• Assembly:
  • Recora Switchmat® main unit — heavy-duty molded pressure-sensitive safety mat
  • Lead wire(s) for connection to the safety/control system: standard single-lead mats ship with 2-conductor wire (normally open); dual-lead (HD) mats ship with the leads required for fail-safe monitoring, with a 4-conductor option available 
  • Molded ramp edging (corrugated series) or molded blunt edge (smooth series); heavy-duty mats include extruded aluminum 2.000" ramp edging, 0.750" blunt edging, and a conduit connector for securing larger layouts 
  • Installation and wiring documentation sheet 

A safety relay, PLC safety module, or machine-safety controller is required to complete the safety system and is not included — a safety mat alone does not constitute a safety system. For fail-safe machine protection, Recora specifies the FSC-6R monitoring relay, which brings a 4-wire heavy-duty mat system up to Safety Category 3. PowerSafe can supply and integrate the correct controller as part of a turnkey solution.

• Output Options
  • Switch type: single-pole, single-throw (SPST), normally open, momentary contact
  • Actuates on 10–15 lb applied load
  • Standard lead wire: 6 ft, 18 AWG, 2-conductor, rated 300 V / 7 A
  • Dual-lead (HD) versions for connection to a Fail-Safe Control Unit; 4-conductor leads optional
  • Operating power: 12 W at 24 V AC or DC
• Series Options:
  • Series 12H & 30H — thin (3/8"), corrugated surface with molded ramp edging
  • Series 15H — thin (3/8"), smooth surface with molded blunt edge
  • Series 14H — standard-duty area coverage in a wide range of stock sizes
  • Series 14HD / 14EHD — heavy-duty and extra-heavy-duty for worker and vehicle protection; customizable to any size or shape with snap-on aluminum edging
  • Standard stock sizes range from roughly 8 × 24 in up to 35.5 × 60 in; custom sizes and shapes available to order
  • Standard color black; brown and yellow available
• Cascade Capacity
  • Multiple mats can be linked and edged together with snap-on aluminum connectors to cover large or irregular areas, including cutouts around machine legs, posts, and walls. 
  • Zone size and layout must be defined by the risk assessment for the protected machine.

Installation Guide

Mat Does Not Detect / Fails to Trigger Stop 

Isolating a failed mat in a series-wired system

• Note that all mats are wired in series — a single shorted mat can disable the string, so mats must be tested individually
• Disconnect the suspect mat (all conductors) and check resistance: a good mat reads infinite (open) with no load and ≤5 Ω under an operator's weight 
• ≤5 Ω with no weight = shorted → replace the mat 
• ∞ Ω under load = open (rare) — inspect for a broken lead or a screw driven through the wire; if none, recheck meter leads 
• Visually inspect the surface first: dents or deformities often reveal the faulty mat without disassembly. The most common failure is a heavy object's corner dropped on the mat, denting the electrode and shorting itConfirm the mat lies completely flat on a stable surface with no folds, curls, or lifting

False Trips / Nuisance Activation 

Machine stops with no operator present, or won't reset

• Inspect for contamination, standing liquid, or debris on or under the mat
• Check for surface wear or cover lift altering the mat's contact behavior
• Confirm edges and fasteners are secure and haven't shifted
• Review controller/relay configuration and diagnostic monitoring settings

Wiring & Control-System Issues 

Safety relay or PLC not registering mat state

• Verify mat outputs are correctly wired into the safety relay / safety-PLC
• Check lead continuity and terminal connections for looseness or corrosion
• Confirm the monitoring controller (e.g., FSC-6R) is configured and reading the signal
• On dual-lead (HD) systems, confirm correct fail-safe wiring to the control unit

Fail-Safe Function Verification 

Confirming the system responds to faults

• Periodically simulate a severed-lead and power-interruption condition and confirm the system enters a safe state
• Confirm the FSC-6R (or specified controller) trips as expected on fault
• Verify positive operation indicators / status LEDs on the controller show correct fault and run states

Physical Damage & Edge Termination 

Degraded performance over time

• Inspect for frayed edges, cover lifting, or cracked molding
• Check aluminum ramp/blunt edging and conduit connectors for damage or loosening
• Confirm the mat's environmental rating matches actual floor conditions (e.g., vehicle traffic → heavy-duty series)

Zone Sizing & Placement 

Coverage doesn't match the hazard

• Confirm mat footprint and location match the machine's risk assessment (approach distance, stop time, hazard geometry)
• Verify no gap allows a person to reach the hazard without loading the mat

Functional Testing (After Install or Maintenance)

• Walk the full mat area; confirm the machine enters a safe state under load
• Remove the load and confirm the machine only restarts under safe conditions
• Document test results

Preventive Maintenance

To avoid recurring issues, on a set interval (quarterly or semi-annually depending on traffic):

• Inspect the mat surface for wear, curling, or cover lift and clean off oil, coolant, and debris
• Check leads, connectors, and terminals for corrosion or loosening
• Confirm mounting and edging remain secure
• Verify correct trip-and-reset behavior across the full surface

Fault Tracking & Continuous Improvement

• Log every trip and fault (date, location on mat, conditions, controller indicators)
• Watch for patterns — repeated false trips or missed detections often point to contamination, wear, loosening wiring, or undersized zones
• Use the data to find root causes and adjust maintenance or mat selection
• Keep installation manuals, wiring diagrams, test logs, and maintenance records accessible for audits and risk assessments