 circuit e-stop 86
cause 67
cause and/or required action 66
cause and/or required action 66
caution 1
caution 1
cautions 1
ce marking / product identification plate 19
certificate of adequacy 19
change name... 61
change name... 61
changing password using pci 50
checking before reset 68
choice 61
circuit symbol 27
circuit symbol examples 88
circuit type 26
circuit type 27
circuit types: 26
circuit types: 28
clamp terminals 20
cleaning 74
clear fault log 17
clear fault log 53
clear fault log 79
clears the faults displayed and gets the latest faults stored in the safety controller’s
fault log. 77
click on this button to generate an extended record of faults and save to file 77
clicking info button links to more information. 25
closed-open debounce time / open-closed debounce time 28
closed-open debounce time / open-closed debounce time 28
closed-open debounce time 28
commissioning checkout 34
commissioning checkout 69
commissioning checkout procedure 69
commissioning pre-checks 69
complementary, 2 terminals - complementary, 3 terminals 89
complementary, 2 terminals - complementary, 3 terminals 92
complementary, 2 terminals - complementary, 3 terminals 95
complementary, 2 terminals - complementary, 3 terminals 105
complementary, 2 terminals - complementary, 3 terminals 107
complementary, 2 terminals - complementary, 3 terminals 109
complementary, 2 terminals - complementary, 3 terminals 111
complementary, pnp switch 89
complementary, pnp switch 93
complementary, pnp switch 95
complementary, pnp switch 105
complementary, pnp switch 107
complementary, pnp switch 109
complementary, pnp switch 111
components 23
135369 06.03.08
I
Alpha-Numerical Index
condition 30
conditions of equipment use 3
configurable properties 26
configurable properties 28
configurable sc22-3 safety controller 19
configuration name 15
configuration name 66
configuration file 17
configuration file 53
configuration file 56
configuration mode 17
configuration mode 53
configuration mode 56
configuration summary 17
configuration summary 53
configuration summary 54
configuration summary 56
configuration summary 61
configuration summary 62
configuration tools 39
configuration validation 48
configuring status outputs 47
configuring the safety controller 11
configuring the safety controller 29
confirm configuration 17
confirm configuration 53
confirm configuration 63
confirm configuration of inputs 63
confirm configuration of outputs 63
confirm configuration of system settings 63
confirm inputs 17
confirm inputs 53
confirm safety outputs 17
confirm safety outputs 53
confirm system settings 17
confirm system settings 53
confirming a configuration 16
confirming a configuration: 16
confirming configuration 11
confirming configuration 32
confirming configuration 48
connecting safety controllers in series 12
connecting sc22-3 safety controller 24
connection options 89
connection options 97
connection options 100
connection options 103
connection options 104
connection options 106
connection options 108
connection options 111
controller operation on power-up 15
corner mirrors, optical safety systems & muting 112
corrective maintenance 74
coschange of state 117
cos* (simultaneity): simultaneous (s) / concurrent (c) 26
creating a new configuration 40
customer information 121
customer service information 22
D
daily operational checks 69
dc common wire installation 33
dc common wire installation 85
deactive 66
debounce 26
declaration of conformity - translation 116
declaration of conformity (doc) 21
declaration of conformity 19
declaration of conformity 115
declaration of conformity 116
defining safeguarding application (risk assessment) 11
II
SC22-3 Safety Controller
defining safeguarding application 32
definition 1
delete input 17
delete input 56
delete input 53
deleteinput 61
description 1
description 21
description 80
description 81
description 82
design & testing 6
designated & qualified persons 4
designated person 4
determining minimum safety distance (s) for the safety mat 101
device name 78
device name 79
device time limit 28
diagnostic display breakdown 75
diagrams & summary 38
disclaimer information 5
displayed message 75
displaying controller information — obi 66
displaying controller information — pci) 65
do not apply power to the safety controller or to the guarded machine at this stage. 70
do not continue checkout until all problems are corrected. 73
do not use machine until system is working properly 69
