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122

P/N 133487

Banner Engineering Corp.

•

Minneapolis, U .S .A .

www .bannerengineering .com • Tel: 763 .544 .3164

SC22-3 Safety Controller

Instruction Manual

Glossary of Terms

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 .
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 .
NOTE: When Automatic Reset is selected, the input device may be

said to be configured to run in Trip mode .

Change of state (COS): 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 describe the

signal disparity limits that can exist between channels before a fault

condition is registered: simultaneous and concurrent .

• Simultaneous: 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 .

• 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 .

NOTE: Simultaneity vs . Concurrency . If simultaneity is a

requirement or a concern for the application, the user has to

ensure that he made the right selection during configuration .

Differences between simultaneity and concurrency are

explained above .

Closed-Open debounce time: Time 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 .
NOTE: A longer closed-open debounce time will also affect and

increase the response time of the system and/or the

machine response time .

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 .

Commissioning: The process of operationally checking a Safety

Controller installation on a working machine, in order to verify that

the control system is working properly .
Complementary Contacts: Two sets of contacts which are always

in opposite states .
Configurable: Describes a control device that has pre-defined

and pre-tested operational parameters that can be selected or

enabled, in order to accommodate a variety of control application

requirements .
Configuration: A selected set of pre-defined and pre-tested input

and output device properties and logic relationships that define

the operating algorithm that the Safety Controller uses to control

hazardous machine motion .
Confirmation: The two-step process where a new or modified

configuration is sent to a Controller for code validation, and a copy

of the validated code is sent back from the Controller to the PCI for

manual parameter (I/O and System settings) verification .
Designated Person: A person or persons identified and

designated in writing, by the employer, as being appropriately

trained and qualified to perform a specified checkout procedure .
Diverse-redundancy: The practice of using components, circuitry

or operation of different designs, architectures or functions to

achieve redundancy and to reduce the possibility of common mode

failures .
Dual-channel: Having redundant signal lines for each safety input

or safety output .
Enable a mute time limit: As soon as a mute sensor is mapped

to a safety input device, a default time limit of 30s will show

up in the properties window . This time limit can be disabled by

unchecking the ‘Enable Time Limit’ box . This extends the time for

the mutable safety device to be muted to infinite .
IEC: International Electrotechnical Commission
Input/output mapping: The configurable logic association,

created during the configuration process, between the state of the

input signals and the corresponding state of the output signals .
NOTE: After an Input is assigned to control one or more outputs, it

is said to have been mapped to these outputs and that the

outputs have been mapped to this input .

ISO: International Organization for Standardization

Glossary of Terms

Summary of Contents for SC22-3

Page 1: ...ity Input device hookup Manages several safety related functions 22 Inputs for safety and non safety input devices 3 dual channel Safety outputs with selectable ON and OFF delay 10 Status outputs track input and output status mute status lockout fault conditions and reset needed Simple configuration procedure using PC interface PCI or on board controller interface OBI maps each input device to any...

Page 2: ...re to follow any of these recommendations can potentially create a dangerous condition that may lead to serious injury or death Section 1 Overview 1 1 1 Applications 1 1 2 Design and Testing 1 1 3 Components 2 1 4 Configuring the Safety Controller 4 1 5 Input and Output Devices 7 1 6 System Settings 10 1 7 Internal Logic 11 1 8 Password Overview 11 1 9 Confirming a Configuration 11 Section 2 Compo...

Page 3: ...troller 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 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 appl...

Page 4: ... cable some models 1 SC XMP XM card programming tool some models 1 CD containing PCI software instruction manual and configuration tutorials p n 134534 1 Quick Start Guide Figure 1 1 SC22 3 Safety Controller kit components Removable Terminals USB A B Cable SC22 3 Safety Controller External Memory Card XM card SC XMP XM card programming tool some models CD containing PCI software instruction manual...

Page 5: ...equire 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 Send a copy to the XM card using the PC Interface PCI and the SC XMP programming t...

Page 6: ...eeded Assign status output signals if needed Create configuration name file name date author name and notes 3 Confirm the configuration Controller verifies that the desired configuration is valid User confirms that the configuration is what is expected 1 4 1 Onboard Interface OBI The Safety Controller can be configured using its built in push buttons and LCD screen the Onboard Interface OBI The LC...

Page 7: ...4 Onboard Interface including push buttons LCD display and status indicators SC22 3 Safety Controller Power Status Tx Rx SO1 SO2 SO3 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 Moves cursor down or causes items within a list to be displayed as the cursor is moving down through the list May als...

Page 8: ...e configuration progresses Creating a configuration is simple Once a configuration is created it can be stored to a computer file for archiving and future use or can be emailed 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 The PCI can be used to create a configuration save it and send it as described above and a...

Page 9: ...rol Section A 5 Safety Mat Edges Section A 6 Emergency Stop Push Buttons Section A 7 Rope Cable Pull Section A 8 Enabling Devices Pendants Section A 9 Bypass Section A 10 Muting Section A 11 For further information about connecting any devices to the Safety Controller contact Banner Engineering Safety Device Hookup Considerations The inputs of the SC22 3 Safety Controller can be configured to inte...

Page 10: ... 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 See Section 3 6 2 for more information ON Delays and OFF Delays Each safety output can be configured to function with a time delay There are two...

