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Banner SC22-3 Instruction Manual

Safety controller
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See also: Instruction Manual
SC22-3/-3E Safety Controller
Instruction Manual
Instruction Manual
Original Instructions
133487 Rev. D
28 October 2015
133487

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Summary of Contents for Banner SC22-3

  • Page 1 SC22-3/-3E Safety Controller Instruction Manual Instruction Manual Original Instructions 133487 Rev. D 28 October 2015 133487...

  • Page 2: Table Of Contents

    ....................19 2.9 Password Overview .........................19 2.10 Confirming a Configuration ....................20 3 Components and Specifications ..................21 3.1 SC22-3 Safety Controller Starter Kit Models ................21 3.2 Replacement Parts/Accessories ....................21 3.3 Ethernet Cordsets ........................21 3.4 Interface Modules ........................22 3.4.1 Mechanically Linked Contactors...
  • Page 3 SC22-3/-3E Safety Controller Instruction Manual 4.7.3 FSD Interfacing Connections ..................40 4.7.4 Common Wire Installation ....................46 4.8 Status Outputs ........................46 4.8.1 Status Output Signal Conventions ................... 46 4.8.2 Status Output Functionality .................... 48 4.9 Virtual Status Outputs ......................49 4.10 Commissioning Checkout .......................
  • Page 4 SC22-3/-3E Safety Controller Instruction Manual 10.4.2 Optical Sensor Requirements ..................94 10.4.3 Optical Sensor Hookup Options ..................95 10.5 Two-Hand Control ........................96 10.5.1 Two-Hand Control Safety Distance (Minimum Distance) ............ 97 10.5.2 Two-Hand Control Hookup Options ................. 98 10.6 Safety Mat ..........................99...

  • Page 5: About This Document

    1.3 Standards and Regulations The list of standards below is included as a convenience for users of this Banner device. Inclusion of the standards below does not imply that the device complies specifically with any standard, other than those specified in the Specifications section of this manual.

  • Page 6: Applicable U.s. Standards

    SC22-3/-3E Safety Controller Instruction Manual 1.3.1 Applicable U.S. Standards ANSI B11.0 Safety of Machinery, General Requirements, and Risk ANSI B11.16 Metal Powder Compacting Presses Assessment ANSI B11.17 Horizontal Extrusion Presses ANSI B11.1 Mechanical Power Presses ANSI B11.18 Machinery and Machine Systems for the Processing of ANSI B11.2 Hydraulic Power Presses...

  • Page 7: Contact Us

    1.5 Banner Engineering Corp Limited Warranty Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the warranty period.
  • Page 8 PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE, COURSE OF DEALING OR TRADE USAGE. This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR...

  • Page 9: Overview

    Controller via a USB port. 2.1 Ethernet-Compatible Model The model SC22-3E provides the same features of the SC22-3, and in addition provides the ability to interface to ™ Ethernet (for example to a PLC or HMI human interface touch panel), using Modbus/TCP or EtherNet/IP protocols.

  • Page 10: Applications

    86 for specific information about integrating devices with the controller. 2.4 Components The Safety Controller Starter Kit includes: • 1 Safety Controller (model SC22-3 or SC22-3E) • 1 set of removable terminals (choose screw or clamp type) • 1 SC-XM1 external memory (XM) card •...

  • Page 11: Pc Requirements

    SC22-3/-3E Safety Controller Instruction Manual 2.4.1 PC Requirements Operating system Third-party software ® ® Microsoft Windows XP, Windows 2000, Vista , Windows 7 Microsoft .NET 2.0, included and installed with PCI, if not already on ® ® computer Adobe Reader for Windows version 7.0 or newer...

  • Page 12: Sc-Xm1 External Memory (Xm) Card

    SC22-3/-3E Safety Controller Instruction Manual 2.4.5 SC-XM1 External Memory (XM) Card The model SC-XM1 external memory (XM) card 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.
  • Page 13 SC22-3/-3E Safety Controller Instruction Manual 1. Moves cursor to the left or selects settings. 2. Moves cursor to the pre-established point in the program to re- establish a menu reference point. 3. Enters/stores the item highlighted in the display as the intended selection or toggles a setting.

  • Page 14: Personal Computer Interface (Pci)

    SC22-3/-3E Safety Controller Instruction Manual 2.5.2 Personal Computer Interface (PCI) ® The Safety Controller can also be configured using a Windows -based computer and the Safety Controller PC Interface (PCI) program. This user-friendly interface makes use of icons and circuit symbols to simplify the selection of device properties during configuration.

  • Page 15: Input And Output Connections

    Bypass • Muting Contact Banner Engineering for additional information about connecting other devices not described in this manual. Safety Device Hookup Considerations The Safety Controller inputs can be configured to interface with many types of safety devices, including safeguarding devices, such as safety light curtains, complementary protective equipment, such as emergency stop push buttons, and other devices that impact the safe use of a machine, such as equipment protection.

