Banner SC22-3 User Manual

Printed in USA 08/07 P/N 133487
SC22-3 Safety Controller
Instruction Manual
Section Contents
Section 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Section 2 Components and Specifications . . . . . . . . . . . . . . . . . . Page 12
Section 3 System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16
Section 4 Configuration — PC Interface . . . . . . . . . . . . . . . . . . . . Page 34
Section 5 Configuration — Onboard Interface . . . . . . . . . . . . . . . . Page 43
Section 6 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . Page 55
Section 7 System Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 60
Section 8 Troubleshooting and Maintenance. . . . . . . . . . . . . . . . . Page 67
Appendix A Input Device and Safety Category Reference . . . . . . . . Page 73
Appendix B Configuration Tutorial — PC Interface . . . . . . . . . . . . . . Page 101
Appendix C Configuration Tutorial — Onboard Interface . . . . . . . . Page 113
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 122
Features
• Easy-to-use Controller with fully configurable inputs
and outputs
• ISO 13849-1 Category 2, 3, or 4 and OSHA/ANSI
Control Reliability 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 of 3 safety outputs
• Configurations are password protected and confirmed
before use, for assurance of safety integrity
• Configurations are transferable to multiple SC22-3
Controllers and can be e-mailed as attachments
• 24V dc operation
• Complies with Safety Integrity Level (SIL) 3 per
IEC 62061 and IEC 61508, and Category 4
Performance Level “e” per ISO 13849-1.
• Live display and fault log provide “real-time” status
information andd historically track faults
• Wiring diagram, Ladder Logic diagram, and
Configuration Summary can be printed or exported as
.pdf or .dxf files

Banner SC22-3 Specifications

General

Brand	Banner
Model	SC22-3
Category	Controller
Language	English

Summary

Section 1. Overview

1.1 Applications

Describes various applications for the SC22-3 Safety Controller.

1.2 Design and Testing

Details the design principles, safety standards compliance, and testing of the controller.

1.3 Components

Lists the items included in the SC22-3 Safety Controller Starter Kit.

1.4 Configuring the Safety Controller

Outlines the process and methods for configuring the safety controller.

1.4.1 Onboard Interface (OBI)

Explains how to use the controller's built-in display and buttons for configuration.

1.4.2 Personal Computer Interface (PCI)

Describes the software interface for configuration using a PC.

1.5 Input and Output Devices

Covers the types of input and output devices that can be connected and configured.

1.5.1 Safety and Non-Safety Input Devices

Details the 22 input terminals for various safety and non-safety devices.

1.5.2 Safety Outputs

Explains the function and configuration of the three independent solid-state safety outputs.

1.5.3 Status Outputs

Describes the 10 configurable status outputs for non-safety signals.

1.5.4 I/O Mapping: the I/O Control Relationship

Explains how inputs are logically linked to outputs or other inputs.

1.6 System Settings

Defines parameters like configuration name, power-up mode, and reset settings.

1.7 Internal Logic

Describes the controller's internal logic for safety output activation.

1.8 Password Overview

Explains the use of passwords for security in configuration.

1.9 Confirming a Configuration

Details the steps required to validate and activate a new configuration.

Section 2. Components and Specifications

2.1 Models

Lists different SC22-3 Safety Controller starter kit models and replacement parts.

2.2 Specifications

Provides detailed technical specifications for the controller's electrical and environmental properties.

2.3 Dimensions

Shows the physical dimensions and clearance requirements for the controller.

Section 3. System Installation

3.1 Appropriate Application

Discusses the suitable applications and responsibilities for installing the safety controller.

3.2 Safety Input Devices

Covers the connection and configuration of various safety input devices.

3.2.1 Signals: Run and Stop States

Explains the Run/Stop state conventions for dual-channel safety inputs.

3.2.2 Safety Input Device Properties

Details the configurable properties for different safety input devices.

3.3 Non-Safety Input Devices

Describes the configuration properties for non-safety input devices like switches.

3.4 Resets

Explains the types of reset operations (Manual, System) and their configuration.

3.5 Safety Input Functions

Details specific safety input functions like Two-Hand Control and Enabling Devices.

3.5.1 Internal Logic

Describes the controller's internal logic for processing safety input signals.

3.5.2 Two-Hand Control (THC)

Explains the setup and operation of the two-hand control safety function.

3.5.3 Enabling Devices

Covers the use and configuration of enabling devices for supervised operation.