Page 11: ...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 pre...

Page 12: ...TION 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 if 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 ...

Page 13: ... occur The rules that apply to these special cases are explained in Appendix A 1 8 Password Overview To provide security the Safety Controller requires use of a password in some cases For information about changing a Controller s password refer to Sections 4 2 1 PCI and 5 3 4 OBI NOTE If the password becomes lost contact the Factory for assistance Creating a Configuration Via computer using the SC...

Page 14: ...y cards SC XMP USB programming tool for XM card SC TS1 Screw terminal blocks 1 set for 1 Safety Controller SC TC1 Cage clamp terminal blocks 1 set for 1 Safety Controller SC USB1 USB A B cable 134534 CD including PCI program and instruction manual Replacement Parts Accessories 2 1 Models Safety Controller Starter Kit Models Kits include SC22 3 Safety Controller a set of plug on terminal blocks scr...

Page 15: ...ts SC IM9A For use with 1 SC22 3 safety output 24V dc Controller supplied 2 SO1 3 N O 10 amps 1 N C pair per output SC IM9B For use with 2 SC22 3 safety outputs 4 SO1 and SO2 Total of 6 3 N O per output SC IM9C For use with 3 SC22 3 safety outputs 6 SO1 SO2 and SO3 Total of 9 3 N O per output Model Supply Voltage Inputs Safety Outputs Output Rating EDM Contacts Aux Outputs IM T 9A 24V dc 2 dual ch...

Page 16: ...on Times Response time ON to OFF 10 ms max with standard 6 ms debounce this can increase if debounce time increases Refer to the configuration summary for actual response time Reaction time OFF to ON 400 ms max with manual reset option Reaction time OFF to ON 400 ms max plus input debounce time auto reset Onboard LCD Information Display Password Requirements Password is not required Run mode I O s...

Page 17: ...49 1 IEC 61131 2 Programmable Controllers Part 2 Equipment Requirements and Tests UL 508 Industrial Control Equipment UL 1998 Software in Programmable Components ANSI NFPA 79 Electrical Standards for Industrial Machinery IEC 60204 1 Electrical Equipment of Machines General Requirements EN 954 1 Safety of Machinery Safety Related Parts of Control Systems General Principles ISO 13851 EN574 Safety of...

Page 18: ...ition any questions regarding safeguarding should be directed to the factory applications department at the number or addresses listed on the front cover WARNING Shock Hazard Always disconnect power from the Safety Controller and the guarded machine before making any connections or replacing any component Electrical installation and wiring must be made by qualified personnel and must comply with t...

Page 19: ...an cause short circuits at that point Using positive opening or direct drive components installed and mounted in a positive mode WARNING Failures and Faults The SC22 3 Safety control can be interfaced with input devices at differing levels of integrity as described in Appendix A The user must conduct a Risk Assessment to determine the appropriate level of integration The user also must eliminate o...

Page 20: ... safety output s it controls will turn back ON when the input device changes to the Run state provided that all other controlling inputs are also in the Run state Reset rules and types are discussed in Section 3 4 Terminal Numbers Connecting the Input Devices The Controller needs to know what device signal lines are to be connected to which wiring terminals so that it can apply the proper signal m...

Page 21: ...multaneity 2 Ch 2 Terminal PNP 24V Gate Switches Single Channel 1 Ch 1 Terminal 1 Ch 2 Terminals 1 Ch 1 Term PNP Gate Switches Dual Channel 2 Ch 2 Terminals 2 Ch 3 Terminals 2 Ch 4 Terminals 24V Gate Switches Dual Channel Complementary Complementary 2 Terminals Complementary 3 Terminals Complementary 2 Terminals PNP 24V Gate Switches 2x Dual Channel Complementary 2x Complementary 4 Terminals 2x Co...

Page 22: ...dependent on the Run 10 to 500 ms and Stop 6 to 100 ms debounce times CAUTION Response Times 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 to closed debounce time will affect the safety output reaction turn ON time The configura...

Page 23: ...output will need a valid manual reset signal before it will turn ON If two safety inputs each configured for manual reset are mapped to the same safety output then only one valid reset operation is required to 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 perfo...

Page 24: ...et option 3 5 3 Enabling Devices Enabling Device 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 ult...

Page 25: ...witch is in the Enable 24V dc state at the time the mute cycle is started After the mute cycle starts the ME input can be turned OFF A mute enable input device can be mapped to one or more mutable safety inputs Mute 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 differen...

Page 26: ...lt in serious injury or death Refer to Sections A 10 and A 11 for more information Mute Enable ON or OFF Safety Input Mute Sensor Pair Safety Output Figure 3 5 Timing diagram for one mute sensor pair with mute enable 3 5 5 Bypass Function The safety device bypass is a manually activated and temporary suspension of one or more safety input stop signals when no immediate hazard is present Bypass swi...

Page 27: ...r a reset is executed and the safety outputs 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 milliseconds of the OSSD outputs going from ON to OFF Two Channel Monitoring an independent connection of closed monitor contacts that are forced guided mechanically linked from each device controlled by th...