  • Page 16: Status Outputs

    SC22-3/-3E Safety Controller Instruction Manual 1. Safety Controller 2. OFF-Delay 3. Solenoid locking switch 4. Robot 5. Contactors Figure 7. Safety Outputs See section Safety Outputs on page 38 for more information about configuring Safety Outputs. Functional Stops according to IEC 60204-1 and ANSI NFPA79 The Controller is capable of performing two functional stop types: •...

  • Page 17: Virtual Status Outputs

    SC22-3/-3E Safety Controller Instruction Manual • When a safety input has a Fault condition • When a safety output's OFF-delay can be cancelled NOTE: 1. Only safety outputs that have inputs mapped to them can be mapped to a status output.

  • Page 18: System Settings

    SC22-3/-3E Safety Controller Instruction Manual Inputs Mapped to Inputs. Muting sensors and bypass switches work in conjunction with certain safety input devices to temporarily suspend the Stop signal of a safety input device. These sensors and switches are mapped directly to the safety inputs;...

  • Page 19: Internal Logic

    To provide security, in some cases, the Safety Controller requires the use of a password. For information about changing a controller’s password, refer to System Options on page 63. If the password becomes lost, contact the Banner Engineering for assistance. 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.

  • Page 20: Confirming A Configuration

    SC22-3/-3E Safety Controller Instruction Manual Creating a Configuration • Via computer using the Safety Controller PC Interface (PCI) program (no password needed) • Via the Controller Onboard Interface (OBI) (password needed) Confirming a Configuration • Via the PCI, using the PC connected to a powered Controller (password needed) •...

  • Page 21: Components And Specifications

    (XM card, with write-on label on reverse side), XM card programming tool (included with some models), a user CD (includes software interface, online manual, ethernet references and configuration tutorials), and quick start guide. 3.1 SC22-3 Safety Controller Starter Kit Models Safety XM Card Communica Terminal...

  • Page 22: Interface Modules

    SC22-3/-3E Safety Controller Instruction Manual Cat5e Shielded Cordsets Cat5e Crossover Shielded Cordsets Length STP25 STPX25 7.62 m (25 ft) STP50 STPX50 15.2 m (50 ft) STP75 STPX75 22.9 m (75 ft) 3.4 Interface Modules NOTE: External device monitoring (EDM) is required to be wired separately to the N.C. contacts to comply with ISO 13849-1 categories and ANSI/OSHA control reliability;...

  • Page 23: Specifications

    24V dc, ± 20% NEMA 1 (IEC IP20), for use inside NEMA 3 (IEC IP54) or better enclosure Model SC22-3: 0.4 A (Controller only), 5.9 A (all outputs ON at full rated load) Operating Conditions Model SC22-3E: 0.4 A (Controller only), 4.9 A (all outputs ON at full Temperature range:0 °C to +55 °C (+32 °F to +131 °F)

  • Page 24: Dimensions

    Allow minimum 65 mm (2.6") clearance for USB cable or Ethernet cable and 43 mm (1.7") for XM Card insertion 64 mm (2.5") 35 mm (1.4") 131 mm (5.2") 112 mm (4.4") 130 mm (5.1") Figure 9. SC22-3 and SC22-3E dimensions www.bannerengineering.com - Tel: 763.544.3164...

  • Page 25: System Installation

    WARNING: Read this Section Carefully Before Installing the System The Banner Safety Controller is a control device that is intended to be used in conjunction with a machine safeguarding device. Its ability to perform this function depends upon the appropriateness of the application and upon the Safety Controller's proper mechanical and electrical installation and interfacing to the machine to be guarded.

  • Page 26: Safety Input Devices

    NOTE: Follow the device manufacturer's installation, operation, and maintenance instructions and all relevant regulations. If there are any questions about the device(s) that are connected to the Safety Controller, contact Banner Engineering for assistance. www.bannerengineering.com - Tel: 763.544.3164...

  • Page 27: Signals: Run And Stop States

    SC22-3/-3E Safety Controller Instruction Manual WARNING: Sharing of Safety Inputs Inputs Inputs S1.....S11 S12...S22 Multiple Safety Controllers must not share safety input devices; this includes solid-state outputs from light curtains, Safety Controllers, or other safety devices. A safety output from one Controller can be connected to a Safety Input of a second Controller.
  • Page 28 SC22-3/-3E Safety Controller Instruction Manual Not all circuit types meet the Category 4 classification per ISO 13849-1; refer to section Safety Circuit Integrity and ISO 13849-1 Safety Circuit Principles on page 86 for a discussion of safety circuit integrity levels.
  • Page 29 SC22-3/-3E Safety Controller Instruction Manual Input Signal COS Timing Rules Input Circuit Stop State—SO turns Off when 3 : Run State—SO turns On when 4 : Dual-Channel A and B Complementary 2 Terminals 3 Terminals 2 Terminals, PNP Simultaneous: A and B are both in the Stop state and then both in the Run state within 3 seconds before outputs turn On.

