How to Install the NexBot Drives 631-002 Pressure Safety Mat

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Tools Required

• Drill with masonry bit
• Floor anchor installation tool
• Torque wrench
• Multimeter
• Wire strippers
• Screwdriver set
• Safety glasses

Article

The NexBot Drives 631-002 Pressure Safety Mat is a critical component for safeguarding personnel in automated environments. Proper installation is essential for ensuring the reliability and effectiveness of your robotic cell's safety system. This guide covers the physical mounting and electrical integration of the mat.

Prerequisites

Before beginning the installation, ensure you have met the following requirements. Failure to do so may result in improper functionality or a hazardous condition.

Safety Precautions:

• Lockout/Tagout (LOTO): The robotic cell and all related machinery must be fully de-energized and placed in a zero-energy state according to your facility's LOTO procedures.
• Personal Protective Equipment (PPE): At a minimum, safety glasses are required. Additional PPE may be necessary based on site-specific rules.
• Qualified Personnel: This installation should only be performed by a qualified technician with experience in industrial electrical wiring and safety systems.

Component and Site Requirements:

• Product: One NexBot Drives 631-002 Pressure Safety Mat.
• Mounting Surface: The floor surface must be clean, dry, level, and free of debris, oils, or chemicals.
• Safety Controller: A compatible safety relay or safety PLC is required for monitoring the mat's status. The mat's output must be connected to a dual-channel safety monitoring device.
• Hardware: Appropriate floor anchors and mounting trim (if applicable) for your floor type (e.g., concrete).

Step-by-Step Instructions

Follow these steps carefully to ensure the mat is installed correctly.

Step 1: Site Preparation and Mat Placement

1. Thoroughly clean the designated installation area. The surface must be smooth and flat to prevent damage to the mat and ensure consistent activation.
2. Carefully unbox the NXB-GEN-631-002 mat. Inspect it for any signs of damage that may have occurred during shipping.
3. Position the mat in its final location within the guarded zone. The mat's dimensions are 1200 x 800 mm. Ensure its placement effectively covers the area where personnel might stand.
4. Using the mounting holes in the mat's edging or optional mounting trim as a template, mark the locations for the floor anchors.

Step 2: Physical Mounting

1. Temporarily move the mat aside.
2. Using an appropriately sized drill bit for your chosen floor anchors, drill holes at the marked locations to the required depth.
3. Clear all debris from the drilled holes.
4. Install the floor anchors according to the anchor manufacturer's instructions.
5. Reposition the mat and secure it to the floor using the specified fasteners. If using a torque wrench, tighten the fasteners to the specification provided by the anchor manufacturer. Do not over-tighten, as this can damage the mat's edging.

Step 3: Electrical Connection

1. Route the mat's integrated 4-wire cable to the safety controller enclosure. Use appropriate conduit or cable protection to prevent damage and create a trip hazard.
2. The NXB-GEN-631-002 operates on a normally open (NO) 4-wire principle, providing two redundant OSSD (Output Signal Switching Device) circuits for safety monitoring.
3. Following the wiring diagram for your safety controller, connect the wires. A typical connection is as follows:

• Wire 1 & 2: Safety Circuit 1
• Wire 3 & 4: Safety Circuit 2

1. Ensure all connections are secure within the terminal blocks of the safety controller. The system operates at 24VDC.
2. Properly ground and shield the cable as required by your controller's documentation to prevent electrical noise interference.

Verification

After installation, you must perform a thorough verification to confirm the safety function is operating as intended.

1. Visual Inspection: Check that the mat is securely mounted, lies flat, and the cabling is protected and does not present a hazard.
2. Power On: Remove the LOTO device and re-energize the robotic cell's control system.
3. Functional Test:

• Before entering the hazardous area, ensure the system is in a safe, operational state.
• Step onto the mat with a force equivalent to a person's body weight. The safety controller must immediately detect the presence and signal a stop command to the robotic system. The robot's motion must cease immediately.
• Test various locations on the mat's surface, including the center, all four corners, and the edges, to confirm consistent activation.
• Step off the mat. The system should remain in a stopped state. It should not automatically restart.
• Perform a manual reset of the safety system using the designated reset button, which must be located outside the hazardous area. The system should return to an operational state, ready for a start command.

1. Documentation: Record the installation and successful verification test in your machine's maintenance log.

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