Page 28: ...onitor both MPCE feedback signals If the channels are not in the same state the system goes into a Lockout condition Figure 3 8 Two channel EDM hookup Safety Output Closed Open OFF ON EDM Don t Care Don t Care Don t Care Don t Care 250 ms Max 250 ms Max Figure 3 9 One channel EDM status with respect to safety output Safety Output 250 ms Max 250 ms Max 250 ms Max 250 ms Max Don t Care Closed Open C...

Page 29: ... delay time will be honored even if the safety input that caused the OFF 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 Saf...

Page 30: ...y related control system that includes the Controller The normally open outputs from an interfacing module see Section 2 1 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 3 12 Dual Channel Control Dual channel or two channel control has the ability to electrically extend the ...

Page 31: ... result in an ON condition and The Safety Controller s solid state safety output maximum leakage current due to the loss of 0V will not result in an ON condition Failure to properly interface the safety outputs to the guarded machine could result in serious bodily injury or death CAUTION Shock Hazard Always disconnect all power from the Safety Controller and the guarded machine before making any c...

Page 32: ... must be designed so that The maximum cable resistance value between the Safety Controller solid state safety outputs 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 0V will not result in an ON conditi...

Page 33: ... manner Depending on the application each safety output requires a separate and individually wired IM T A module See Section 3 6 1 on external device monitoring and Section 3 6 3 on interfacing safety stop circuits WARNING Use of Transient Suppressors Transient suppressors are recommended They MUST be installed across the coils of the machine control elements NEVER install suppressors directly acr...

Page 34: ... manner Depending on the application each safety output requires a separate and individually wired IM T A module See Section 3 6 1 on external device monitoring and Section 3 6 3 on interfacing safety stop circuits WARNING Use of Transient Suppressors Transient suppressors are recommended They MUST be installed across the coils of the machine control elements NEVER install suppressors directly acr...

Page 35: ...tus Output s State Signal Convention 1 24V dc Run Default Signal Convention 2 0V dc Run Input Run Input Stop 24V dc 0V dc 0V dc 24V dc Output Run Output Stop 24V dc 0V dc 0V dc 24V dc System in Lockout System in Run mode 24V dc 0V dc 0V dc 24V dc I O fault exists No I O fault exists 24V dc 0V dc 0V dc 24V dc System Reset required System Reset not required 24V dc 0V dc 0V dc 24V dc Output Reset req...

Page 36: ... 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 and ladder logic diagrams These diagrams provide I O device wiring detail for the installer and a symbolic representation of t...

Page 37: ...play real time Run mode data from a working Controller over a USB connection Figure 4 1 PCI Main screen components Send receive and confirm buttons appear in color when a powered Controller or programming tool is connected to the PC Access the live display I O Properties Double click to access property settings Tool Bar Add a safety input to the configuration Add a non safety input to the configur...

Page 38: ...in PCI screen should appear Figure 4 3 PCI main screen before configuration The three support documents if opened at this point show the following information The 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 The Ladder Logic Diagram shows the vertical lines representing 24V and 0V dc ...

Page 39: ... 1 5 4 Monitored system reset OFF or ON default see Section 3 4 When complete click OK 4 3 2 Add an Input Device Click the Add Safety Input icon and the Safety Input Device selection menu appears Figure 4 5 It displays the device types the Controller can accommodate If the non safety input icon is clicked the Non Safety Input Device selection menu appears Figure 4 6 While their functions differ th...

Page 40: ...5 see Figure 4 7 designate that these terminals supply the 24V dc source for the device contacts NOTE See Appendix A for more information about safety circuit integrity levels and the capabilities of each circuit type Reset Logic Select between Manual or Automatic Reset from the drop down menu Mapping Map each safety input device to one or more safety outputs at least one must be selected by check...

Page 41: ...tion selected Signal convention depending on function selected 4 3 4 Save and Confirm the Configuration You will need to confirm this new configuration before it can be used in a safeguarding application A 4 digit Controller password is required to save and confirm a configuration and to enable it to run on a Safety Controller The confirmation process has two parts 1 Code validation The microcontr...

Page 42: ...properties are correct either click on Confirm or click in the corresponding checkbox A check mark will appear in the box and the section will compress to a list as shown in Figure 4 11 If the columns do not match or if you wish to change any circuit Select Edit for the device to be changed The Properties menu for the device will open Make the necessary change s Select OK A message will appear ask...

Page 43: ...tool bar 4 5 3 Open a Configuration from the XM Card Both confirmed and unconfirmed configurations can be sent to or received from the XM card To open a copy of a configuration from the XM card and display it in the PCI Connect the SC XMP programming tool to the PC using the USB cable Insert the XM card into the programming tool Go to File Open From XM Card in the upper left corner of the screen A...

Page 44: ...se The password is now changed Record the password for safekeeping NOTE If the password becomes lost contact Banner Engineering for assistance 4 5 7 Export Documents The configuration documents wiring diagram ladder logic diagram and configuration summary can be saved as either pdf or dxf files To export a configuration file Open the configuration file that you want to save Go to File Export in th...

Page 45: ...ween input devices and between the input devices and the outputs This section provides a map and description of Run mode and Configuration mode options using the OBI See Figure 5 1 for an overview of all the Run mode and Configuration mode options available For an example of a beginning to end configuration process using the OBI refer to Appendix C To move through the menus in most cases press the...