  • Page 30: Non-Safety Input Devices

    SC22-3/-3E Safety Controller Instruction Manual When a safety mat is used, the response time calculation for the safety mat depends on the Stop (6 to 100 ms) debounce time. 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.

  • Page 31: Input Device Resets

    SC22-3/-3E Safety Controller Instruction Manual Table 1: Cancel Off-Delay Timing Safety Input(s) (Manual or Auto) Stop Cancel Delay Performed Reset Cancel Delay Input (Monitored Option Shown) Safety Input(s) (Manual or Auto) Stop Off Delay Off Delay Cancel Delay Ended Normal End...

  • Page 32: Reset Signal Requirements

    SC22-3/-3E Safety Controller Instruction Manual WARNING: Reset Switch Location All reset switches must be accessible only from outside, and in full view of, the hazardous area. Reset switches must also be out of reach from within the safeguarded space, and must be protected against unauthorized or inadvertent operation (for example, through the use of rings or guards).

  • Page 33: Perimeter Guarding And Pass-Through Hazards

    SC22-3/-3E Safety Controller Instruction Manual 4.5.3 Perimeter Guarding and Pass-Through Hazards A pass-through hazard is associated with applications, such as perimeter guarding, where personnel may pass through a safeguard (which issues a stop command to remove the hazard), and then continue into the guarded area, where their presence is no longer detected.

  • Page 34: Enabling Devices

    SC22-3/-3E Safety Controller Instruction Manual Two-Hand Control Device Safety Device 2 (Manual Reset) Reset Signal Safety Output Figure 18. Timing logic: Two-Hand Control device and manual reset safety input device Two-Hand Control Activation on Power-Up Protection. The Controller’s two-hand control logic will not permit the assigned safety output to turn ON when power is initially supplied while the THC actuators are in their Run state.
  • Page 35 SC22-3/-3E Safety Controller Instruction Manual • Safety mats • Protective stops E-stop buttons, rope pulls, enabling devices, external device monitoring, and bypass switches are non-mutable devices or functions. At least two mute sensors are required for each muting operation (the mute occurs typically 100 ms after the second mute sensor input has been satisfied).

  • Page 36: Bypass Function

    SC22-3/-3E Safety Controller Instruction Manual WARNING: Mute and Bypass Mute and Bypass operations must be done in a way that minimizes personnel risk. Implement the following 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 key-secured bypass switch.

  • Page 37: Edm, Ossd (Safety Output), And Fsd Hookup

    SC22-3/-3E Safety Controller Instruction Manual Safety Output Closed Don’t Care Don’t Care Open 100 ms 100 ms 100 ms 5 sec. 5 sec. 5 sec. NOTE: 100 ms to 5 s time period is adjustable in 50 ms intervals (default is 100 ms).

  • Page 38: Safety Outputs

    SC22-3/-3E Safety Controller Instruction Manual CAUTION: EDM Configuration If the application does not require the EDM function, it is the user’s responsibility to ensure that this does not create a hazardous situation. CAUTION: External Device Monitoring Hookup It is strongly recommended that at least one normally closed, forced-guided monitoring contact of each MPCE or external device is wired to monitor the state of the MPCEs (as shown in the hookup figures).
  • Page 39 SC22-3/-3E Safety Controller Instruction Manual the outputs will 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.

  • Page 40: Fsd Interfacing Connections

    SC22-3/-3E Safety Controller Instruction Manual 4.7.3 FSD Interfacing Connections Final switching devices (FSDs) may take many forms, though the most common are forced-guided (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.
  • Page 41 SC22-3/-3E Safety Controller Instruction Manual WARNING: OSSD Interfacing To ensure proper operation, the Banner device output parameters and machine input parameters must be considered when interfacing the solid state safety outputs to the machine inputs. Machine control circuitry must be designed so that: •...
  • Page 42 SC22-3/-3E Safety Controller Instruction Manual Safety Stop Circuit Input Terminals Safety Controller 1A 1B 2A 2B 3A 3B Safety Stop Circuit 3A 3B +24V dc 2A 2B +24V dc 1A 1B Figure 29. Generic Hookup: 1-channel, 2-channel, and no EDM...
  • Page 43 SC22-3/-3E Safety Controller Instruction Manual One-Channel EDM Hookup to SC-IM9A Interface Module The SC-IM9A interface module depicted in the following figure is shown in one-channel EDM hookup. The SC-IM9B and SC- IM9C modules are connected in the same manner, using individual one-channel EDM circuits (terminals 21/22 on each pair of contactors).
  • Page 44 SC22-3/-3E Safety Controller Instruction Manual Two-Channel EDM Hookup to IM-T-9A Interface Module The IM-T-9A interface module depicted in the following figure is shown in two-channel EDM hookup. The IM-T-11A module is connected in a similar manner. Depending on the application, each Safety Output requires a separate and individually wired IM-T-..A module.
  • Page 45 SC22-3/-3E Safety Controller Instruction Manual One-Channel EDM Hookup to IM-T-9A Interface Module The IM-T-9A interface module depicted in the following figure is shown in one-channel EDM hookup. The IM-T-11A module is connected in a similar manner. Depending on the application, each Safety Output requires a separate and individually wired IM-T-..A module.