3.5.4 Mute Function

Details how to configure the mute function for suspending safety signals.

3.5.5 Bypass Function

Explains the temporary suspension of safeguards using bypass switches.

3.6 EDM, OSSD (Safety Output), and FSD Hookup

Provides guidance on connecting External Device Monitoring, OSSD outputs, and Final Switching Devices.

3.6.1 External Device Monitoring (EDM)

Describes the EDM function for monitoring the state of output devices.

3.6.2 Safety Outputs

Explains the connection and configuration of solid-state safety outputs (OSSDs).

3.6.3 FSD Interfacing Connections

Covers the connection of Final Switching Devices (FSDs) and safety stop circuits.

3.7 Status Outputs

Details the configuration and signal conventions for status outputs.

3.7.1 Status Output Signal Convention

Explains the two selectable signal conventions for status outputs.

3.8 Commissioning Checkout

Outlines the procedure for verifying the system's operation before placing it into service.

Section 4. Configuration — PC Interface (PCI)

4.1 PC Interface (PCI) Overview

Introduces the PC Interface software for configuration and diagnostics.

4.2 Configuration Tools

Describes the main screen elements and toolbar functions of the PCI software.

4.3 Building a Configuration

Guides users through the process of creating a new configuration using the PCI.

4.3.1 Create a New Configuration

Steps to set up a new configuration, including naming and system settings.

4.3.2 Add an Input Device

Explains how to add safety and non-safety input devices to the configuration.

4.3.3 Finish the Configuration

Steps to complete the configuration by adding outputs and reviewing diagrams.

4.3.4 Save and Confirm the Configuration

Details the process of saving, validating, and confirming the configuration.

4.3.5 System Reset

Explains when and how to perform a system reset for the controller.

4.4 Revise an Existing Configuration

How to open and modify an existing configuration file.

4.5 Other Functions

Describes additional functions like data transfer and password management.

Receive a Configuration from the SC22-3

How to upload a configuration from the controller to the PC.

Send a Configuration to the SC22-3

How to download a configuration from the PC to the controller.

Open a Configuration from the XM Card

How to load configurations from an external memory card.

Send a Configuration to the XM Card

How to save configurations to an external memory card.

Lock the XM Card

How to permanently secure a configuration on an XM card.

Changing the Password Using the Personal Computer Interface (PCI)

Procedure to change the controller password using the PC software.

Export Documents

How to save configuration diagrams and summaries as PDF or DXF files.

Print Options

Instructions for printing configuration documents.

Section 5. Configuration — Onboard Interface (OBI)

5.1 Onboard Interface (OBI) Overview

Introduces the controller's built-in interface for configuration and monitoring.

5.2 Run Mode

Explains how to view controller status and navigate menus in Run mode.

5.3 Configuration Mode

Guides users to enter and navigate the configuration menu.

5.3.1 Enter Controller Password

How to enter the default or custom password to access Configuration mode.

5.3.2 Configuration File

Options for editing, erasing, sending, and receiving configuration files.

5.3.3 Confirm Configuration

Details the process of reviewing and confirming safety-critical settings.

5.3.4 System Options

How to change the password and select the display language.

5.3.5 Exit Configuration Mode

Procedure to exit Configuration mode and return to Run mode.

5.4 Edit Configuration

Steps for editing existing configuration elements like inputs and outputs.

5.4.1 Name Configuration

How to rename the configuration file using the OBI.

5.4.2 Inputs

Steps to add, delete, or edit safety and non-safety input devices.

5.4.3 Outputs/System Settings

How to configure safety and status outputs, and system settings.

5.4.4 Configuration Summary

Provides read-only screens to review current configuration settings.

5.4.5 Save Configuration

How to permanently save configuration changes to non-volatile memory.

5.5 Add an Input

Guides adding safety or non-safety input devices via the OBI.

5.5.1 Add a Safety Input

Lists and describes the available safety input device options.

5.5.2 Add a Non-Safety Input

Lists and describes the available non-safety input device options.

Section 6. Operating Instructions

6.1 Display Controller Information — PC Interface (PCI)

How to view real-time status and fault information using the PCI Live Display.

6.2 Display Controller Information — Onboard Interface (OBI)

How to view controller status and information using the OBI.

6.2.1 Run Mode Screen — OBI

Explains the information displayed on the OBI Run mode screen.

6.3 Manual Reset

Details the procedure and requirements for performing a manual reset.

