AT-FM-10K Two-Hand Control Module
Datasheet
DUO-TOUCH® SG, for use with two actuating devices
•
•
•
•
•
•
•
•
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, machine operator, and/or maintenance personnel
or electrician to apply and maintain this device in full compliance with all applicable regulations and standards. The device can
provide the required safeguarding function only if it is properly installed, properly operated, and properly maintained. This manual
attempts to provide complete installation, operation, and maintenance instruction. Reading the manual in its entirety is highly
recommended to ensure proper understanding of the operation, installation, and maintenance. Please direct any questions regarding
the application or use of the device to Banner Engineering Corp.
The user is responsible for satisfying all local, state, and national laws, rules, codes, and regulations relating to the use of this
product and its application. Banner Engineering Corp. has made every effort to provide complete application, installation, operation,
and maintenance instructions. Please contact a Banner Applications Engineer with any questions regarding this product.
U.S. Application Standards
ANSI B11.0 Safety of Machinery, General Requirements, and Risk Assessment
ANSI B11.19 Performance Criteria for Safeguarding
NFPA 79 Electrical Standard for Industrial Machinery
International/European Standards
EN ISO 12100 Safety of Machinery – Basic Concepts, General Principles for Design
EN 60204-1 Electrical Equipment of Machines Part 1: General Requirements
EN ISO 13849-1 Safety-Related Parts of Control Systems
EN 13855 (EN 999) The Positioning of Protective Equipment in Respect to Approach Speeds of Parts of the Human Body
ISO 13851 Two-Hand Control Devices – Principles for Design and Selection
(also request a type C standard for your specific machinery.)
Sources of Standards and Regulations
OSHA Documents: www.osha.gov (Tel: 202-512-1800)
American National Standards Institute (ANSI): www.ansi.org (Tel: 212-642-4900)
Robotics Industries Association (RIA): www.robotics.org (Tel: 734-994-6088)
National Fire Protection Association (NFPA): www.nfpa.org (Tel: 800-344-3555)
NSSN National Resource for Global Standards : www.nssn.org (Tel: 212-642-4980)
IHS Standards Store: www.global.ihs.com (Tel: 303-397-7956, 800-854-7179)
Document Center: www.document-center.com/home.cfm (Tel: 650-591-7600)
EU/UK Declaration of Conformity (DoC)
Banner Engineering Corp. herewith declares that these products are in conformity with the provisions of the listed directives,
regulations, and all essential health and safety requirements have been met. For the complete DoC, please go to
www.bannerengineering.com.
Original Document
64137 Rev. J
19 July 2022
64137
AT-FM-10K Two-Hand Control Module
Product
Directive
AT-FM-10K Two-Hand Control Module
EU: 2006/42/EC
UK: Machinery (Safety) Regulations 2008
Representative in EU: Spiridon Lachanidis, Managing Director, Banner Engineering Europe Park Lane, Culliganlaan 2F bus 3,
1831 Diegem, BELGIUM
Representative in UK: Tony Coghlan, Managing Director, Turck Banner LTD Blenheim House, Blenheim Court, Wickford, Essex
SS11 8YT, Great Britain
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:
• Use adequate point-of-operation guarding
• Failure to properly guard hazardous machinery can result in a dangerous condition that could lead to
serious injury or death.
• When properly installed, a two-hand control safety device provides protection only for the hands of the
machine operator. It might be necessary to install additional safeguarding, such as safety light curtains,
additional two-hand controls, and/or hard guards, to protect all individuals from hazardous machinery.
The Duo-Touch SG® Two-Hand Control Kit system complies with:
• Two-hand control and Control Reliability requirements per OSHA 29CFR1910.217, NFPA 79, and ANSI B11.19,
• Type IIIC requirements of ISO 13851 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 EN 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.