documentation 82
documentation order numbers 82
dual channel 83
dual channel a & b complementary 27
dual channel control 33
dual channel edm connection 83
dual channel edm connection to im-t-9a interface module 84
dual channel edm status, with respect to safety output 10
dual channel edm used to monitor both mpce feedback signals. if the channels are
not in the same state, the system goes into a lockout condition. 83
dual channel monitoring 10
dual channel monitoring 32
dual channel, 2 terminals - dual channel, 3 terminals - dual channel, 4 terminal 97
dual channel, 2 terminals - dual channel, 3 terminals 89
dual channel, 2 terminals - dual channel, 3 terminals 92
dual channel, 2 terminals - dual channel, 3 terminals 95
dual channel, 2 terminals - dual channel, 3 terminals 103
dual channel, 2 terminals - dual channel, 3 terminals 104
dual channel, 2 terminals - dual channel, 3 terminals 106
dual channel, 2 terminals - dual channel, 3 terminals 108
dual channel, 2 terminals - dual channel, 3 terminals 111
dual channel, 4 terminal 89
dual channel, 4 terminal 92
dual channel, 4 terminal 103
dual channel, 4 terminal 104
dual channel, 4 terminal 106
dual channel, 4 terminal 109
dual channel, 4 terminal 111
dual channel, pnp 89
dual channel, pnp 92
dual channel, pnp 95
dual channel, pnp 97
dual channel, pnp 103
dual channel, pnp 104
dual channel, pnp 106
dual channel, pnp 108
dual channel, pnp 111
dual channel a & b 27
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E
edit configuration 17
edit configuration 53
edit configuration 56
edit input 17
edit input 56
edit password 17
edit password 53
edit password 64
editing an existing configuration 49
editing configuration 49
editing obi status outputs - options 61
edit input 53
edit input 61
edm 10
edm 17
edm 32
edm 53
edm 61
edm contacts 81
edm contacts 81
edm external device monitoring 117
edm, ossd safety output & fsd connection 32
electrical connection 24
electrical safety 3
electromagnetic immunity levels 6
emc 20
emergency stop (es01) example menu breakdown 57
emergency stop 26
en engineering norm 117
enable device 9
enable mode 66
enable mode 9
enable startup test 28
enabling device & enable mode timing logic 9
enabling device (pendants) 106
enabling device 17
enabling device 26
enabling device 53
enabling device 61
enabling device 88
enabling device function 72
enabling device time limit 9
enabling devices 8
enter name 61
enter password
(block 6.2.1) 17
enter password (block 6.2.1) 53
entering configuration mode 55
entering controller password 55
environmental rating 20
equipment noise levels 5
equipment radiation levels 6
equipment vibration levels 5
erase configuration 17
erase configuration 53
erase configuration 62
espeelectro-sensitive protective equipment 117
e-stop & rope pull functions 71
e-stop 17
e-stop 53
e-stop 61
e-stop 88
e-stop functions 102
e-stops 102
example 1
examples of muting sensors and switches 111
exit configuration 53
exit configuration mode 64
exporting documents 50
external device monitoring – edm01 58
INSTRUCTION MANUAL - EUROPEAN VERSION
Alpha-Numerical Index
external device monitoring – edm02 58
external device monitoring – edm03 58
external device monitoring 26
external device monitoring 6
failures and faults 4
F
fault 66
fault 66
fault code 75
fault code 78
fault code 79
fault description 78
fault description 79
fault diagnostics 17
fault diagnostics 53
fault diagnostics screen 53
fault diagnostics via obi 78
fault diagnostics via pci 77
fault exclusion 87
fault log — pci 77
fault log recording — pci 78
features 7
final confirmation step 64
fmeafailure mode & effects analysis 117
for creating a configuration: 16
from 10 ms to 500 ms in 1 ms intervals 28
from 6 ms to 100 ms in 1 ms intervals 28
fsd interfacing connections 33
fsdfinal switching device 117
function 58
function 60
function time limit 26
functional stops as per iec 60204-1 12
further steps & checks 75
G
gate switch – gs01 58
gate switch (or interlocked guard) connection options 92
gate switch 17
gate switch 26
gate switch 53
gate switch 61
gate switch 88
gate switches (or interlocked guard) 90
general 110
general 26
general formula 101
general formula 94
general formula 97
general information 19
general safety 1
general warning 1
generic connection 95
generic connection showing single channel, dual channel, & no edm options 83
glossary & abbreviations 117
glossary of terms 117
guarding multiple areas 113
H
hand controls 96
