User information

These operating instructions refer to

HSM series contact mats
(position as per 5/99)

Manufacturer: Haake Technik GmbH

Weseker Weg 34
D-46354 Südlohn
Tel: ++49/2862/9981-0
Fax: ++49/2862/9981-61

Application:
HSM series contact mats are used for the protection of areas, including shearing and crushing
edges (e.g. at automatic door and gate installations). They are also used for the protection of
automated production sequences (e.g. robot systems) and can also be used for control
purposes.

HSM series contact mats comply with the safety requirements of EN 1760-1 and the
requirements of category 3 according to EN 954-1.

The contact mat is connected to a relay safety combination of the category 3 or higher according
to EN 954-1. As a rule, this relay safety combination is an integral part of the machine control.

Warning: The categories according to EN 954-1 for contact mats at machines are defined in
the respective type C standards.
If no type C standard exists, risk assessment must be made according to the
machine directives, EN 292-1 and the standard EN 1050. This provides the
necessary category according to EN 954-1 for selection of the protective device.

Design:
In principle, the contact mat is identical in design, independent of its dimensions and shape. It
consists mainly of the following basic elements:
• Haake HSM safety contact mat (positively driven NC contact) as the signal transmitter.
• PU covering of the signal transmitter with respective surface structure.
• Aluminium ramp profile as tripping protection and contact mat fixing element.
Depending on the individual application, various cable connections (see technical data).
• Relay safety combination (category 3 according to EN 954-1).

Mode of operation:
On actuation of the contact mat, the closed-circuit current of the contact mat is interrupted. The
interruption off the closed-circuit current initiates the OFF signal. This signal can be processed
directly via the relay safety combination. After relieving the contact mat, the contact is closed
again.

Appropriate to the employed relay safety combination (e.g. Dold/BN 5983 or Pilz/PNOZ), a
circuit with manual or automatic reset can be configured.

When using a relay safety combination, the recovery time of the same must be taken into
account.

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Packaging, transport, handling and storage
The contact mats are generally delivered on flat pallets. The contact mats are additionally
protected with cardboard packaging to prevent damage. The contact mats and cardboard
packaging are fixed with packaging straps and appropriate clamps.
Several contact mats can be placed one on top of the other and packed as described above. It
must be ensured that the pallet or unpacked contact mat is stored horizontally.
When removing the packaging it must be ensured that the contact mat is not damaged.
Particular care must be taken not to cut open the surface of the contact mat when using a knife.

During the transport of unpacked contact mats, it must be ensured that the supply cables are not
damaged. Under no circumstances must the supply cable be used as a ”transport aid” as it can
be damaged due to the high tensile stress.
The contact mat can be bent or folded during transport. Please also read the information
provided under Installation Instructions.

Installation Instructions:
Prior to installation, these operating instructions must be read completely.
During installation of the contact mat, it must be ensured that:
• The surface is clean and even (well-swept). Small objects (e.g. screw) can cause undesired
actuation of the contact mat. A certain degree of unevenness can be compensated by the
contact mat.
• The contact mat is smoothed flat after being spread out on the surface. This is important if
the contact mat was bent during installation or transport.
If a closed-circuit current flows after spreading out the contact mat (check, e.g. with a
continuity tester), installation has been carried out correctly.
• The contact mat (surface) and supply cable are not damaged.
• The cables are routed (in cable ducts, conduit, etc.) so that damage through mechanical
effects is impossible.
• The cable from the contact mat in the area of the aluminium ramp profile is additionally
protected by the supplied protective tubing.

Fixing of the contact mat to the surface takes place with the supplied aluminium ramp profile.
This type of fixing takes place with the contact mat arranged flat, whereby the aluminium ramp
profile simultaneously serves as tripping protection. Holes for the fixing screws must be made in
the aluminium ramp profile and closed with sealing plugs. The associated screws, dowels and
sealing plugs are included in the scope of supply. The use of other fixing elements must be
clarified with the manufacturer.
The contact mat can also be recessed in the ground. The depth of the recess depends on the
data provided under Dimensioning and Arrangement; use of the aluminium ramp profile is
unnecessary with this type of arrangement. The overall height of the contact mat and in turn the
depth of the recess are shown in the characteristic data table.

Warning: The overall safety of the machine and its protective devices depends on the
function of the interface.

It must be ensured that the categories (according to EN 954-1) of the device are
adequate and that they correspond with the respective data.

Check after installation:

After installation, it is recommended to check whether
• proper functioning is ensured.
• the contact mat is not damaged.
• the cables have been routed correctly and are not damaged.
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Maintenance:
Warning: Before starting maintenance work, the section ”Maintenance” must be read
completely.
The contact mat is maintenance-free. However, it is recommended to inspect the contact mats
for any damage at regular intervals.
Cleaning of the contact mat must take place so that any damage to the signal transmitter is
impossible. Particularly when using cleaning agents, it must be ensured that the signal
transmitter is not attacked. Under no circumstances must the contact mat be sprayed with high-
pressure cleaning equipment.

