User Manual

ManualsBrandsBanner ManualsSpecial machineryDUO-TOUCH SG Two-Hand Control Safety Modules

Models AT-GM-11KM and AT-HM-11KM with Muting and Safety Stop Interface Inputs

For the latest technical information about this product, including specifications, dimensions, and wiring, see www.BannerEngineering.com

Features

• Diverse-redundant microcontrollers

• Supplies power and monitors two Banner STB Self-Checking Optical Touch But-

tons, or two mechanical push buttons

• Two redundant, forced-guided (mechanically linked) output contacts rated at 6 A

• Two auxiliary solid-state outputs (NPN and PNP), plus auxiliary N.C. relay output

• Feedback input monitors external machine control elements

• Seven indicator LEDs for Power, Fault, Input 1, Input 2, SSI, Mute, and Output

• 24V dc plus 115V ac or 24V dc, 230V ac operation, depending on model

• DIN-rail-mountable 67.5 mm-wide housing with removable terminal blocks

• 500 ms (max.) simultaneity requirement for touch-/push-button operation

• Two mute inputs allow release of actuating buttons during the non-hazardous por-

tion of the machine cycle

• Safety Stop Interface (SSI) allows for connection of supplemental safeguards, E-

stop, “Top” stop or anti-repeat devices, or the output of a brake monitor

Description

A DUO-TOUCH SG Two-Hand Control Safety Module may be used with:

• Two Banner STB Self-Checking Optical Touch Buttons, each with one normally open and one normally closed relay output contact, or

• Two Banner STB Self-Checking Optical Touch Buttons, each with two current-sourcing PNP outputs, or

• Two mechanical push buttons with one normally open and one normally closed contact each (Form C contact)

If the machine operator removes one or both hands from the actuating device(s), the Duo-Touch SG relays de-energize, causing the

output contacts to open. The relays will not re-energize until both actuating devices are deactivated and then simultaneously reactivated

(SSI input channels closed).

The Duo-Touch SG Two-Hand Control Kit system has been designed to meet:

• Type IIIC requirements of ISO 13851 (EN 574) Safety of Machinery – Two-Hand Control Devices, and

• Category 4 requirements of ISO 13849-1 (EN 954-1) Safety of Machinery – Safety-Related Parts of Control Systems – Part 1: Gener-

al Principles of Design

The Safety Module’s output signal consists of four sets of redundant, forced-guided (mechanically linked) contacts (see Figures in Electri-

cal Installation on page 10). Circuitry within the Safety Module monitors these internal contacts and prevents an output signal from

occurring if a fault is detected. A feedback loop is offered for monitoring the status of the machine control elements.

WARNING: Point-of-Operation Guarding

When properly installed, a two-hand control device provides protection only for the hands of the machine

operator. It may be necessary to install additional safeguarding, such as safety light screens, addition-

al two-hand controls, and/or hard guards, to protect all individuals from hazardous machinery.

Failure to properly guard hazardous machinery can result in a dangerous condition which could

lead to serious injury or death.

DUO-TOUCH® SG Two-Hand Control Modules

P/N 109782 Rev.B 12/28/2011

0 109782 9

Summary of content (20 pages)