hard drive space 35
high voltage 1
I
hmihuman machine interface 117
i/o fault existsno i/o fault exists 34
i/o mapping & the i/o control relationship 14
iec 60529 (2001-02) 2
iecinternational electro-technical commission 117
iec/en 60204-1 (2005-10) 2
iec/en 60947-1 (2004-03) 2
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Alpha-Numerical Index
iec/en 60947-5-1 (2003-11) 2
iec/en 61496-1 (2004-02), & iec/en 61496-2 (2006-04) 2
im-t-9 series 81
incomplete information 94
indicates safety controller status 30
inductive proximity sensors 111
ingress protection ratings 3
initial check 75
initial setup & commissioning/periodic check-outs 70
input & output mapping 14
input device & safety category reference 87
input device status message 66
input device status message breakdown 66
input devices with solid state outputs 87
input devices, circuit options, & their potential safety categories 88
input is muted no mute 34
input run input stop 34
input signal run state cos (simultaneity) timing rules 27
input status 66
input terminals 27
input/output mapping 17
input/output mapping 53
input/output mapping 54
input/output mapping 56
input/output mapping 61
inputs 17
inputs 53
inputs 56
inputs 56
inputs 61
inputs 81
inputs 81
inputs 81
inputs mapped to inputs 14
inputs mapped to outputs 14
install hand controls to prevent accidental actuation 96
installation - system 23
installation 100
installation guidelines 104
installation guidelines 106
installing pci software 37
installing the software 35
interface modules 81
interface modules series im-t-9 81
interface modules series sc-im9 81
interfacing of both ossds 12
internal logic 16
internal logic 8
ip...ingress protection (class) 117
iso 12100-1 (2003) & -2 (2003)(en 292-1 & -2) 2
iso 13849-1 (2006)(en 954-1) 2
iso 13850 (2006) (en418) 2
iso 13852 (1996)(en 294) 2
iso 13853 (1998) (pren 811) 2
iso 14119 (1998) (en 1088) 2
iso 14121-1 (2007)(en 1050) 2
iso 3864-2 (2004) 2
iso 7010 (2003) 2
iso international organisation for standardisation 117
iso/dis 13851 (2002)(en 574) 2
iso/dis 13855 (2002)(en 999) 2
K
kit & accessory information for sc22-3 safety controller 80
label identification sc22-3 safety controller 2
L
lcd liquid crystal display 117
led light emitting diode 117
light screen with mute sensors & bypass switch timing logic 10
list of abbreviations 117
live display 51
IV
SC22-3 Safety Controller
location of touch button controls 97
location/meaning 2
locking the xm stick 50
lockout/tagout 108
M
machine control 84
machine control 85
machine control must provide anti-repeat control 96
magnetically operated safety interlocking switches 90
maintenance 69
manual manual reset 7
manual monitored manual reset input 7
manual reset 28
manual reset 5
manual reset 68
manual reset devices 28
manual reset signal 8
mapped status output(s) state 34
mapped to: 26
mapped to: 27
mapped to: 28
maximum time 113
maximum time 113
maximum time 114
maximum time 114
memute enable 117
mechanical stress 20
mechanically linked contactors 81
minimum safety distance 101
minimum safety distance 94
minimum safety distance 97
minimum safety distance for optical sensors 6
minimum safety distance for safety mats 6
minimum safety distance for two-hand controls 6
minimum safety distances 6
mlmute lamp 117
model # (number) 55
model 21
model no. 21
model/type numbering 21
monitored mute lamp outputs 14
monitored reset 28
monitored reset 68
monitored system reset 15
monitoring series-connected safety interlocking switches 91
mpcemachine primary control element 117
mssimutable safety stop interfaces 117
multiple e-stop switches 103
multiple presence sensing safety devices 113
mute and bypass switch 10
mute cycle ends due to the expiration of the backdoor timer 113
mute cycle prevented due to open mute enable input 113
mute cycle prevented due to open mute enable input 114
mute enable – me01 60
mute enable (me) 112
mute enable 113
mute enable 114
mute enable 17
mute enable 28
mute enable 53
mute enable 61
mute enable 9
mute enable 9
mute enable switch. 28
mute functions 71
mute functions 9
mute inputs must be redundant 110
mute lamp output (ml) 112
mute on power-up 112
mute on power-up 112
mute on power-up 62
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SC22-3 Safety Controller
Alpha-Numerical Index
mute on power-up 9
mute on power-up enable 15
mute on power-up enabled 9
mute on power-up function 9
mute on power-up option 72
mute sensor – m1 + m2 59
