Banner DUO-TOUCH SG Two-Hand Control Safety Modules User Manual

AT-FM-10K Two-Hand Control Module

AT-FM-10K Two-Hand Control Module

DUO-TOUCH® SG, for use with two actuating devices

Original Instructions

• Diverse-redundant microcontrollers

• Monitors two Banner STB Self-Checking Optical Touch Buttons, or two mechanical
push buttons

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

• Feedback input monitors external machine control elements

• 5 indicator LEDs for Power, Fault, Input 1, Input 2 and Output

• 24V ac/dc operation

• DIN-rail-mountable 22.5 mm-wide housing with removable terminal blocks

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

Important . . . Read This Before Proceeding!

It is the responsibility of the machine designer, controls engineer, machine builder and/or maintenance electrician to apply and maintain
this product in full compliance with all applicable regulations and standards. The product can provide the required safeguarding function
only if it is properly installed, properly operated, and properly maintained. This manual attempts to provide complete installation, opera­tional, and maintenance instruction. Reading the manual completely is highly recommended. Please direct any questions regarding the
application or use of the product to a Banner Engineering Applications Engineer at the locations listed in this document.

WARNING: User Responsibility

The user is responsible for ensuring that all local, state, and national laws, rules, codes, and regulations
relating to the use of this device in any particular application are satisfied. Make sure that all legal require­ments have been met and that all installation, operation, and maintenance instructions contained in the
device documentation are followed.

U.S. Application Standards

ANSI B11.0 Safety of Machinery; General Requirements and Risk Assessment

ANSI B11.19 Performance Criteria for Safeguarding

ANSI NFPA 79 Electrical Standard for Industrial Machinery

International/European Standards

ISO TR12100-1 & -2 (EN 292-1 & -2) Safety of Machinery – Basic Concepts, General Principles for Design

IEC 60204-1 Electrical Equipment of Machines Part 1: General Requirements

ISO 13849-1 (EN 954-1) Safety-Related Parts of Control Systems

ISO 13855 (EN 999) The Positioning of Protective Equipment in Respect to Approach Speeds of Parts of the Human Body

ISO 13851 (EN 574) Two-Hand Control Devices – Functional Aspects – Principles for Design (also request a type "C" standard for your

specific machinery.)

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AT-FM-10K Two-Hand Control Module

Sources of Standards and Regulations

OSHA Documents: www.osha.gov (Tel: [phone])

American National Standards Institute (ANSI): www.ansi.org (Tel: [phone])

Robotics Industries Association (RIA): www.robotics.org (Tel: [phone])

National Fire Protection Association (NFPA): www.nfpa.org (Tel: [phone])

NSSN National Resource for Global Standards : www.nssn.org (Tel: [phone])

IHS Standards Store: www.global.ihs.com (Tel: [phone])

Document Center: www.document-center.com/home.cfm (Tel: [phone])

EC Declaration of Conformity

Banner Enginering Corp. herewith declares that AT-FM-10K Two-Hand Control Module for industrial control is in conformity with the
provisions of the Machinery Directive (Directive 98/37/EEC), and all essential Health and Safety Requirements have been met.

Download the complete EC Declaration of Conformity as a PDF file at www.bannerengineering.com/THCmodule

Overview

A DUO-TOUCH SG Two-Hand Control Safety Module (the “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 electro-mechanical push buttons, each with one normally open and one normally closed contact (Form C contact)

If the machine operator removes one or both hands from the actuating device(s), the Module 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.

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, addition­al 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.

The Duo-Touch SG® Two-Hand Control Kit system complies with:

• Two-hand control and Control Reliability requirements per OSHA 29CFR1910.217, ANSI NFPA 79, ANSI B11.19, and ANSI/RIA
R15.06,

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

• Safety-related applications up to Category 4 PL e, per EN ISO 13849-1 and SIL3 per IEC 61508 and IEC 62061.

The Safety Module’s output signal consists of two sets of redundant, forced-guided (mechanically linked) contacts (see wiring diagrams).
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.