LED Indicators
Figure 1. Status indicators and terminal locations
S12 S11 S13
A1 13
Power ON
(green)
Internal Fault (red)
Input 1 Status
(green)
S12
A1
Input 2 Status
(green)
Output Status
(green)
S11
13
23
S13
Y1
13
23
14
24
Fault
K1
In 1
Output
Y2
S23
K2
Machine
Safety
AT-FM-10K
14
24
S21
ON
OFF
Flashing
Power ON
Power is applied
Fault
Simultaneity is not met or
External wiring fault
—
Internal fault condition
is detected
Input 1 Status and
Input 2 Status
Touch button is activated
Button is not activated
External wiring fault is
detected
Output Status
Both relays (K1 and K2) are
energized
23 Y1
Power
In 2
LED
No power
—
—
Feedback error
A2
S22
Y2 14 24 A2
S23 S21 S22
Module Operation
CAUTION:
• Anti-repeat control is not a function of this two-hand control safety module
• Failure to follow these instructions could result in serious injury or death.
• 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.
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AT-FM-10K Two-Hand Control Module
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 NFPA 79 / EN 60204-1 and EN ISO 13851 (Type IIIc/Cat 4) and the requirements of NFPA 79 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.
Figure 2. Model AT-FM-10K timing logic
Power
Feedback
Loop*
SW1
SW2
Output
< 0.5 s
< 0.5 s
> 0.5 s
Feedback Open
SW1 tied down
SW2 tied down
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.
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
additional 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 (for example, exhaust fans), adequate enclosure
exterior surface area, and spacing between modules and other sources of heat.
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AT-FM-10K Two-Hand Control Module
Installation of Hand Controls
CAUTION:
• Avoid installing hand controls in contaminated environments—Severe contamination or other
environmental influences could cause a slow response or false on condition of mechanical or ergonomic
buttons.
• A slow response or false on condition could result in exposure to a hazard.
• The environment in which hand controls are installed must not adversely affect the means of actuation.
CAUTION:
• Install hand controls to prevent accidental actuation
• It is not possible to completely protect the two-hand control system from defeat.
• OSHA regulations require the user to arrange and protect hand controls to minimize possibility of defeat
or accidental actuation.
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 24 V 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. ANSI B11.19 and EN ISO 13851 include 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 inches in a straight line, but using guards or alternate mounting arrangement
can allow shorter distances, per ANSI B11.19 and EN ISO 13851. Arrange hand controls on a horizontal (or nearly horizontal)
surface that is 1,100 mm/43.3 inches above the floor for ergonomic purposes.
Figure 3. Install activation devices so that they are protected to prevent defeat or inadvertent actuation (Banner STB Touch Buttons shown)
Field Covers
Top Mount
Top Plate Shield
Side Mount
When installing the hand controls, consider ergonomic principles, in order to avoid unnecessary user fatigue. See EN ISO 13851
Two-Hand Control, ANSI B11.TR1 – Ergonomic Guidelines, and EN 894, 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.
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AT-FM-10K Two-Hand Control Module
Requirements for Multiple-Operator Control
Standards have specified several conditions for situations where multiple operators work together to control one machine:
•
•
•
•
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
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)
Install all hand controls far enough away from the nearest hazard point that the operator cannot reach the hazard with a hand or
other body part before the hazardous motion ceases. This is the separation distance (safety distance), and may be calculated as
follows.
WARNING:
• Mount hand controls at a safe distance from moving machine parts
• Failure to establish and maintain the safety distance (minimum distance) could result in serious injury or
death.
• Mount hand controls as determined by the applicable standard. The operator or other non-qualified
persons must not be able to relocate the hand controls.
U.S. Applications
The Safety Distance formula, as provided in ANSI B11.19:
Part-Revolution Clutch Machinery (the machine and its controls allow the machine to stop motion during the hazardous portion of
the machine cycle)
Ds = K x (Ts + Tr) + Dpf
For Full-Revolution Clutch Machinery (the machine and its controls are designed to complete a full machine cycle)
Ds = K x (Tm + Tr + Th)
Ds
the Safety Distance (in inches)
K
the OSHA/ANSI recommended hand-speed constant (in inches per second), in most cases is calculated at 63 in/s, but may
vary between 63 in/s to 100 in/s based on the application circumstances;
not a conclusive determination; consider all factors, including the physical ability of the operator, when determining the
value of K to be used.