6.4 System Resets and Lockout Conditions

Explains when system resets are necessary and how to recover from lockouts.

6.5 Reset Signal Requirements

Specifies the timing requirements for monitored and non-monitored reset signals.

Section 7. System Checkout

7.1 Schedule of Checkouts

Outlines the schedule for commissioning, periodic, and daily safety system checks.

7.2 Commissioning Checkout Procedure

Provides a step-by-step procedure for initial safety system checkout.

7.3 Initial Setup and Commissioning/Periodic Checkouts

Details the checks required for initial setup and ongoing periodic maintenance.

Section 8. Troubleshooting and Maintenance

8.1 Cleaning

Instructions for cleaning the controller's enclosure and display.

8.2 Repairs and Warranty Service

Information on contacting the factory for repairs and warranty service.

8.3 Troubleshooting — Finding and Fixing Faults

Covers common faults detected by the controller and how to fix them.

8.3.1 Troubleshooting Table

A comprehensive table listing fault codes, messages, and troubleshooting steps.

8.4 Recovering from a Lockout

Steps to take to recover the controller from a lockout condition.

8.5 Fault Diagnostics — PCI

How to use the PCI software to diagnose faults via the Live Display and Fault Log.

8.5.1 Fault Log — PCI

Accessing and viewing the controller's fault log using the PCI.

8.5.2 Fault Log Recording — PCI

How to schedule fault log capture for detailed analysis.

8.6 Fault Diagnostics — OBI

How to access and interpret fault information using the controller's onboard interface.

8.6.1 View Current Faults

How to view active fault conditions and suggested remedies on the OBI.

8.6.2 View Fault Log — OBI

How to view stored fault history using the OBI.

8.6.3 Clear Fault Log — OBI

Procedure to clear the fault log using the OBI.

Appendix A. Input Device and Safety Category Reference

A.1 Safety Circuit Integrity and ISO 13849-1 (EN954-1) Safety Circuit Principles

Explains safety circuit integrity levels and principles based on ISO standards.

A.2 Protective (Safety) Stop

Covers the application and hookup options for protective stop devices.

A.2.1 Protective (Safety) Stop Requirements

Details requirements for protective stop circuit integrity and design.

A.2.2 SC22-3 Protective (Safety) Stop Hookup Options

Illustrates hookup options for single-channel and dual-channel protective stops.

A.3 Interlocked Guard or Gate

Discusses the use and requirements for interlocked guard and gate switches.

A.3.1 Safety Interlock Switch Requirements

General requirements for installing safety interlock switches.

A.3.2 SC22-3 Interlock Switch Hookup Options

Shows hookup diagrams for various interlock switch types.

A.4 Optical Sensor

Covers the use and hookup options for optical sensors as safety devices.

A.4.1 Optical Sensor Requirements

Details requirements for optical sensors used in safety applications.

A.4.2 Optical Sensor Generic Hookup

Illustrates typical hookup configurations for optical sensors.

A.5 Two-Hand Control

Explains the function and installation requirements for two-hand control devices.

A.5.1 Two-Hand Control Separation Distance

Provides formulas and guidelines for calculating safe separation distances.

A.5.2 SC22-3 Two-Hand Control Hookup Options

Shows hookup diagrams for different types of two-hand control circuits.

A.6 Safety Mats

Covers the use, requirements, and hookup options for safety mats.

A.6.1 Safety Mat Requirements

Minimum requirements for designing and installing four-wire safety mats.

A.6.2 SC22-3 Safety Mat Hookup Options

Illustrates hookup configurations for safety mats with the SC22-3.

A.6.3 Safety Mat Installation

Guidelines for the proper installation of safety mats.

A.7 Emergency Stop Push Buttons

Discusses the use, requirements, and hookup options for E-stop buttons.

A.7.1 Emergency Stop Push Button Requirements

Details requirements for E-stop switches, including positive opening and self-latching.

A.7.2 SC22-3 Emergency Stop Hookup Options

Shows hookup diagrams for various E-stop switch configurations.

A.8 Rope/Cable Pull

Covers the function, installation, and hookup options for rope/cable pull emergency stops.

A.8.1 Rope/Cable Pull Installation Guidelines

Guidelines for the proper installation of rope pull switches.

A.8.2 SC22-3 Rope Pull Hookup Options

Illustrates hookup diagrams for rope pull switches with the SC22-3.

A.9 Enabling Device

Explains the function, requirements, and hookup options for enabling devices.