  • Page 46: Common Wire Installation

    SC22-3/-3E Safety Controller Instruction Manual 4.7.4 Common Wire Installation Keep in mind the lead wire resistance of the 0V common wire and the currents flowing in that wire to avoid nuisance lockout codes 1.1, 1.2, or 1.5. Note the location of the block in the diagram below representing lead wire resistance (RL).
  • Page 47 SC22-3/-3E Safety Controller Instruction Manual Mapped Status Output(s) State Signal Convention 1 (default) Signal Convention 2 Tracked Function 24V dc = Run 0V dc = Run Track Output Output ON Output OFF Output ON Output OFF 24V dc 0V dc...

  • Page 48: Status Output Functionality

    SC22-3/-3E Safety Controller Instruction Manual 4.8.2 Status Output Functionality Track Input A Status Output configured for this function will indicate the current state of an input. Track Output A Status Output configured for this function will indicate the current physical state of a Safety Output, either ON or OFF.

  • Page 49: Virtual Status Outputs

    SC22-3/-3E Safety Controller Instruction Manual OK to Cancel OFF-Delay Status Outputs configured for this function will indicate when an OFF-delay can be cancelled — that is, when the cancel delay input can be activated in order to keep the OFF-delayed Safety Output ON, or to immediately turn the Safety Output OFF.

  • Page 50: Pc Interface Configuration (Pci)

    SC22-3/-3E Safety Controller Instruction Manual 5 PC Interface Configuration (PCI) 5.1 PC Interface (PCI) Overview The PC Interface (PCI) is a computer program with real-time display and diagnostic tools that can be used to: • Create, confirm, edit, store, send, and receive a configuration •...

  • Page 51: Build A Configuration

    SC22-3/-3E Safety Controller Instruction Manual 5.1.2 Build a Configuration To install the software on your computer, double-click on the Banner Safety Controller icon . Read and understand the warning on the Start-up page, and click OK. The main PCI screen should appear. The support documents, if opened at this point, show basic information, and auto-populate as the configuration develops;...
  • Page 52 SC22-3/-3E Safety Controller Instruction Manual Create a New Configuration Open the software program, and a new un-named file is created. You may name the Configuration and the Author, and establish the system settings at this time. Double-click the System Settings icon , on the right-hand side of the Tool Bar.
  • Page 53 SC22-3/-3E Safety Controller Instruction Manual Select the Input Device Properties After an input device is selected, the Properties menu for that device pops up. This menu presents the properties that must be established for each type of input device. The user-defined properties include (depending on the device): •...
  • Page 54 SC22-3/-3E Safety Controller Instruction Manual Figure 40. Wiring diagram populates with devices and output mapping Figure 41. Ladder logic diagram develops along with wiring diagram Finish the Configuration Repeat the steps in the previous section to include additional safety or non-safety input devices.
  • Page 55 SC22-3/-3E Safety Controller Instruction Manual Save and Confirm the Configuration You will need to confirm this new configuration before it can be used in a safeguarding application. A 4-digit Controller password is required to save and confirm a configuration and to enable it to run on a Safety Controller. The confirmation process has two parts: 1.

  • Page 56: Revise An Existing Configuration

    SC22-3/-3E Safety Controller Instruction Manual Figure 43. Confirm Configuration screen, all devices confirmed by user (checklist is compressed) If the columns do not match, or if you wish to change any circuit: ◦ Select Edit for the device to be changed.
  • Page 57 SC22-3/-3E Safety Controller Instruction Manual 3. Click Receive in the tool bar. 4. If the configuration is not already confirmed, you may choose to confirm it at this time. Send a Configuration to the Safety Controller To send a configuration from the PCI to a Controller: 1.
  • Page 58 SC22-3/-3E Safety Controller Instruction Manual NOTE: If the password becomes lost, contact Banner Engineering for assistance. Export Documents Configuration notes can be exported in different formats. To export a configuration document: 1. Open the configuration file that you want to save.