Repair:
The contact mat can be repaired. This can take place only by the manufacturer.
Warning: For maintenance/cleaning purposes or a possible repair, components such as the
aluminium ramp profile, connecting cables, etc. have to be removed, these
components must be refitted properly. Otherwise there is a risk that the demands
on the contact mat are not met.
Changes to the contact mat or the use of unapproved spare parts are not
permitted, as the function of the contact mat can be rendered ineffective as a
result.

Dimensioning and Arrangement:

The signal transmitter must be dimensioned and arranged so that sufficient distance to the
hazardous point is ensured. Furthermore, the signal transmitter must be designed and arranged
in such a way that it cannot easily be reached over, walked over or bypassed.
The specifications of EN 999 ”Arrangement of protective devices in respect of the approach
speeds of parts of the body” can be taken as a basis for safety distance dimensioning. The
safety distance is calculated according to the following formula:

S = 1600 (mm/s) x T (s) + 1200 (mm)

S = safety distance; T = operating time (= time from actuation of the signal transmitter to
stopping of the dangerous movement) in seconds (s)

Example:
T = 0.08 s, this results for S = 1600 mm/s x 0.08 s + 1200 mm = 1328 mm.

Based on the calculation of the safety distance, the active area of the contact mat can be
determined. The overall dimensions of the contact mat can be calculated as follows:
• Active area + inactive edge zone
• Active area + inactive edge zone + aluminium ramp profile
The values for the inactive edge zone and the aluminium ramp profile are shown in the
characteristic data table.

Example:
Determined active area = 1000 mm x 1000 mm
Values for inactive edge zone: 30 mm and on the cable connection side 40 mm
Width of aluminium ramp profile: 60 mm
• Overall dimensions of the contact mat without aluminium ramp profile:
1060 mm x 1070 mm.
• Overall dimensions of the contact mat with aluminium ramp profile:
1180 mm x 1190 mm.

The largest dimensions for the active area as an individual signal transmitter are 2000 mm x
1000 mm.

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Technical data:
Response time of the contact mat:
The longest determined response time is: t = 21 ms
Characteristic data:
Contact plate, contact element and end piece Thermoplastic POM
of contact mat
Contact strip Punched part of E-copper, silver-plated
Expander cord 40 % TD 150 polyester textr. 60 % EPDM-
rubber, extensibility 110 %, effective
elongation 10-30 %
Aluminium ramp profile AlMgSi0,5 F22
Signal transmitter covering material Elastomer two-component system on
polyurethane basis. Other materials available
on request.
Surface structure Cross ribbing (”bulb plate”)
Operating voltage Max. 50 V AC, 75 V DC, (functional extra-low
voltage with safety separation)
Current Max. 0.5 A
Degree of protection IP 54 according to IEC 529/EN 60529/
DIN VDE 470T.1
Operating temperature range +5 °C to +55 °C
Cable Standard: Double insulated, single-core
2
FLKM cable 0.5 mm , highly flexible.
Other cable connections possible after
consulting with the manufacturer.
Maximum cable length 50 metre
Permissible load Max. 750 N based on test piece 1 (d =
11 mm) according to EN 1760-1. The
permissible load depends on the size of the
area and must be clarified with the
manufacturer.
Inactive edge zone On all sides 30 mm, on the cable connection
side 40 mm.
When using the aluminium ramp profile, an
additional 60 mm on all sides.
Minimum dimensions of active area Width of signal transmitter: 60 mm
Length of signal transmitter: 50 mm
Maximum dimensions of active area Width of signal transmitter: 1000 mm
Length of signal transmitter: 2000 mm
With very narrow signal transmitter type,
longer lengths than 2000 mm are possible
after consulting with the manufacturer.
Overall height of contact mat 15 mm (without aluminium ramp profile)
2
Weight About 18 kg/m , without aluminium ramp
profile
Driving over Unsuitable
Use for children (child protection) Unsuitable
Application For indoor use only

Warning: Driving, braking and turning on the signal surface with wheeled vehicles is not
permitted:
 -5-

Resistance to diverse media

Medium g/l % Room 50 °C

temperature
Acetic acid 80 8.0 - -
Oxalic acid 30 3.0 + o
Gluconic acid 100 10.0 o -
Amidosulphuric acid 10 1.0 + o
Phosphoric acid 80 8.0 + +
Nitric acid (HNO3, 36 %) 120 4.3 -- --
Sulphuric acid (H2S4, 37 %) 80 3.0 + +
Hydrochloric acid (Hcl, 32 %) 80 2.6 + +
Sodium hydroxide (NaOH) 30 3.0 + +
Diethanolamine 85 8.5 + +
Triethanolamine 80 8.0 + +
Hydrogen peroxide 60 2.1 + +

+: largely resistant
o: limited resistance
-: not resistant
--: absolutely no resistance

Integration of the contact mat into the control:

The determined category must be met by all components involved in the ”stopping of dangerous
movements” process.
Control design takes place according to EN 60204-1 ”electrical equipment in machines”. The
heart of the control is a safety relay combination designed according to the determined category.
On account of the positive opening principle of the contact mat, it is connected directly to the
relay safety module, which is responsible for executing the control command of the contact mat.
It causes the drive to stop.

Circuit example:

Single-channel shutdown circuit at drive units

 Contact mat
Off Auxiliary contacts Positively driven
safety contacts
On Emergency stop

Figure 1