Th
the response time of the slowest hand control from the time when a hand disengages that control until the switch opens;
Th is usually insignificant for purely mechanical switches. However, Th should be considered for safety distance calculation
when using electronic or electromechanical (powered) hand controls.
For Banner Engineering Corp Self-checking Touch Buttons (STBs) the response time is 0.02 seconds.
Tm
the maximum time (in seconds) the machine takes to cease all motion after it has been tripped. For full revolution clutch
presses with only one engaging point, Tm is equal to the time necessary for one and one-half revolutions of the crankshaft.
For full revolution clutch presses with more than one engaging point, Tm is calculated as follows:
Tm = (1/2 + 1/N) x Tcy
N = number of clutch engaging points per revolution
Tcy = time (in seconds) necessary to complete one revolution of the crankshaft
Tr
the response time of the Safety Controller as measured from the time a stop signal from either hand control is received.
The Safety Controller response time is obtained from the Configuration Summary tab in the Software.
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AT-FM-10K Two-Hand Control Module
Ts
the overall stop time of the machine (in seconds) from the initial stop signal to the final ceasing of all motion, including stop
times of all relevant control elements and measured at maximum machine velocity.
Ts is usually measured by a stop-time measuring device. If the specified machine stop time is used, add at least 20% as a
safety factor to account for brake system deterioration. If the stop-time of the two redundant machine control elements is
unequal, the slower of the two times must be used for calculating the separation distance.
Dpf
Per ANSI B11.19, the adder to account for the distance that is possible for the individual to be reaching toward the hazard
zone before a protective stop is initiated. For two-hand control applications where encroachment towards the hazard is not
restricted, Dpf = 550 mm (21.65 in). When encroachment is obstructed (for example, shrouding the two-hand actuating
controls, orientation of the work station, etc.), the reaching distance (dds) may be reduced to zero. Dpf is also known as
"dds".
European Applications
The Minimum Distance Formula, as provided in EN 13855:
S = (K x T) + C
S
the Minimum Distance (in millimeters)
K
the EN 13855 recommended hand-speed constant (in millimeters per second), in most cases is calculated at 1600 mm/s,
but may vary between 1600 mm/s to 2500 mm/s based on the application circumstances;
not a conclusive determination; consider all factors, including the physical ability of the operator, when determining the
value of K to be used.
T
the overall machine stopping response time (in seconds), from the physical initiation of the safety device to the final ceasing
of all motion.
C
the added distance due to the depth penetration factor equals 250 mm, per EN 13855. ISO/DIS 13855:2022 increases the
C factor (dds) to 550 mm. The EN 13855 C factor may be reduced to 0 if the risk of encroachment is eliminated, but the
safety distance must always be 100 mm or greater.
Electrical Installation
It is not possible to give exact wiring instructions for a Safety Module that interfaces to a multitude of machine control configurations.
The following guidelines are general in nature.
The Safety Module has no delay function. Its output relay contacts open within 35 milliseconds after a safety input opens. This
classifies the Safety Module as functional stop “Category 0”, as defined by NFPA 79 and IEC/EN 60204-1.
WARNING:
• Determine the safety category
• The design and installation of the safety devices and the means of interfacing of those devices could
greatly affect the level of safety circuit integrity.
• Perform a risk assessment to determine the appropriate safety circuit integrity level or safety category,
as described by ISO 13849-1, to ensure that the expected risk reduction is achieved and that all
applicable regulations and standards are met.
WARNING:
• Risk of electric shock
• Use extreme caution to avoid electrical shock. Serious injury or death could result.