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S12A1S11

S13

S23 S21 S22

13 23 Y1

Y2 14 24 A2

K1

K2

14 24

13 23

Machine

Safety

AT-FM-10K

Power

Fault

In 1

In 2

Output

S12

S11

S13

A1 1323Y1

S23

S21

S22

Y2 1424A2

Power ON

(green)

Input 1 Status

(green)

Internal Fault (red)

Input 2 Status

(green)

Output Status

(green)

AT-FM-10K Two-Hand Control Module

LED Indicators

LED ON OFF Flashing

Power ON Power is applied No power —

Fault Simultaneity is

not met or
External wiring

— Internal fault

condition is de­tected

fault

Input 1 Status
Input 2 Status

Output Status Both relays (K1

Touch button is
activated

Button is not ac­tivated

— Feedback error

External wiring
fault is detected

and K2) are
energized

Figure 1. Status indicators and terminal locations

Module Operation

CAUTION: Not an Anti-Repeat Control Device
Anti-repeat control is not a function of this Two-Hand Control Safety Module. The user of this device

must provide a suitable means of accomplishing anti-repeat control for any single-stroke or single-cycle
machine.

The Two-Hand Control Safety Module may be used as an initiation device for most powered machinery when machine cycling is control­led by a machine operator.

Using a two-hand control system makes the operator a “hostage” while the hazard is present, thus limiting or preventing exposure to the
hazard. The two-hand control actuators must be located in a way that hazardous motion is completed or stopped before the operator can
release one or both of the buttons and reach the hazard (see Separation Distance).

The Safety Module’s safety inputs are used to monitor the actuation of the hand controls to comply with the functionality of Type III
requirements of IEC60204-1 and ISO 13851 (Type IIIa/Cat 4) and the requirements of ANSI NFPA79 and ANSI B11.19 for two-hand
control, which include:

• Concurrent (simultaneous) actuation by both hands within a 500 ms time frame

• Where this time limit is exceeded, a requirement that both hand controls must be released before operation is initiated

• Continuous actuation during hazardous condition

• Cessation of hazardous condition if either hand control was released

• Release and re-actuation of both hand controls to re-initiate the hazardous motion or condition (i.e., “anti-tie down”)

• The appropriate performance level of the safety-related function (e.g., Control Reliability, Category/Performance Level, or SIL) as
determined by a risk assessment or the applicable regulation and standards.

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Power

< 0.5 s < 0.5 s Feedback Open SW1 tied down SW2 tied down

Feedback

Loop*

SW1

SW2

Output

> 0.5 s

AT-FM-10K Two-Hand Control Module

In addition, the Safety Module logic will not permit
the safety outputs to turn ON when power is initially
supplied and if the hand controls (actuators) are in
their Run state (e.g. both actuators tie-down). The
hand controls must change to their Stop state and
return to the Run state before the safety outputs
can turn ON.

The actuating devices must be protected from acci­dental or unintended operation. This can be ac­complished by their mounting position and/or
through the use of protective shields such as rings,
guards or shields; see Mechanical Installation.

Figure 2. Model AT-FM-10K timing logic

Part- and Full-Revolution Clutched Machinery

When used on part-revolution clutched machinery that can be stopped at any point during the cycle, the Safety Module can be used

for the following function types: “inch” (jog), “single-stroke,” or “continuous” (run).

When used on full-revolution clutched machinery (that can not be stopped until the end of the cycle), the Safety Module is used to
initiate the cycle and is known as a “two-hand trip device.”

In either situation, the hand controls must be safely located and protected from false operation (see Mechanical Installation and Separa­tion Distance) and the Safety Module must be appropriately interfaced to the machine (see Electrical Installation).

When used in single-cycle or single-stroke mode, the machine control must provide an anti-repeat feature so that the operator must
release the two-hand control actuators after each machine cycle, before a new cycle can be initiated.

NOTE: Two-hand control and two-hand trip safeguarding protect only the operator’s hands . Additional safe­guarding (e.g., additional two-hand controls) may be required. Refer to the relevant standards for addition-

al requirements.