  • Page 59: Onboard Interface Configuration (Obi)

    SC22-3/-3E Safety Controller Instruction Manual 6 Onboard Interface Configuration (OBI) 6.1 Onboard Interface (OBI) Overview The Safety Controller’s onboard 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 •...
  • Page 60 SC22-3/-3E Safety Controller Instruction Manual Run Mode System Menu Configuration Model Number Set Display Fault Configuration Mode software and Contrast Diagnostics Summary (Section 5.3) hardware versions View Current View Clear Terminal Input/Outpu t Configuration Status Output View Response View Network...

  • Page 61: Run Mode

    SC22-3/-3E Safety Controller Instruction Manual 6.2 Run Mode From Run mode, press OK to view the System menu. This menu provides the ability to read fault diagnostic information, enter the Configuration mode to create or edit a configuration, read the configuration summary, view the Safety Controller's model number, and adjust the contrast of the display.

  • Page 62: Confirm Configuration

    SC22-3/-3E Safety Controller Instruction Manual Receive File from XM—This selection is used to receive a configuration from the XM card. Highlight the selection and press OK. The Controller will ask if you want to overwrite the current configuration (if not, send the existing configuration to an empty XM card first).

  • Page 63: System Options

    SC22-3/-3E Safety Controller Instruction Manual Final Confirmation Step—After all of the safety-critical configuration settings are confirmed, the configuration can be used in a safeguarding application. If any changes are made to the configuration, the confirmation process must be repeated. Select <Done> and press OK to exit the Confirm Configuration menu. Press ESC or go to Exit Configuration to return to Run mode.
  • Page 64 SC22-3/-3E Safety Controller Instruction Manual Safety Outputs This option is used to configure the safety outputs. Use the Up/Down arrows to select Safety Outputs and press OK. Select the output to configure and press OK. You will be given the opportunity to change the output’s name, and give it an ON- or OFF-delay.

  • Page 65: Configuration Summary

    SC22-3/-3E Safety Controller Instruction Manual Mute on Power-Up—Use the Left/Right arrows to toggle between Off or On, and press OK. 6.4.4 Configuration Summary The Configuration Summary menu provides read-only screens to review: • Input device Terminal Assignments for each device in the current configuration •...
  • Page 66 SC22-3/-3E Safety Controller Instruction Manual 1. Use the left/right arrows to select the character position. 2. Use the up/down arrows to select the character for each position (choices A-Z, 0-9, -, +, or space). 3. When the screen (as shown below) shows the correct device name, press Input Properties Menu—The Input Properties menu is used to:...
  • Page 67 SC22-3/-3E Safety Controller Instruction Manual Save the Input Device Parameters—When all of the device’s parameters have been set as desired, select < Done > and press OK to save the parameters. 1. The display indicates the input parameters were saved. Press OK to continue.

  • Page 68: Operating Instructions

    To display real-time Run mode information on a PC, the computer must be connected to the Controller, via a USB cable (see Section 1.3 for connection instructions). Open the Banner Safety Controller program and click on the Live Display button in the PCI screen to launch the Live Display screen.
  • Page 69 SC22-3/-3E Safety Controller Instruction Manual • Input status • System status • XM card status Configuration Name Arrowhead designates selected Safety Output Safety Output Status Input Status Cause of Output SO1 Status, or Required Action Figure 49. Run mode screen—OBI 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.

  • Page 70: Manual Reset

    SC22-3/-3E Safety Controller Instruction Manual Input Device Status Cause and/or Required Action Message A start-up test needs to be completed on the safety input. To perform the test, cycle the Test input (Run-Stop-Run) to turn the Safety Output ON. A two-hand control input or an enabling device needs to be cycled (Run-Stop-Run)

  • Page 71: Reset Signal Requirements

    SC22-3/-3E Safety Controller Instruction Manual • 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 •...

  • Page 72: System Checkout

    If all of these checks cannot be verified, do not attempt to use the safety system that includes the Banner device and the guarded machine until the defect or problem has been corrected. Attempts to use the guarded machine under such conditions may result in serious bodily injury or death.

  • Page 73: Initial Setup, Commissioning And Periodic Checkout Procedures

    SC22-3/-3E Safety Controller Instruction Manual 2. Whenever any maintenance or modification is performed on the System or on the machine being guarded by the System, to ensure continued proper Controller function (see Schedule of Required Checkouts on page 72) 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.
  • Page 74 SC22-3/-3E Safety Controller Instruction Manual b. Apply power to the Safety Controller and all input devices that require power, but not to the guarded machine. c. Verify that the configuration file is appropriate for the application. At a minimum, have a copy of the Configuration Summary from the PC Interface software available for reference during the checkout procedure.
  • Page 75 SC22-3/-3E Safety Controller Instruction Manual c. Verify operation of all protective stops (for example, other safety/safeguarding devices not listed). d. Verify operation of all On/Off inputs. If Mute, Bypass and/or Enabling Device functions are not used, proceed to the final step in this procedure.
  • Page 76 SC22-3/-3E Safety Controller Instruction Manual 2. Wait at least 10 seconds after power-up and apply a system reset. 3. Verify that all safety outputs turn On. 4. Verify that the mute status output (if used) turns On. c. Generate a stop command from the safeguarding device that has been muted.
  • Page 77 SC22-3/-3E Safety Controller Instruction Manual 19. Bypass Function (without Mute) a. Verify that when the safety input to be bypassed is in the Stop state: The associated safety outputs are Off. b. Verify that when the bypass input is in the Run state: •...
  • Page 78 Test the machine stopping response time, using an instrument designed for that purpose, to verify that it is the same or less than the overall system response time specified by the machine manufacturer. A Banner Applications Engineer may be able to recommend a suitable instrument.