PAGE 1
DUO-TOUCH® SG Two-Hand Control Modules Models AT-GM-11KM and AT-HM-11KM with Muting and Safety Stop Interface Inputs For the latest technical information about this product, including specifications, dimensions, and wiring, see www.BannerEngineering.
PAGE 2
DUO-TOUCH® SG Two-Hand Control Modules Important . . . Read This Before Proceeding! In the United States, the functions that the Banner DUO-TOUCH SG Two-Hand Control Module is intended to perform are regulated by the Occupational Safety and Health Administration (OSHA). Whether or not any particular DUO-TOUCH SG Two-Hand Control Module installation meets all applicable OSHA requirements depends upon factors that are beyond the control of Banner Engineering Corp.
PAGE 3
DUO-TOUCH® SG Two-Hand Control Modules Appropriate Applications Power ON (green) Internal Fault (red) Input 1 Status (green) Input 2 Status (green) SSI (green ) Mutin g (green ) Output Status (green) Powe r S11 S12 A1 A2 B1 S13 S22 S21 B2 Z3 Z4 24 X3 X4 Y1 Faul t Input 1 K1 Input 2 SSI Mutin g Output 31 K2 K1 31 32 K2 13 14 23 32 Figure 1.
PAGE 4
DUO-TOUCH® SG Two-Hand Control Modules Part-Revolution Clutched Machinery A two-hand control safety module can be used for the following functions: “inch” (jog), “single-stroke,” or “continuous” (run).
PAGE 5
DUO-TOUCH® SG Two-Hand Control Modules CAUTION: Do Not Use a Single Muting Device A single device, such as one relay or one switch with two N.O. output contacts, may fail due to a single fault. Such a fault could result in an unintentional mute cycle and cause an unsafe situation. Muting Device Requirements The muting devices (typically sensors or switches) must, at a minimum, comply with the following requirements: • A minimum of two independent hard-wired muting devices must be used.
PAGE 6
DUO-TOUCH® SG Two-Hand Control Modules Examples of Muting Sensors and Switches Photoelectric Sensors (Opposed Mode) Opposed-mode sensors, which initiate the muted condition when the beam path is blocked, should be configured for Dark Operate and have open (non-conducting) output contacts in a power OFF condition. Photoelectric Sensors (Polarized Retroreflective Mode) The user must ensure that false “proxing” (activation due to shiny or reflective surfaces) is not possible.
PAGE 7
DUO-TOUCH® SG Two-Hand Control Modules Backdoor Timer Safety Stop Interface (SSI) The SSI provides for easy integration of safeguards, E-stop buttons, process control, etc. This input is always active: opening either channel will cause the AT-..M-11KM to issue a stop command. The channels operate concurrently (both must open and re-close, but not necessarily within a certain time frame). If the SSI is not to be used, terminal X3 must be jumpered to X4, and terminal X5 must be jumpered to X6.
PAGE 8
DUO-TOUCH® SG Two-Hand Control Modules Installation of Hand Controls Each actuating device typically requires a normally open and a normally closed Field Covers (e.g., Form C or SPDT) hard contacts, each capable of reliably conducting 20 mA at 12V dc. For complementary PNP operation, model STBVP.. touch buttons must be used to ensure proper functionality. Standards require that the actuating devices be mounted to protect them from accidental or unintentional operation.
PAGE 9
DUO-TOUCH® SG Two-Hand Control Modules Separation Distance WARNING: Location of Touch Button Controls Hand controls must be mounted a safe distance from moving machine parts, as determined by the appropriate standard. It must not be possible for the operator or other non-qualified persons to relocate them. Failure to establish and maintain the required safety distance could result in serious injury or death.
PAGE 10
DUO-TOUCH® SG Two-Hand Control Modules Example Separation Distance (Ds) Calculation The following example illustrates the use of the formula to calculate separation distance for a part-revolution clutch machine. This example uses 0.50 seconds as a typical value for Ts and 0.02 seconds for Th: K = 63" per second Ts = 0.50 seconds (measured by a stop-time measuring device) Tr = 0.035 seconds Th = 0.02 seconds Ds = K x (Ts + Tr + Th) = 63" (0.50 + 0.035 + 0.
PAGE 11