Mechanical Installation

Install the Safety Module inside an enclosure rated NEMA 3 (IEC IP54), or better. It is not designed for exposed wiring. The Module

mounts directly onto a standard 35 mm DIN rail.

Heat Dissipation Considerations

For reliable operation, ensure that the operating specifications are not exceeded. The enclosure must provide adequate heat dissipation,
so that the air closely surrounding the Module does not exceed the maximum operating temperature stated in the Specifications. Methods
to reduce heat build-up include venting, forced airflow (e.g., exhaust fans), adequate enclosure exterior surface area, and spacing be­tween modules and other sources of heat.

Installation of Hand Controls

CAUTION: Hand Controls
The environment in which hand controls are installed must not adversely affect the means of ac­tuation. Severe contamination or other environmental influences may cause slow response or false ON
conditions of mechanical or ergonomic buttons. This may result in exposure to a hazard.

CAUTION: Install Hand Controls to Prevent Accidental Actuation
Total protection for the two-hand control system from “defeat” is not possible. However, the user is re­quired by OSHA regulations to arrange and protect hand controls to minimize possibility of defeat
or accidental actuation.

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Field Covers

Top Mount Side Mount

Top Plate Shield

AT-FM-10K Two-Hand Control Module

Each actuating device requires a normally open and a normally closed (e.g., Form C or SPDT) hard contact, each capable of reliably
conducting 25 mA at 24V dc (nominal). 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. Use shields, covers,
rings, collars, dividers, or similar protection to prevent accidental switch actuation and to discourage use of forearms or elbows. European
standard ISO13851 includes a detailed discussion of approaches to protection of hand controls.

The installation of the hand controls must also consider:

• Failure modes that would result in a short circuit, a broken spring(s), mechanical seizure, etc. that would result in not detecting the
release of a hand control.

• Severe contamination or other environmental influences that may cause slow response when released or false ON condition of the
hand control(s), e.g., sticking of a mechanical linkage.

The hand controls must be arranged far enough apart so that the operator cannot operate both hand controls by the use of one arm.
Typically, this distance is not less than 550 mm/21.7” in a straight line, but using guards or alternate mounting arrangement can allow
shorter distances, per ISO13851 (EN574). This standard also recommends that the hand controls be arranged on a horizontal (or nearly
horizontal) surface that is 1,100 mm/43.3" above the floor for ergonomic purposes.

When installing the hand controls, consider ergonomic princi­ples, in order to avoid unnecessary user fatigue. See
ISO13851 (EN574) Two-Hand Control, ANSI B11.TR1 – Er­gonomic Guidelines, and EN894, Safety of Machinery – Er­gonomic Requirements – Control Actuators for further infor­mation.

The figure shows two examples for mounting Banner’s STB
Touch Buttons. When mounted on top of the control bar, the
protective field covers should be in place, as shown. For add­ed protection, mount the devices sideways under and behind
a protective hood, rather than on top of the bar, leaving the
field covers off. This side mount reduces the possibility of the
operator easily positioning and leaving an object in the path
of the beam, intentionally bypassing the safeguard.

Requirements for Multiple-Operator Control

Standards have specified several conditions for situations where multiple operators work together to control one machine:

It is the user's responsibility to determine if this two-hand control system can be interfaced to the machine in a manner to
satisfy all existing requirements for multiple-operator control.

Two-Hand Control Safety Distance (Minimum Distance)

Figure 3. Install activation devices so that they are protected to pre-

vent defeat or inadvertent actuation (Banner STB Touch Buttons

shown)

• Each operator must actuate his/her own pair of actuating devices, with all pairs of actuators active at one time, in order to initiate a
machine cycle; the machine may not be allowed to operate until this condition is true.

• The actuators all must be released between cycles.

• The actuation and de-actuation of all workstations requiring two-hand control must be supervisable and must provide indication.

• The clutch/brake control system must be designed so that the clutch cannot be actuated if all the operating workstations are by­passed.

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.

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