A.9.1 Enabling Device Guidelines

Guidelines for the application and installation of enabling devices.

A.9.2 SC22-3 Enabling Device Hookup Options

Shows hookup diagrams for different enabling device configurations.

A.10 Bypass Switches (Bypassing Safeguards)

Discusses the use, requirements, and hookup options for bypass switches.

A.10.1 Requirements of Bypassing Safeguards

Outlines the requirements for implementing bypass functions safely.

A.10.2 SC22-3 Bypass Switch Hookup Options

Illustrates hookup diagrams for bypass switches with the SC22-3.

A.11 Mute Sensor Pair

Covers the function, requirements, and hookup options for mute sensors.

A.11.1 Mute Device Requirements

Details the minimum requirements for muting devices.

A.11.2 SC22-3 Muting Device Hookup Options

Shows hookup diagrams for mute sensor pairs with the SC22-3.

A.11.3 Mute Enable (ME)

Explains the function of the Mute Enable input.

A.11.4 Mute Lamp Output (ML)

Discusses the use of status outputs for mute lamp indication.

A.11.5 Muting Time Limit (Backdoor Timer)

How to set a maximum time limit for muting operations.

A.11.6 Mute on Power-Up

Configuration option to initiate a mute cycle upon power-up.

A.11.7 Corner Mirrors, Optical Safety Systems, and Muting

Discusses the use of mirrors and their limitations with muting applications.

A.11.8 Multiple Presence-Sensing Safety Devices

Considerations for using multiple presence-sensing safety devices with muting.

Appendix B. Configuration Tutorial — PC Interface (PCI)

B.1 Install the PC Interface Software

Step-by-step instructions for installing the PC Interface software.

B.2 Open the PC Interface Program

How to launch the PC Interface program after installation.

B.3 Interface Elements: Tool Bar, I/O Property Files and Documents

Overview of the PCI software's main screen components and tabs.

B.4 Documents

Explains the Wiring Diagram, Ladder Logic Diagram, and Configuration Summary.

B.5 Create a Configuration

Guides the creation of a sample configuration with various input devices.

B.6 Configuration Confirmation

Details the process of validating and confirming the created configuration.

B.7 Other Functions

Covers additional PCI functions like data transfer and password management.

Receive a Configuration from the Controller

How to upload a configuration from the controller to the PC.

Send a Configuration to the Controller

How to download a configuration from the PC to the controller.

Open a Configuration from the XM Card

How to load configurations from an external memory card.

Send a Configuration to the XM Card

How to save configurations to an external memory card.

Lock the XM Card

How to permanently secure a configuration on an XM card.

Change the Controller Password

Procedure to change the controller password using the PC software.

Export Documents

How to save configuration diagrams and summaries as PDF or DXF files.

Print Options

Instructions for printing configuration documents.

Fault Log

How to access and manage the controller's fault log using the PCI.

Appendix C. Configuration Tutorial — Onboard Interface (OBI)

Enter Configuration Mode

Steps to enter Configuration mode via the OBI.

Enter Password

How to enter the password to access Configuration mode.

Edit Configuration

Steps to edit the configuration settings using the OBI.

Add Input Devices

Guides the process of adding various input devices via the OBI.

Add E-Stop Input

Step-by-step instructions for adding an E-stop input device.

Configuring Input Device Properties

Details on setting name, circuit type, terminals, and reset logic for inputs.

Adding Other Input Devices

Describes adding Gate Switch, Two-Hand Control, Optical Sensor, and Mute Sensor.

Configure Status Outputs

Steps to configure status outputs for tracking inputs or reset needs.

Configure Status Output 02

Specific steps to configure status output O2 for 'Need Reset' function.

Review the Configuration

How to review input, output, and system settings via the Configuration Summary.

Review Terminal Assignments

Reviewing assigned terminal numbers for inputs.

Review Input/Output Mapping

Reviewing how inputs are mapped to outputs.

Review Status Output Settings

Reviewing the configuration of status outputs.

Saving the Configuration

How to permanently save the configuration changes.

Confirming the Configuration

The final step to validate and confirm the configuration.

Confirm Configurations of Inputs

Verifying the settings for each safety input.

Confirm Safety Output Configuration

Verifying the settings for each safety output.

Final Confirmation Step

Final review and confirmation of all safety-critical settings.

Exit Configuration Mode

Procedure to exit Configuration mode and return to Run mode.

Glossary of Terms