Page 46: ...and hardware versions Configuration Mode Section 5 3 Configuration Summary Fault Diagnostics Clear Fault Log View Fault Log View Current Faults Status Output Settings Input Output Mapping Terminal Assignments Set Display Contrast Exit Configuration Section 5 3 4 Edit Configuration Section 5 4 Edit Input Delete Input Inputs Section 5 4 2 Outputs System Settings Section 5 4 3 Configuration Summary S...

Page 47: ... itself Use the up down arrows to highlight your selection then press OK to select Fault Diagnostics Use this screen to view current faults view the fault log or clear the fault log Refer to Section 8 3 for more information Configuration Mode Use this selection to enter Configuration mode and create or edit a configuration refer to Section 5 3 for more information Configuration Summary This select...

Page 48: ...OK ESC OK ESC OK ESC OK ESC Enter Password Section 5 3 1 Figure 5 3 OBI Configuration mode options 5 3 2 Configuration File Edit Configuration To edit the configuration from the Configuration Mode menu select Configuration File and press OK See Section 5 4 for more instructions To begin editing the configuration select Edit Configuration from the Configuration File menu and press OK Erase Configur...

Page 49: ... Use the up down arrows to select a safety output and press OK The next series of menus displays the safety critical configurations for the selected safety output Review each setting and press OK When the safety output is confirmed a checked box should appear in front of it on the Confirm Outputs screen Repeat the confirmation process for each safety output When all safety outputs have been confir...

Page 50: ...and French Highlight the correct language to select it then press OK NOTE Language can also be changed immediately 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 5 3 5 Exit Config...

Page 51: ...ut Select this option to add either a safety or non safety input device See Section 5 5 for the procedure Delete Input This option is used to remove a previously added input device from the configuration A screen will appear with all of the previously configured inputs use the left right arrows to select a device and press OK A screen will ask whether you really intend to delete this input select ...

Page 52: ...atus waiting for reset and mute status Use the up down arrows to select Select Function and press OK Use the left right arrows to select a function then press OK The display returns to the Status Output Properties menu Select the source for the status output function Select Select Source and press OK Use the left right arrows to select a device and press OK The display returns to the Status Output...

Page 53: ...OK to select 5 4 5 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 select Save Configuration and press OK If you do not want to save the changes while at the Edit Configuration menu press the ESC push button and select Yes when asked if you want to exit without savin...

Page 54: ...nabling devices Mute sensors Bypass switches NOTE See Appendix A for more information about each of the input device types 5 5 2 Add a Non Safety Input Non safety input device options include Manual reset switches ON OFF switches Mute Enable switches Select an Input Device Either Safety or Non Safety Use the left right arrow buttons to select the proper device then press OK The arrows at the top o...

Page 55: ... Optical Sensor E Stop Safety Mat Protective Stop Two Hand Control Enabling Device Rope Pull EDM Bypass Switch Mute Sensor Add Input Section 5 5 Add an Input continued Select the Circuit Type of the Input Use the up down arrows to select Select Circuit Type and press OK NOTE See Appendix A for more information about safety circuit integrity levels and the capabilities of each circuit type The Sele...

Page 56: ...ect the output and press OK When the input is mapped to the safety outputs as desired select Save and press OK After the input is mapped to the safety outputs the display returns to the Input Properties menu Screen below shows device ES01 mapped to all three safety outputs OK ESC Safety Input Section 5 5 1 Non Safety Input Section 5 5 2 OK ESC OK ESC Mute Enable Reset ON OFF Gate Switch Optical Se...

Page 57: ...it in a pop up screen see Figure 6 1 The Live Display screen 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 6 Operating Instructions 6 2 Display Controller Information Onboard Interface OBI Figure 6 1 Live Display screen PCI Figure 6 2 Run m...

Page 58: ...lls through the safety outputs that are OFF at 2 second intervals Line 5 of the display states the reason for the status of the selected safety output NOTE Output faults are recoverable via a system reset see Section 6 4 Safety Output Status Message Cause and or Required Action ON The safety output is ON ON Delay The safety output will turn ON when the ON delay time expires OFF The safety output i...

Page 59: ...ycle through the inputs If more than one output is OFF a small arrowhead indicates the safety output to which the input messages correspond see Figure 6 3 Input Device Status Message Cause and or Required Action Stop The safety input is in a state that causes the safety output to turn OFF Test A start up test needs to be completed on the safety input To perform the test cycle the input Run Stop Ru...

Page 60: ... condition exists the fault must be corrected before the system reset operation will turn the safety outputs ON External Memory Card XM Card Status The status of the XM card is temporarily displayed when it is inserted while the Run mode screen is active Remove and replace the correct XM card as necessary XM Card Message Cause XM matches the active configuration The configuration stored on the car...

Page 61: ...ut 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 will turn 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 t...

Page 62: ...laced into service and after each Safety Controller configuration is created or modified Periodic Semi Annual Checkout A Qualified Person must also perform a safety system re commissioning semi annually every 6 months or at periodic intervals based on the appropriate local or national regulations Daily Operational Checks A Designated Person must also check the effectiveness of the protective devic...

Page 63: ... ensure proper installation and 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 Section 7 1 for a schedule of required checkouts For the initial part of the commissioning checkout the Controller and associated safety systems must be checked without power being available to the gua...