  • Page 79: Troubleshooting

    Proper transient suppression is applied across the output loads Contact Banner Engineering for troubleshooting of this device. Do not attempt any repairs to this Banner device; it contains no field-replaceable parts or components. If the device, device part, or device component is determined to be defective by a Banner Applications Engineer, they will advise you of Banner's RMA (Return Merchandise Authorization) procedure.
  • Page 80 DC common wire for each pair of outputs and/or avoid sharing this DC common return path with other devices (see Common Wire Installation on page 46) 1.3 – Internal failure – Contact Banner Factory (see Repairs and Warranty Service Internal Fault on page 79) A safety output appears ON prematurely. •...
  • Page 81 2.4 or Simultaneity Cycle Input Fault • Check the wiring • Check the input signal timing Check Internal failure – Contact Banner Engineering (see Repairs and Warranty Internal Fault Terminal xx Service on page 79). Input stuck high. 2.8 – Check Input Fault •...
  • Page 82 PC Interface or an XM card • Or, erase and recreate the configuration using the on-board user interface 4.3 – Internal failure – Contact Banner Engineeing (see Repairs and Warranty Internal Fault 4.11 Service on page 79).

  • Page 83: Recovering From A Lockout

    79 • Perform a system reset • Cycle the power and perform a system reset, if needed If these steps do not remedy the lockout condition, contact Banner Engineering (see Repairs and Warranty Service on page 79). 9.5 Fault Diagnostics The first step in diagnosing faults via the PCI is to open the Live Display screen (see Display Controller Information —...

  • Page 84: Fault Diagnostics-Obi

    SC22-3/-3E Safety Controller Instruction Manual 9.6 Fault Diagnostics—OBI Troubleshooting the Controller and connected I/O devices is easy using the Onboard Interface. Any event that causes a safety output to turn OFF or stay OFF (either for fault or input stop events) will be immediately detected and displayed on the Controller’s display.

  • Page 85: Clear Fault Log-Obi

    SC22-3/-3E Safety Controller Instruction Manual • The fourth line displays how long ago the fault occurred. For instance, a time of 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.

  • Page 86: Input Device And Safety Category Reference

    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 Safety Controller, contact a Banner Applications Engineer for assistance. 10.1 Safety Circuit Integrity and ISO 13849-1 Safety Circuit Principles Safety circuits involve the safety-related functions of a machine that minimize the level of risk of harm.
  • Page 87 SC22-3/-3E Safety Controller Instruction Manual Circuit Symbol E-Stop Safety Optical Two-Hand Rope Protect. Safety Enabling Gate Sensor Control Pull Stop Device Cat. 2 Cat. 2 Cat. 2 — Cat. 2 Cat. 2 — — Cat. 2 Cat. 2 Type IIIa Cat. 1 Cat.

  • Page 88: Fault Exclusion

    SC22-3/-3E Safety Controller Instruction Manual WARNING: Category 2 or 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 (for example, the same terminal from the Controller in a dual-channel, 3-terminal hookup, or from an external 24 V supply) is not possible, if the two contacts are closed.

  • Page 89: Interlocked Guard Or Gate

    The application requirements for interlocked guards or gates vary for the level of control reliability or safety category per ISO 13849-1. While Banner Engineering always recommends the highest level of safety in any application, the user is responsible to safely install, operate, and maintain each safety system and comply with all relevant laws and regulations.
  • Page 90 SC22-3/-3E Safety Controller Instruction Manual 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.
  • Page 91 SC22-3/-3E Safety Controller Instruction Manual inappropriate reset can lead to serious injury or death. The following scenarios assume two positive-opening safety switches on each guard, both connected in series to switches of a second guard: 1. Masking of a failure. If a guard is opened but the switch fails to open, the redundant safety switch will open and cause the Controller to de-energize its outputs.
  • Page 92 SC22-3/-3E Safety Controller Instruction Manual Category 3 Interlocked Guard Circuit A dual-channel hookup switching +24V dc is typically a +24V dc Category 3 application because a single failure does not result in a loss of safety. Loss of the switching action in one...
  • Page 93 SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (2 or 3 terminals) This circuit typically meets ISO 13849-1 Category 2 or Category 3 requirements, depending on the safety rating and the installation of the device. The Dual Channel 3-terminal hookup uses pulse monitoring and can...

