Rockwell Automation 440F MatGuard, 440F-C4000 Mat Controllers - Manual (Page 38)

Section 8 - MAINTENANCE
This section should be read in full before any maintenance is attempted.
Attention is drawn to requirements for planned preventive maintenance.
During maintenance operations, disconnect the machine’s prime mover before working on the mat
system. Observe electrical safety precautions.
8.1 MAT CLEANING
The sensor mats should be regularly swept to clear them of deposits such as swarf and other materials.
If it is necessary to wash or hose down the sensor mats to clean or remove grease etc it is
permissible to use warm water and detergent. DO NOT USE SOLVENTS.
8.2 ROUTINE INSPECTION AND TEST - (Recommended Weekly)
Stop the machine. Clean the sensor mats and allow them to dry off. Inspect the top surface of the mat
for damage. Minor nicks and abrasions of the vinyl cover are acceptable but any damage which
exposes the metal plate must be dealt with immediately. Check that the perimeter trim and uniting trim
are not cracked, broken or distorted and that the fixings are secure. Damaged parts must be replaced
immediately.
Test the mat operation. Two persons are required, one to walk on the mat, the other to observe the
control unit. On systems using manual reset mode the reset button must be continuously pressed and
released. Check that the MACHINE ENABLED LED is ON prior to actuation of the mat and goes OFF as
soon as the mat is stepped on. One person should walk over each section of the mat in turn and each
joining section in turn (i.e. stand with both feet on the same uniting trim between two sections). The
MACHINE ENABLED LED must remain OFF during the entire time. Step off the mat, operate the reset
button. Check the MACHINE ENABLED LED is illuminated. Start the machine, step onto the mat and
check that the machine stops immediately.
Check that all fixed guards and angle plates etc. are in place, undamaged and securely fixed.
IF THESE CHECKS REVEAL ANY PROBLEMS, DO NOT ALLOW USE OF THE MACHINE UNTIL
THEY ARE RECTIFIED. RECORD THE INSPECTION AND TEST IN A WRITTEN LOG.
8.3 THOROUGH EXAMINATION AND TEST - (Recommended twice yearly or after damage)
Contact the supplier for information on an authorised testing service.
To be undertaken by a person competent in electrical and mechanical engineering.
- Carry out the test at 8.2 above.
- Isolate power source to the machine and mat system. Observe electrical safety precautions.
- Inspect the mat components thoroughly for mechanical damage.
- Disconnect the wires to the mat at terminals 1, 2, 3 and 4 at the control unit.
- Connect the two white wires to one test input of an ohmmeter and connect the two black wires to the
other input. One person should walk over each section of the mat in turn and each joining
section in turn (i.e. stand with both feet on the same uniting trim between two sections) until all
areas of the sensor mat have been covered. The maximum resistance with presence on the
mat should not exceed 100ohms.
IF THESE CHECKS REVEAL ANY PROBLEMS, DO NOT ALLOW USE OF THE MACHINE UNTIL
THEY ARE RECTIFIED.
Check that the stopping performance of the machine has not deteriorated from that used in the original
safety distance calculations (see section 5).
Record the inspection and test in a written log.
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