• Always disconnect power from the safety system (for example, device, module, interfacing, etc.),
guarded machine, and/or the machine being controlled before making any connections or replacing any
component. Lockout/tagout procedures might be required. Refer to OSHA 29CFR1910.147, ANSI
Z244-1, or the applicable standard for controlling hazardous energy.
• Make no more connections to the device or system than are described in this manual. Electrical
installation and wiring must be made by a Qualified Person 1 and must comply with the applicable
electrical standards and wiring codes, such as the NEC (National Electrical Code), NFPA 79, or IEC
60204-1, and all applicable local standards and codes.
1
6
A person who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and experience, has
successfully demonstrated the ability to solve problems relating to the subject matter and work.
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AT-FM-10K Two-Hand Control Module
Connecting Power to the Safety Module
The Safety Module requires a 24 V ac/dc supply voltage (see Specifications). Use extreme caution when installing ac power. Use a
minimum of 16 to 18 AWG wire for power and output connections. Use a minimum of 20 AWG wire for all other terminal
connections. A hand-operated supply disconnect and over-current protection (e.g., a circuit breaker) must be provided per ANSI
NFPA79 and IEC/EN60204-1.
Connecting Input Switches (Hand Control Actuators)
Connect the actuation devices to the Module as shown in the following wiring diagrams. SW1 and SW2 must both have normally
open and normally closed output contacts, or two current-sourcing complementary outputs each, all capable of reliably switching 25
mA at 24 V DC (nominal). If hand controls have metal housings, the housings must be connected to protective earth ground.
If STB Touch Buttons with PNP outputs are used, the entire STB/AT-FM-10K system must be supplied with 24 V DC.
Electronic actuation devices, including STB Touch Buttons, must share the same voltage supply with the Safety Module
WARNING:
• Electronic hand controls cannot guarantee the state of their outputs at the time power is applied
to them
• Failure to power hand controls (such as optical touch buttons, capacitive touch buttons and similar
devices) and the safety module from the same voltage source creates a potentially dangerous condition,
which could result in serious injury or death.
• When electronic hand controls are used as input switches for a safety module, the hand controls and the
safety module must be powered from the same voltage source. If power is applied to the safety module
before power is applied to the electronic hand controls, an output from the safety module could result
and could trigger machine motion.
Figure 4. Connection to two STB Touch Buttons with contact outputs
STB2
STB1
Figure 5. Connection to two STB Touch Buttons with PNP (sourcing) outputs
STB2
STB1
Logic
+–
+–
Logic
+–
+–
Blue
Blue
Brown
24 V ac/dc
Fuse*
White
Yellow
Black
White
Yellow
Black
L1/+V dc
Machine
Control
Circuit
Brown
A2
A1
AT-FM-10K
S12
S11
Y1
S13
S22
S21
S23
K1
0 V ac/dc
24 V dc
White
(1)
MPCE2
Black
MPCE1
Y2
White
L1/+V dc
L2/–V dc
14
23
24
Black
*
K2
13
Fuse*
MPCE
1
MPCE
2
Machine
Control
Circuit
A1
A2
AT-FM-10K
S12
S11
S13
S22
S21
S23
K1
Y1
0 V dc
(1)
MPCE2
L2/–V dc
*
K2
13
14
23
24
MPCE
1
MPCE
2
*
*
* 500 mA slow blow fuse recommended
MPCE1
Y2
* 500 mA slow blow fuse recommended
WARNING:
• Interfacing safety outputs
• Failure to follow these instructions could result in serious injury or death.
• Never wire or interface an intermediate device (PLC, PES, PC) that can fail in such a manner that
there is a loss of the safety stop command to the master primary control element(s).
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AT-FM-10K Two-Hand Control Module
Figure 6. Connection to two mechanical push buttons with contact outputs
SW1
SW2
24 V ac/dc
Fuse**
A2
A1
AT-FM-10K
S12
S11
Y1
S13
S22
S21
S23
K1
L1/+V dc
Machine
Control
Circuit
0 V ac/dc
(1)
MPCE2
MPCE1
Y2
L2/–V dc
*
K2
13
14
23
24
WARNING:
• Properly install arc or transient
suppressors
• Failure to follow these instructions
could result in serious injury or
death.