  • Page 94: Optical Sensor

    The application requirements for optical safeguarding vary for the level of control reliability or safety category per ISO 13849-1. While Banner Engineering always recommends the highest level of safety in any application, the user is responsible to safely install, operate, and maintain each safety system and comply with all relevant laws and regulations.

  • Page 95: Optical Sensor Hookup Options

    SC22-3/-3E Safety Controller Instruction Manual AOPDDRs include area or laser scanners. The primary designation for these devices is a Type 3, for use in up to Category 3 applications. WARNING: Incomplete Information—many installation considerations that are necessary to properly apply input devices are not covered in this document. Refer to the appropriate device installation instructions to ensure the safe application of the device.

  • Page 96: Two-Hand Control

    SC22-3/-3E Safety Controller Instruction Manual Complementary (2 or 3 terminals) This circuit meets ISO 13849-1 Category 2, 3, or 4 requirements depending on the safety rating and the installation of the device. This circuit can detect a short circuit between channels. In the actuated condition (S1 open/S2 closed), as shown, a short across the closed contact may cause the response time to increase based on the debounce time.

  • Page 97: Two-Hand Control Safety Distance (Minimum Distance)

    T h is usually insignificant for purely mechanical switches. However, T h should be considered for safety distance calculation when using electronic or electromechanical (powered) hand controls. For Banner Self-checking Touch Buttons (STBs) the response time is 0.02 seconds www.bannerengineering.com - Tel: 763.544.3164...

  • Page 98: Two-Hand Control Hookup Options

    SC22-3/-3E Safety Controller Instruction Manual U.S. Applications the maximum time (in seconds) the machine takes to cease all motion after it has been tripped. For full revolution clutch presses with only one engaging point, T m is equal to the time necessary for one and one-half revolutions of the crankshaft. For full revolution clutch presses with...

  • Page 99: Safety Mat

    Safety Mat application requirements vary for the level of control reliability or category and performance level as described by ISO 13849-1 and ISO 13856. While Banner Engineering always recommends the highest level of safety in any application, the user is responsible to safely install, operate, and maintain each safety system per the manufacturer's recommendations and comply with all relevant laws and regulations.

  • Page 100: Safety Mat Requirements

    SC22-3/-3E Safety Controller Instruction Manual 10.6.1 Safety Mat Requirements The following are minimum requirements for the design, construction, and installation of four-wire safety mat sensor(s) to be interfaced with the Safety Controller. These requirements are a summary of standards ISO 13856-1, ANSI/RIA R15.06 and ANSI B11.19.
  • Page 101 SC22-3/-3E Safety Controller Instruction Manual Routinely inspect and test each safety mat according to the manufacturer’s recommendations. Do not exceed operational specifications, such as the maximum number of switching operations. Securely mount each safety mat 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.

  • Page 102: Emergency Stop Push Buttons

    The application requirements for emergency stop buttons vary for the level of control reliability or safety category per ISO 13849-1. While Banner Engineering always recommends the highest level of safety in any application, the user is responsible to safely install, operate, and maintain each safety system and comply with all relevant laws and regulations.
  • Page 103 SC22-3/-3E Safety Controller Instruction Manual • Emergency stop push buttons must be located at each operator control station and at other operating stations where emergency shutdown is required • Stop and Emergency stop push buttons must be continuously operable and readily accessible from all control and operating stations where located.
  • Page 104 SC22-3/-3E Safety Controller Instruction Manual Category 3 E-Stop Circuit A dual-channel hookup switching +24V dc is typically a Category 3 application, because a single failure does not result in a loss of safety. A loss of the switching action in one...

  • Page 105: Rope (Cable) Pull

    SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (4 terminals) This circuit meets ISO 13849-1 Category 2, 3, or 4 requirements, depending on the safety rating and the installation of the device. This circuit can detect a short circuit between channels or to another source of power.

  • Page 106: Enabling Device

    SC22-3/-3E Safety Controller Instruction Manual Dual-Channel (2 or 3 terminals) This circuit typically meets ISO 13849-1 Category 2 or Category 3 requirements, depending on the safety rating and the installation of the device. The Dual Channel 3-terminal hookup uses pulse monitoring and can detect a short circuit to another source of power.

  • Page 107: Enabling Device Hookup Options

    SC22-3/-3E Safety Controller Instruction Manual Many standards require the use of three-position devices due to an individual’s reaction to either release or tighten the grip in an emergency situation. • Position #1: the Off function of the switch (actuator is not operated) •...