mute sensor (pair) 110
mute sensor 1 (2) 10
mute sensor 1 113
mute sensor 1 114
mute sensor 17
mute sensor 2 (1) 10
mute sensor 2 113
mute sensor 2 114
mute sensor 26
mute sensor 3 114
mute sensor 4 114
mute sensor 53
mute sensor 61
mute sensor 88
mute sensor pair 9
mute status 61
mute status must be readily observed 112
mute timing diagram with four mute sensors, mute enable, safety light screen &
limited mute time with safety light screen configured for automatic reset 114
mute timing diagram with muting sensor pair, mute enable, safety light screen and
limited mute time with mutable safety device configured for automatic reset 113
mute timing diagram with muting sensor pair, mute enable, two-hand control & limited
mute time 114
mute timing sequences 113
muteable 26
muting 5
muting function 110
muting limitations 110
muting sensor pair 28
muting time limit (backdoor timer) 112
muting time limit (backdoor timer) 9
muting time limit 112
N
n.c. normally closed 117
n.o. normally open 117
name 26
name configuration 17
name configuration 56
name configuration 56
name configuration 53
no monitoring 32
nomenclature 20
non-monitored reset 68
non-monitored resets 68
non-safety input 17
non-safety input 53
non-safety input 61
non-safety input device properties 28
non-safety input devices 28
non-safety inputs 58
not a stand alone point-of-operation guarding 3
notes 1
O
obi 29
obi configuration options 17
obi on board interface 117
off 66
off-delay 66
on 66
on board interface overview 16
on/off 17
on/off 28
on/off 53
on/off 61
INSTRUCTION MANUAL - EUROPEAN VERSION
on/off switch 28
onboard interface including push buttons, lcd display & status indicators 29
onboard interface status indicator breakdown 30
onboard lcd information display — password requirements 20
on-delay 66
open-closed debounce time 28
opening a configuration from the xm stick 49
operating conditions 20
operating instructions — general 65
operating instructions - obi 53
operating instructions - pci 37
operating system 35
optical sensor – os01 59
optical sensor 17
optical sensor 26
optical sensor 53
optical sensor 61
optical sensor 88
optical sensors 94
order no. 21
order part no 81
order part no. 80
order part no. 82
ossd interfacing 12
ossd output connections 12
ossdoutput signal switching device 117
other stopping device functions 71
output rating 81
output rating 81
output rating 81
output run
output stop 34
output system reset required
output system reset not required 34
outputs 81
outputs/system settings 17
outputs/system settings 53
outputs/system settings 56
outputs/system settings 61
outputs/system settings 61
overview 7
P
password overview 16
pc interface 31
pc interface overview 16
pc to safety controller usb port connection 24
pc to sc-xmp programming tool connection 24
pci software installation 35
pci pc interface 117
periodic (6 monthly) checkout 69
periodic checkouts 69
photoelectric sensors (opposed mode) 111
photoelectric sensors (polarized retroreflective mode) 111
pl performance level 117
plc programmable logic controller 117
point-of-operation guarding 96
positive-opening safety interlocking switches 90
positive-opening safety switches 111
power 113
power 114
power 20
power 30
power-up & reset functions 70
power-up mode 15
power-up option 62
pren preliminary engineering norm 117
preventive maintenance 69
printing options 50
procedure 70
product 19
product performance standards 21
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Alpha-Numerical Index
product safety labelling information 2
proper electrical connection 3
proper wiring 12
protective stop 26
protective stop 53
protective stop 61
protective stop 88
protective stops (safety) 89
protective stops 17
psdi presence-sensing-device initiation 117
pssd presence sensing 117
Q
qd quick disconnect 117
qualified person 4
R
read this block 1.6 on page 3 carefully before installing the system 3
receive file from xm 17
receive file from xm 53
receive file from xm 62
receiving a configuration from sc22-3 safety controller 49
recovering from a lockout 77
removable terminals 20
repairs and warranty service 74
requirements 89
requirements 90
requirements 94
requirements 99
requirements 102
requirements 108
requirements 110
reset – rs01 60
reset 17
reset 53
reset 61
reset additional information 7
reset configuration 71
reset logic 27
reset logic: 26
reset needed 66
reset routine required 102
reset signal requirements 68
reset switch location 5
resets 5