Page 64: ...ion 3 6 3 Verify that all two hand control devices enabling devices muting sensors and bypass switches are in the inactive Stop state NOTE In all cases outputs associated with a two hand control device should not turn ON at power up Also bypass or enabling devices in the active Run state at power up will not function until they are seen as OFF first 4 Ensure that all other input devices are in the...

Page 65: ...h an enabling device will remain OFF If a particular function or device is not part of the application skip that step and proceed to next check or to step 20 Two Hand Control Functions 10 Ensure all inputs are in the ON state associated with safety outputs and activate each two hand control device to turn ON the remaining outputs Verify that the associated safety output remains OFF unless both han...

Page 66: ...le must be initiated for each one 16 Mute on Power Up Option Turn the SC22 3 power OFF Activate the 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 the Stop inactive state Verify proper operation at...

Page 67: ...ts turn OFF when the bypass timer backdoor timer expires Verify that when the bypass switch is in the Stop state and goes back into the Run state The associated safety outputs turn ON Generate a stop command from the non bypassed safeguarding device s one at a time Verify that the associated safety output s turns OFF while the input is bypassed 19 Enabling Device Function Verify that all inputs as...

Page 68: ... the Safety Controller and verify for each input device that The safety outputs and status outputs operate as expected e g ON delays OFF delays etc Use the configuration summary to verify operation It is not possible for the guarded machine to be put into motion Initiate machine motion of the guarded machine and while it is moving generate a stop command from each of the safety devices or safeguar...

Page 69: ... contact the factory In case of a non recoverable fault do not open the housing of the Controller and do not attempt to repair the Controller yourself Contact a Banner factory applications engineer at Banner Engineering Corp 9714 Tenth Avenue North Minneapolis MN 55441 Phone 763 544 3164 Toll Free US only 888 373 6767 Email sensors bannerengineering com An applications engineer will attempt to tro...

Page 70: ...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 2 3 or 2 5 Concurrency Fault Cycle Input On a complementary pair with both inputs in the ...

Page 71: ...tage for longer than 6 ms Check the power supply voltage and current rating Check for an overload on the outputs that might cause the power supply to limit the current 4 2 4 11 Internal Fault Internal failure Contact Banner Engineering 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 ...

Page 72: ...ays real time fault information via the Fault Log screen shown in Figure 8 1 The fault information 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 lookup table reference Additional code information can be displayed should factory applications ...

Page 73: ...t log and clear the fault log 8 6 1 View Current Faults To view current fault conditions select View Current Faults using the up down arrow buttons and press OK Figure 8 4 View current faults OBI The screen shows the fault conditions that currently exist one at a time Use the left right arrow keys to view all the faults Shortcut To view current faults when the Run mode screen is displayed simply p...

Page 74: ...f 01 30 23 indicates the 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 the fault log is being viewed the time is displayed as New Fault If a fault is older than twenty four hours the time is displayed as 24hours The fifth line provides the fault code Use the fault code and information ...

Page 75: ...ty Category Reference If the requirements described by ISO 13849 1 are to be implemented 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 U S control reliability or European C level standards to ensure that the minimum level of...

Page 76: ...rminals 2x Complementary 5 Terminals mentary 4 Terminals PNP from OFF ON OFF ON to ON OFF ON OFF o outlines nnel PNP 2 Ch 2 Terminal PNP Complementary 2 Terminal PNP 2x Complementary 5 Terminals and 2x Complementary 4 Terminals PNP ON ON OFF ON OFF ON OFF ON 2 Ch 2 Terminal PNP 24V Gate Switches Single Channel 1 Ch 1 Terminal 1 Ch 2 Terminals 1 Ch 1 Term PNP Gate Switches Dual Channel 2 Ch 2 Termi...

Page 77: ...nals 2 Ch 3 Terminals 2 Ch 4 Terminals 24V 2 Ch 2 Terminals 2 PNP Muting Sensor Pair Dual Complementary Complementary 2 Terminals Complementary 3 Terminals Complementary PNP 24V 01 Aug 2007 Optical Sensors and Protective S OFF OFF ON OFF 24V 1 Ch 1 Terminal 1 Ch 2 Terminals 1 Ch 1 Term PNP Revision Histo Dual Channel PNP device This circuit can meet ISO 13849 1 Category 2 3 or 4 requirements depen...

Page 78: ...ate standard The guard must be strong enough to contain hazards within the guarded area which may be ejected dropped or emitted by the machine 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 can not shift using reliable fasteners that require a tool to remove them Posi...

Page 79: ...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 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 long...

Page 80: ... 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 24V dc Open Open Open Figure A 3 Category ...

Page 81: ...inals 4 PNP 20 Sept 06 Rev D Moved 24V ON and OFF text closer to drawings 21 Nov 06 Rev E Added sign to 1 Ch 2 Terminals 2 Ch 3 and 4 Terminals Complementary 3 Terminals 2x Complementary 5 Terminals 08 Dec 06 Rev F Changed 2x Complementary 4 Terminals PNP from OFF ON OFF ON to ON OFF ON OFF 10 Jan 07 Rev G Changed sign text to outlines 25 May 07 Rev H Changed Single Channel PNP 2 Ch 2 Terminal PNP...