  • Page 108: Bypass Switches (Bypassing Safeguards)

    SC22-3/-3E Safety Controller Instruction Manual Complementary (2 or 3 terminals) This circuit meets ISO 13849-1 Category 2, 3, or 4 requirements depending on the safety rating and the installation of the device. This circuit can detect a short circuit between channels. In the actuated condition (S1 open/S2 closed), as shown, a short across the closed contact may cause the response time to increase based on the debounce time.

  • Page 109: Bypass Switch Hookup Options

    SC22-3/-3E Safety Controller Instruction Manual • 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 •...

  • Page 110: Mute Sensor Pair

    SC22-3/-3E Safety Controller Instruction Manual Complementary (2 or 3 terminals) This circuit meets ISO 13849-1 Category 2, 3, or 4 requirements depending on the safety rating and the installation of the device. This circuit can detect a short circuit between channels. In the actuated condition (S1 open/S2 closed), as shown, a short across the closed contact may cause the response time to increase based on the debounce time.

  • Page 111: Muting Function Requirements

    SC22-3/-3E Safety Controller Instruction Manual A pair of muting devices must be triggered simultaneously (within 3 seconds of one another). This reduces the chance of common mode failures or defeat. Directional muting, in which sensor pair 1 is required to be blocked first, also may reduce the possibility of defeat.

  • Page 112: Muting Device Hookup Options

    Photoelectric Sensors (Polarized Retroreflective Mode) The user must ensure that false proxying (activation due to shiny or reflective surfaces) is not possible. Banner low profile sensors with linear polarization can greatly reduce or eliminate this effect.

  • Page 113: Mute Enable (Me)

    SC22-3/-3E Safety Controller Instruction Manual Complementary (2 or 3 terminals) This circuit meets ISO 13849-1 Category 2, 3, or 4 requirements depending on the safety rating and the installation of the device. This circuit can detect a short circuit between channels. In the actuated condition (S1 open/S2 closed), as shown, a short across the closed contact may cause the response time to increase based on the debounce time.

  • Page 114: Muting Time Limit (Backdoor Timer)

    SC22-3/-3E Safety Controller Instruction Manual 10.11.6 Muting Time Limit (Backdoor Timer) The muting time limit (Backdoor Timer) allows the user to select a maximum period of time that muting is allowed to occur. This feature hinders the intentional defeat of the muting devices to initiate an inappropriate mute. It is also useful for detecting a common mode failure that would affect all mute devices in the application.

  • Page 115: Mute Timing Sequences

    SC22-3/-3E Safety Controller Instruction Manual 10.11.10 Mute Timing Sequences Power Safety Light Screen Mute Enable Mute Sensor 1 < 3s < 3s Mute Sensor 2 Max. Max. Max. Max. Backdoor Timer Time Time Time Time Safety Output Mute cycle ends due to the...

  • Page 116: Ethernet Reference

    The Industrial EtherNet Guide provides details and examples to aid in the setup and connection to your PLC. Contact Banner Engineering for this guide and the EDS files for the SC22-3E controller. Information on Ethernet functionality can also be found in the following sections of this manual:...

  • Page 117: Support Files

    During installation of the PCI, the following support files are copied to the computer’s Program Files directory (C:\Program Files\Banner Engineering\Banner SC\Network Tables), in both .csv and .pdf formats. These files contain network communication information and fault diagnostic information. To access the files, use your computer’s navigation tools (for example, “My Computer”...

  • Page 118: Table Row And Column Descriptions

    Indicates the offset from 30000 or 40000 followed by the specific bit in the register. Reserved Banner has reserved these registers for internal use. Seconds Since Power-up (System Info File) The time in seconds since power was applied to the Safety Controller. May be used in conjunction with the time stamp in the Fault Log and a real time clock reference to establish a time that a fault occurred.
  • Page 119 SC22-3/-3E Safety Controller Instruction Manual SO1/2/3 is OFF Due to… (Advanced View) A bit will be set high if the input device associated with this virtual output is a reason why the output is off. String Format (Ethernet/IP and PCCC Protocol) The default format Ethernet/IP string format has a 32 bit length preceding the string (suitable for ControlLogix).

  • Page 120: Glossary

    SC22-3/-3E Safety Controller Instruction Manual 12 Glossary 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. Change of State (COS)
  • Page 121 SC22-3/-3E Safety Controller Instruction Manual Safety-Rated Device Start Up Test A device that is designed to an applicable safety standard and For certain safety devices, like safety light screens or safety when properly applied, reduces the level of risk. gates, it can be an advantage to test the device on power up at least one time for proper function.
  • Page 122 Index String 118 System Checkout 72, 73 Checkout 72, 73 System Reset 70 Cleaning 79 Lockout 71, 83 Commissioning Checkout 72, 73 Troubleshooting 79 Daily Checkout 72 Octet 118 Dword 118 UDINT 118 UINT 118 Periodic Checkout 72, 73 Ethernet 11 Fault Diagnostics 79 Warranty 79 Repairs 79...

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