DUO-TOUCH® SG Two-Hand Control Modules STB2 STB1 STB2 STB1 Logic +– +– +– Brown Blue Whit e Yell ow Black Whit e Yell ow Black AT-GM- 11K M AT-HM- 11K M SW1 +– Brown Blue Whit e Z1 Z2 S12 S11 S13 S22 S21 S23 Figure 8. Hookup to two STB touch buttons with contact outputs SW2 Logic Black Whit e Black AT-GM- 11K M AT-HM- 11K M AT-GM- 11K M AT-HM- 11K M Z1 Z2 S12 S11 S13 S22 S21 S23 Z1 Z2 S12 S11 S13 S22 S21 S23 Figure 9.
PAGE 12
DUO-TOUCH® SG Two-Hand Control Modules The connection of the safety outputs must be in such a manner that the stop command issued by the ATxM-11KM can not be overridden by a device or circuit that is not at the same level of safety integrity. This means that the safety outputs are interfaced on the output of the machine logic (e.g., PLC or PC). Then, normally, a feedback signal identifies to the machine logic the status of the safety module and, if possible, the status of the MPCEs.
PAGE 13
DUO-TOUCH® SG Two-Hand Control Modules Initial Checkout Procedure CAUTION: Disconnect Power Prior to Checkout Before performing the initial checkout procedure, make certain all power is disconnected from the machine to be controlled. Dangerous voltages may be present along the Safety Module wiring barriers whenever power to the machine control elements is ON. Exercise extreme caution whenever machine control power is or may be present.
PAGE 14
DUO-TOUCH® SG Two-Hand Control Modules Periodic Checkout and Maintenance WARNING: Do Not Use System Until Checkouts Are Verified If all of the described checks cannot be verified, do not attempt to use the two-hand control safety system until the defect or problem has been corrected. Attempts to use the guarded machine under such conditions could result in serious bodily injury or death.
PAGE 15
DUO-TOUCH® SG Two-Hand Control Modules Specifications Supply Voltage and Current A1-A2: 115V ac (AT-GM-11KM) or 230V ac (ATHM-11KM), +/- 15%; 50/60Hz B1-B2: 24V dc, +/- 15%, 10% max. ripple Supply Protection Circuitry Protected against transient voltages and reverse polarity Power Consumption Approx. 4 W/7 VA Output Configuration Outputs (K1 and K2): two redundant (total of four) safety relay (forced-guided) contacts Contact ratings: Maximum voltage: 250V ac or 250V dc Maximum current: N.O.
PAGE 16
DUO-TOUCH® SG Two-Hand Control Modules LED Indicators Two-Hand Control Module AT-..M-11KM provides seven indicator LEDs. Indicator Power (Green) ON – Power is connected to terminals A1-A2 OFF – No power or low power to terminals A1-A2, or internal power supply failure Flashing (only; no other LEDs are ON) – DIP Switch Fault (see Muting Functions and Safety Stop Interface on page 6) Fault (Red) ON – External fault or configuration fault.
PAGE 17
DUO-TOUCH® SG Two-Hand Control Modules Troubleshooting Condition: Outputs Will Not Energize Condition: Outputs Will Not Energize Indicator Status Possible Reason/Solution Indicator Status Possible Reason/Solution Power ON Power ON Fault ON Two-Hand Control Input Simultaneity Error Fault Flashing Two-Hand Control Input Short Circuit In #1 ON or OFF In #1 Flashing In #2 ON or OFF - Simultaneity failure (> 500 ms) with status of input In #2 Flashing SSI ON SSI OFF MUTE OFF MUTE
PAGE 18
DUO-TOUCH® SG Two-Hand Control Modules Condition: Module Will Not Mute Condition: Mute Drops Out and Will Not Mute Again Indicator Status Possible Reason/Solution Indicator Status Possible Reason/Solution Power ON M1/M2 Input Simultaneity Error Power ON Backdoor Timer Expired Fault ON Fault OFF In #1 ON In #1 Flashing In #2 ON In #2 Flashing SSI ON SSI ON MUTE Flashing MUTE Flashing OUT ON OUT ON - Simultaneity failure (> 3.
PAGE 19
DUO-TOUCH® SG Two-Hand Control Modules Dimensions Power 84 mm (3.3") S11 A2 B1 S13 S22 S21 B2 Z3 Z4 24 X3 X4 Y1 S23 Z1 Z2 Y2 M11 M12 M21 M22 X6 Y30 Y31 Y32 Y33 Input 1 K1 Input 2 SSI Mutin g Output 118.0 mm (4.6") S12 A1 Faul t 31 K2 32 K2 K1 13 14 31 23 X5 32 X1 X2 67.5 mm (2.66") Removal of Terminal Blocks To remove a terminal block, insert a small screwdriver into the slot and pry to loosen.
PAGE 20
DUO-TOUCH® SG Two-Hand Control Modules Banner Engineering Corp Limited Warranty Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the warranty period.