Page 82: ...NP Gate Switches 2x Dual Channel Complementary 2x Complementary 4 Terminals 2x Complementary 5 Terminals 2x Complementary 4 Terminals PNP 24V F and ON on Two hand Operation 2x Dual Channel Complementary 2x Complementary 4 Terminals 4 PNP oved 24V ON and OFF text closer to drawings ded sign to 1 Ch 2 Terminals 2 Ch 3 and 4 Terminals Complementary 3 Terminals 2x Complementary 5 Terminals anged 2x Co...

Page 83: ...short circuit capabilities of the input device The SC22 3 does not provide short circuit detection in this configuration 2 Ch 2 Terminals PNP ht Curtain erminals 2 Ch 3 Terminals 2 Ch 4 Terminals 06 Rev D Moved 24V ON and OFF text closer to drawings 06 Rev E Added sign to 2 Ch 3 Terminals and 2 Ch 4 Terminals 07 Rev F Change sign text to outlines 07 Rev G Changed PNP diagram 07 Rev H Changed all t...

Page 84: ... 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 CAUTION Machine Control Must Provide Anti Repeat Control Appropriate anti repeat control must be provided by the machine control and is req...

Page 85: ... Dual Channel Complementary 2x Complementary 4 Terminals 2x Complementary 5 Terminals Revision History Rev C Corrected OFF and ON on Two hand Operation 2x Dual Chan 20 Sept 06 Rev D Moved 24V ON and OFF text closer to drawings 13 Oct 06 Rev E Gray lines moved below the black lines 21 Nov 06 Rev F Added sign to 2 Ch 3 Terminals 2 Ch 4 Terminals 2 10 Jan 07 Rev G Changed sign text to outlines change...

Page 86: ...Complementary 5 Terminals centered arrow and 2x Complementary 4 Terminals 4 PNP V OFF OFF ON OFF ON OFF 2X Complementary 4 terminals or 5 terminals The figure 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...

Page 87: ...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 A 6 2 SC22 3 Safety Mat Hookup Options Pressure sensitive mats and pressure sensitive floors must meet the requirements of the category for which they are...

Page 88: ...e exterior edge of the sensing surface is at or beyond the safety distance unless solely used to prevent start restart or solely used for clearance safeguarding see ANSI RIA R15 06 The separation 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...

Page 89: ...cluding the following Emergency stop push buttons shall be located at each operator control station and at other operating stations where emergency shutdown is required Stop and Emergency 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 emergency stop devices shall be colo...

Page 90: ...jury or death This check must be performed during periodic checkouts Category 2 A single channel emergency stop application typically provides a Category 2 level of circuit performance because a short circuit could cause the loss of the safety function The principle of fault exclusion must be incorporated into the design and installation to either eliminate or reduce to an acceptable minimal level...

Page 91: ...dded sign to 1 Ch 2 Terminals 2 Ch 3 Terminals Dual Channel 4 Terminals 10 Jan 07 Rev G Changed gray lines to 6 pt dashed lines Converted sign text to outlines 25 May 07 Rev H Updated all 24V 24V ON ON 2 Ch 2 Terminals PNP E Stop Input Single Channel 1 Ch 1 Terminal 1 Ch 2 Terminals 1 Ch 1 Term PNP E Stop Input Dual Channel 2 Ch 2 Terminals 2 Ch 3 Terminals 2 Ch 4 Terminals 13Sept 06 Rev C Added O...

Page 92: ...Terminals 24V Rope Pull Dual Channel Complementary Complementary 2 Terminals Complementary 3 Terminals Complementary 2 Terminals PNP 24V Revision History 1 Aug 2007 Protective Stop was removed from this document and is with the Optical Sensor documen ON ON OFF ON 2 Ch 2 Term PNP 24V Rope Pull Single Channel 1 Ch 1 Terminal 1 Ch 2 Terminals 1 Ch 1 Term PNP Rope Pull Dual Channel 2 Ch 2 Terminals 2 ...

Page 93: ...d 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...

Page 94: ...h 3 Terminals 2 Ch 4 Terminals 24V 2 Ch 2 Terminals 2 PNP Enabling Device Circuit Diagrams 2x Dual Complementary 2x Complementary 4 Terminals 24V 2x Complementary 5 Terminals Revision History OFF OFF Enabling Device Circuit Diagrams Dual Complementary Complementary 2 Terminals Complementary 3 Terminals Complementary 2 Terminals 2 PNP 24V ON OFF 2x Complementary 4 Terminals 2 PNP ON OFF ON OFF S1 S...

Page 95: ...dous motion or create a hazardous situation This summary was derived from the following and other sources ANSI NFPA79 ANSI RIA R15 06 ISO 13849 1 EN954 1 IEC60204 1 ANSI B11 19 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...

Page 96: ...NP 24V ON OFF 2x Complementary 4 Terminals 2 PNP ON OFF ON OFF S1 S2 Enabling Device Circuit Diagrams Dual Channel 2 Ch 2 Terminals 2 Ch 3 Terminals 2 Ch 4 Terminals 24V 2 Ch 2 Terminals 2 PNP Enabling Device Circuit Diagrams 2x Dual Complementary 2x Complementary 4 Terminals 24V 2x Complementary 5 Terminals Revision History OFF OFF Enabling Device Circuit Diagrams Dual Complementary Complementary...