response and reaction times 20
risk assessment 32
rope pull 17
rope pull 26
rope pull 53
rope pull 61
rope pull 88
rope pulls (cable) 104
run mode 53
run mode 66
S
safe working procedures and training 108
safety (protective) stop circuits 33
safety categories 87
safety circuit integrity & iso 13849-1 (en954-1) safety circuit principles 87
safety circuit integrity levels & multiple e-stop buttons 103
safety circuit integrity levels 87
safety circuit integrity levels 90
safety circuit integrity levels 94
safety circuit integrity levels 102
safety controller connection to interface modules 33
safety controller safety input device & circuit type monitoring breakdown 26
safety controller starter kit 80
safety device connection considerations 25
safety input & non-safety input (22 terminals) 20
safety input & non-safety input configurable devices 40
VI
SC22-3 Safety Controller
safety input 1 (auto) 7
safety input 1 (manual) manual reset) 7
safety input 1 14
safety input 1 8
safety input 13
safety input 17
safety input 2 (manual monitored manual reset) 7
safety input 2 (manual) 7
safety input 2 (manual) 8
safety input 2 14
safety input 2 8
safety input 9
safety input 9
safety input 3 14
safety input 4 14
safety input 53
safety input 61
safety input device properties 25
safety input internal logic 8
safety input properties breakdown 25
safety inputs & non-safety inputs 8
safety inputs 4
safety inputs 56
safety inputs with a common manual reset, mapped to the same safety output, timing
logic 7
safety inputs with common manual reset mapped to same safety output 7
safety light screen 113
safety light screen 114
safety mat 17
safety mat 26
safety mat 53
safety mat 61
safety mat 88
safety mat system design & construction 99
safety mats (safety edges) 99
safety notice breakdown 1
safety notices 1
safety output (on-delayed) 9
safety output 1 8
safety output 7
safety output 7
safety output 8
safety output 9
safety output 10
safety output 113
safety output 114
safety output lead resistance 12
safety output on-delays & off-delays 13
safety output so1, so2, so3 30
safety output status 66
safety output status message 66
safety output status message breakdown 66
safety output terminal block 69
safety output with off delay timing logic 13
safety outputs 12
safety outputs 13
safety outputs 17
safety outputs 53
safety outputs 56
safety outputs 61
safety outputs 81
safety outputs (6 terminals, 3 redundant outputs) 20
safety standards 2
safety stop circuit 83
safety stop circuit 83
safety system & safeguarding device checkout 70
save configuration 17
save configuration 53
save configuration 55
save configuration 56
save configuration 61
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SC22-3 Safety Controller
Alpha-Numerical Index
save configuration 62
saves the displayed faults to a file for later reference. 77
sc22-3 safety controller 21
sc22-3 safety controller 85
sc22-3 safety controller ce marking / production identification plate 19
sc22-3 safety controller connections to sc-xm1 external memory card (xm card) 24
sc22-3 safety controller dimensions 22
sc22-3 safety controller dimensions 22
sc22-3 safety controller general specifications 20
sc22-3 safety controller interfacing 23
sc22-3 safety controller interfacing 3
sc22-3 safety controller kit components 23
sc22-3 safety controller model/type numbering 21
sc22-3 safety controller obi configuration mode options 56
sc22-3 safety controller obi run mode options 53
scenario 1 masking of a failure 91
scenario 2 non-detection of a failure 91
schedule of check-outs 69
scheduled fault log capture 51
sc-im9 series 81
screen 58
screen 60
screw terminals 20
sc-xm1 external memory xm stick 24
sc-xmp programming tool 24
security protocol 4
select function... 61
select source... 61
selecting safety inputs 41
send file to xm 17
send file to xm 62
send file
to xm 53
sending a configuration to the sc22-3 safety controller 49
sending a configuration to the xm stick 49
sending a confirmed configuration to the safety controller: 16
series connection & safety circuit integrity considerations 91
set display contrast 55
set language 17
set language 64
set mute limit timers 60
set power-up option configuration 70
set language 53
settings breakdown 15
shock hazard - disconnect power 3
shows selected circuit type & input terminals assignment 25
signal change-of-state (cos)(simultaneity) types 27
signal change-of-state (simultaneity) 27
signal convention 1 24 v dc = run (default) 34