Page 97: ...ssed 5 The muting devices must be mounted so that their physical position and alignment can not be easily changed 6 It must not be possible for environmental conditions to initiate a mute condition e g extreme airborne contamination 7 The muting 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...

Page 98: ...tary 2 Terminals Complementary 3 Terminals Complementary 2 Terminals 2 PNP 24V 20 Sept 06 Rev D Moved 24V ON and OFF text closer to drawings 21 Nov 06 Rev E Add to 2 Ch 3 and 4 Terminals and Complementary 3 Terminals 10 Jan 07 Rev F Change sign text to outlines 25 May 07 Rev G Revised Dual Channel PNP and Complementary PNP OFF OFF ON OFF Muting Sensor Pair Dual Channel 2 Ch 2 Terminals 2 Ch 3 Term...

Page 99: ...pen for longer than 1 4 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 A 11 4 Mute Lamp Output ML Some applications require that a lamp or other means be used to indicate when the safety device e g light screen is muted the Control...

Page 100: ...t be possible for an individual to enter the guarded area without being detected and a stop command issued to the machine control This supplemental 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 A 11 8 Multiple Presence Sensing Safety Devices Muting multiple pre...

Page 101: ...iration of the Backdoor Timer Mute cycle prevented due to open Mute Enable input Mute cycle prevented due to open Mute Enable input Power Safety Light Screen Mute Enable Mute Sensor 1 Mute Sensor 2 Mute Sensor 3 Mute Sensor 4 Backdoor Timer Safety Output Max Time Max Time Max Time Max Time 3s 3s 3s 3s Figure A 9 Mute timing diagram with two mute sensors mute enable safety light screen and limited ...

Page 102: ...Inputs Mute Enable Mute Sensor 1 Mute Sensor 2 Backdoor Timer Safety Output Max Time Max Time Max Time Max Time Mute cycle prevented due to open Mute Enable input Mute cycle prevented due to open Mute Enable input 3s 3s 3s 3s A 11 9 Mute Timing Sequences continued Figure A 11 Mute timing diagram with two mute sensors mute enable two hand control and limited mute time ...

Page 103: ... to provide the basic skills and processes needed to explore the features on your own It also is not intended to explain the operation of the SC22 3 Safety Controller For complete operational instructions read Sections 1 8 of this manual Appendix B Configuration Tutorial PC Interface PCI B 1 Install the PC Interface Software Insert the Banner Safety Controller CD Select Install PC Interface progra...

Page 104: ...n shows its numbered terminals S1 through S22 for input devices both safety and non safety A1 for 24V 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 Click on the Ladder Logic Diagram tab just above the Wiring Diag...

Page 105: ...afety Input button in the center of the tool bar The Add Safety Input Device pop up menu will appear Select Emergency Stop Button Properties Double click on the Emergency Stop icon in the Add Safety Input device menu The ES01 Properties menu will appear Abbreviated sequentially numbered device names are automatically assigned but can be changed Name Keep ES01 Circuit type Keep the Dual channel 4 t...

Page 106: ... this tutorial one common manual reset signal is used to reset all of the safety outputs In a real application it is possible to assign a separate reset for each safety output if needed To do this choose the Circuit Type from the Reset Properties menu and then select the safety output that the reset device should reset Individual Reset Properties menus will appear until all safety outputs that are...

Page 107: ...it Your Gate Switch properties menu should match the one shown above Click OK Add a Two Hand Control Input Device Click on Add Safety Input Double click on the Two Hand Control icon Create a Two Hand Control configuration with the properties listed below Name THC01 Circuit 2X complementary PNP switch Terminals S7 S8 S9 and S10 Map to SO3 Click OK NOTE The reset logic is set to Automatic for Two Ha...

Page 108: ...pped to the safety input devices that they mute and not to the safety outputs Add an External Device Monitoring Input Click on Add Safety Input Double click the External Device Monitoring icon Create an External Device Monitoring configuration with the properties listed below Name EDM01 Circuit Single Channel 1 terminal Reset Automatic Terminals S17 Use the drop down terminal number field to chang...

Page 109: ... the tool bar or double left click on the O1 icon in the properties field of the screen The O1 Properties pop up menu will appear Configure status output O1 with the properties listed below Name ES01 Function Track input A drop down Source field will now appear Source ES01 Signal Convention 24V dc Run When ES01 is in the Run state O1 will be at 24V dc When ES01 is in the Stop state O1 will be at 0...

Page 110: ...ion Manual Appendix B Add Another Status Output Select status output O2 Configure status output O2 with the properties listed below Name Need Reset Function Output waiting for Reset Source SO1 Signal Convention 24V dc Reset needed Click OK The Wiring Diagram should now look like this The Ladder Logic Diagram should now look like this ...

Page 111: ...eady loaded in the Controller will be overwritten and therefore lost during this confirmation process It is the user s responsibility to save existing configurations as needed Select Yes to save the configuration or No to proceed to overwrite the Controller s existing Configuration Enter the password the factory default is 0000 on the Confirm Configuration pop up menu Click OK A pop up warning mes...

Page 112: ...ard see Section 4 5 3 To open a copy of a configuration from the XM card and display it in the PCI Connect the SC XMP programming tool to the PC using the USB cable see Section 1 3 1 Insert the XM card into the programming tool Open the File menu in the upper left of the PCI tool bar Select Open From XM Card A message will appear when the operation is complete NOTE Both confirmed and unconfirmed c...