signal convention 14
signal convention 2 0 v dc = run 34
signal convention breakdown 34
signal convention... 61
signal convention... 62
signals run & stop states 4
silsafety integrity level 117
simultaneity timer reset function 112
single channel 83
single channel 83
single channel control 33
single channel edm connection 83
single channel edm connection to im-t-9a interface module 85
single channel edm connection to sc-im9a interface module 84
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. 83
single channel monitoring 10
single channel monitoring 32
single channel, 1 terminal - single channel, 2 terminal - single channel,
pnp switch 103
single channel, 1 terminal - single channel, 2 terminal - single channel,
pnp switch 104
INSTRUCTION MANUAL - EUROPEAN VERSION
single channel, 1 terminal - single channel, 2 terminal - single channel, pnp switch 89
single channel, 1 terminal - single channel, 2 terminal - single channel, pnp switch 92
single channel, 1 terminal - single channel, 2 terminal - single channel, pnp switch 95
software and hardware versions 17
software and hardware versions 53
software installation 35
spare parts 80
spare parts, special tools & material 80
specifications 20
ssisafety stop interface 117
starting pci program 38
start-up test 26
status (safety controller mode) 30
status indicator 30
status output settings 17
status output setting 53
status output setting 61
status output settings 54
status output settings setting 17
status output settings setting 56
status output signal convention 34
status outputs 14
status outputs 17
status outputs 34
status outputs 53
status outputs 56
status outputs 61
status outputs (10 terminals) 20
stop 66
suggested remedy 78
supplied terminal block 84
supply voltage 81
symbol 2
system (final) checkout 73
system checkout 69
system in lockout
system in run mode 34
system options 17
system options 53
system options 64
system requirements 35
system requirements 35
system reset & lockout conditions 68
system reset 9
system reset 5
system reset 49
system reset 62
system reset required
system reset not required 34
system settings 15
system settings 17
system settings 53
system settings 56
system settings 61
system settings 62
system status 66
system switch location 68
T
technical data 20
terminal assignments 17
terminal assignments 53
terminal assignments 54
terminal assignments 56
terminal assignments 61
test 66
time since fault 79
timed out 66
timing diagram for one mute sensor pair with mute enable 9
timing for dual channel edm between channels 10
timing for single channel edm status with respect to safety output 10
to add non-safety input: 41
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Alpha-Numerical Index
SC22-3 Safety Controller
to add safety input: 41
track fault status 61
track input 61
track output 61
tracked function 34
transmit/receive tx/rx 30
troubleshooting 74
turning a delayed output on/off 13
two-hand control – thc01 59
two-hand control 8
two-hand control 17
two-hand control 26
two-hand control 53
two-hand control 61
two-hand control 88
two-hand control 96
two-hand control activation on power-up protection 8
two-hand control device & manual reset safety input timing logic 8
two-hand control device 8
two-hand control devices – functional aspects – principles for design 2
two-hand control functions 71
two-hand control inputs 114
type no. 80
type no. 81
U
unassigned 61
usb b port 24
usb connections 24
usb port 35
usbuniversal serial bus 117
use of mute and bypass switch functions 10
use of transient suppressors 12
use of warnings 3
used to select circuit type from drop-down menu 25
used to select reset logic from drop-down menu 25
used to type in name for safety input device 25
user responsibility for application safety 3
V
v dc voltage direct current 117
vac voltage alternating current 117
value/meaning 20
verifying system operation 69
view current faults 17
view current faults 53
view current faults 78
view fault log 17
view fault log 53
view fault log 79
view response times 17
view response times 53
view response times 54
view response times 56
W
waiting fo reset 61
warning 1
warnings 1
wiring diagrams 83
working with the pci program 37
X
x2 complementary a & b 27
x2 complementary a & b 27
xm card message 67
xm card status message breakdown 67
xm matches the active configuration 67
xm card obi status 67
xm card port 24
VIII
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