Page 113: ...the PCI tool bar Select Print Select the configuration document you want to print A page setup menu will appear Make the page and printer choices and click OK Fault Log To access the Controller s internal Fault Log using the PCI Connect the SC22 3 Controller to the PC using the USB cable Apply 24V dc power to the Controller Open the View menu in the PCI tool bar Select Fault Log The Fault Log scre...

Page 114: ...y Controller Instruction Manual Appendix B Live Display To access live Controller information from the PCI Connect the SC22 3 Controller to the PC using the USB cable Apply 24V dc power to the Controller Click on the Live Display button in the tool bar or open View Live Display The Live Display screen will appear ...

Page 115: ...onfiguration mode To enter Configuration mode from the Run mode display press OK to display the main System Menu At the System Menu press the Down arrow button until Configuration Mode is highlighted on the display then press OK Enter Password The default password is 0000 Use the left right arrow keys to select the password digit to change Use the up down arrow buttons to change the selected passw...

Page 116: ...erminal assignments Advanced settings Reset logic Output mapping Enter Input Device Name After selecting to add an E Stop Input device the next menu displayed is the Enter Name menu Use the left right arrow keys to select the character to be changed up to 10 characters Use the up down arrow keys to change the character choices A Z 0 9 or space In this case the name of the E Stop Input was set to t...

Page 117: ... A filled in circle next to an output indicates the input is mapped to that output To remove the input mapping select the output and press OK An open circle indicates the input is not mapped to that output Map the E stop to all three safety outputs select Save and press OK After mapping the input to the safety outputs the display returns to the Input Properties menu Set Reset Logic To set the rese...

Page 118: ...trol THC01 Circuit Type 2X complementary PNP switch Terminals S7 S8 S9 and S10 Mapped to SO3 Non Safety Input Reset Input RS01 Circuit Type Single Channel 2 Terminal Contact Switch Terminals S21 and S22 Mapped to SO1 SO2 and SO3 Safety Input Optical Sensor OS01 Circuit Type Dual Channel PNP Terminals S11and S12 Mapped to SO1and SO2 Automatic Reset Logic Safety Input Mute Sensor M1 M2 The next inpu...

Page 119: ...he next menu is displayed press OK to display the Mute Time Limit Enable menu Using the up down arrow buttons select Change Time and press OK NOTE If the box in front of Enable Time Limit is not checked select Enable Time Limit and press OK to enable the time limit Change the mute time limit to 1 minute Use the left right arrows to select the digit to be changed and the up down arrows to change th...

Page 120: ... arrow keys to select the character to be changed up to 10 characters Use the up down arrow keys to change the character choices A Z 0 9 or space Set the name to ES01 and press OK The display returns to the Status Output Properties menu The top line of the display now displays the name assigned to the status output Configure the status output to track an input Select Select Function and press OK U...

Page 121: ...nput Review the configuration of each status output Review Terminal Assignments Select Terminal Assignments and press OK The display shows the terminal assignments for the first input Use the left right arrow keys to view the terminal assignments for the other inputs When finished press either OK or ESC Review Input Output Mapping Select Input Output Mapping and press OK The display shows the inpu...

Page 122: ... used in a safeguarding application To confirm the configuration select Confirm Configuration and press OK The Confirm Configuration menu will appear To confirm you ll need to review the safety critical configurations for the inputs safety outputs and the system settings An unchecked box in the Confirm Configuration menu indicates the safety critical settings have not yet been confirmed Confirm Co...

Page 123: ...puts are confirmed The last step is to confirm the System Settings Select System Settings and press OK The next series of menus lists the safety critical system settings Press OK after reviewing each setting Final Confirmation Step All of the safety critical configurations settings have been confirmed and the configuration can be used in a safeguarding application If any changes are made to the co...

Page 124: ...unce time will also affect and increase the response time of the system and or the machine response time 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 Commissioning The process of operationally checking a Safety Controller installation on a working machine i...

Page 125: ...nce time will also affect the reaction time of the Controller Qualified Person A person who by possession of a recognized degree or certificate of professional training or who by extensive knowledge training and experience has successfully demonstrated the ability to solve problems relating to the subject matter and work Run Signal The input signal monitored by the Controller that when detected ca...

Page 126: ...124 P N 133487 Banner Engineering Corp Minneapolis U S A www bannerengineering com Tel 763 544 3164 SC22 3 Safety Controller Instruction Manual System Installation ...

Page 127: ...ed Parts of Control Systems ISO DIS 13855 EN 999 The Positioning of Protective Equipment in Respect to Approach Speeds of Parts of the Human Body ISO 14121 EN 1050 Principles of Risk Assessment ISO 14119 EN 1088 Interlocking Devices Associated with Guards Principles for Design and Selection IEC EN 60204 1 Electrical Equipment of Machines Part 1 General Requirements IEC EN 61496 Electro sensitive P...

Page 128: ...free from defects for one year Banner Engineering Corp will repair or replace free of charge any product of its manufacture found to be defective at the time it is returned to the factory during the warranty period This warranty does not cover damage or liability for the improper application of Banner products This warranty is in lieu of any other warranty either expressed or implied P N 133487 ...

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