• Install any suppressors as shown
across the coils of the machine
primary control elements. Do not
install suppressors directly across
the output contacts of the safety or
interface module. In such a
configuration, it is possible for
suppressors to fail as a short
circuit.
MPCE
1
MPCE
2
*
* Arc Suppressor – See Warning
(1) See Warning about Interfacing Safety Outputs
** 500 mA slow blow fuse recommended
Connecting to the Guarded Machine
WARNING:
• Interfacing master stop controls
• Failure to follow these instructions could result in serious injury or death.
• Unless the same degree of safety is maintained, never wire an intermediate device(s) (PLC, PES, PC)
between the safety module outputs and the master stop control element it switches such that a failure
causes a loss of the safety stop command or the failure allows the safety function to be suspended,
overridden, or defeated.
• When forced-guided, mechanically linked relays are added as intermediate switching devices, a
normally closed (N.C.) forced-guided monitor contact from each relay must be added to the series
feedback loop or properly wired external device monitoring channel.
The wiring diagrams show a generic connection of the Safety Module’s redundant output contacts to machine primary control
elements MPCE1 and MPCE2. An MPCE is defined as an electrically-powered element, external to the Safety Module, which
directly controls the machine’s normal operating cycle so that it is the last (in time) to operate when the cycle is either initiated or
arrested. Some older machines offer only one MPCE; for such machines, it may be necessary to add a second MPCE to establish
the appropriate level of safety integrity (e.g., control reliability).
The connection of the safety outputs must be in such a manner that the stop command issued by the Safety Module 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.
In summary, Control Reliability (OSHA 29CFR1910.217, ANSI B11, and ANSI/RIA R15.06) and Category 3 and 4 (EN ISO 13849-1)
requirements demand that a single failure does not lead to the loss of the safety function, or does not prevent a normal or immediate
stop from occurring. The failure or the fault must be detected at or before the next demand of safety (e.g., at the beginning or end of
a cycle, or when a safeguard is actuated). The safety-related function of the machine control then must issue an immediate stop
command or prevent the next machine cycle or hazardous situation until the failure or fault is corrected.
External Device Monitoring
To satisfy the requirements of Control Reliability (OSHA and ANSI) and Category 3 and 4 of EN ISO 13849-1, the machine primary
control elements (MPCEs) must each offer a normally closed, forced-guided (mechanically linked) monitor contact. Connect one
normally closed monitor contact from each master stop control element in series to Y1 and Y2 (see wiring diagrams).
In operation, if one of the switching contacts of either MPCE fails in the energized condition, the associated monitor contact will
remain open. Therefore, it will not be possible to reset the Safety Module. If no MPCE-monitor contacts are monitored, a jumper
must be installed between terminals Y1 and Y2 (dotted line), as shown in the hookup drawings. It is the user’s responsibility to
ensure that any single failure will not result in a hazardous condition and will prevent a successive machine cycle.
Overvoltage Category II and III Installations (EN 50178 and IEC 60664-1)
The AT-FM-10K is rated for Overvoltage Category III when voltages of 1 V to 150 V AC/DC are applied to the output relay contacts.
It is rated for Overvoltage Category II when voltages of 151 V to 250 V AC/DC are applied to the output relay contacts and no
additional precautions are taken to attenuate possible overvoltage situations in the supply voltage. The AT-FM-10K can be used in
an Overvoltage Category III environment (with voltages of 151 V to 250 V AC/DC) if care is taken either to reduce the level of
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AT-FM-10K Two-Hand Control Module
electrical disturbances seen by the AT-FM-10K to Overvoltage Category II levels by installing surge suppressor devices (for
example, arc suppressors), or to install extra external insulation in order to isolate both the AT-FM-10K and the user from the higher
voltage levels of a Category III environment.
For Overvoltage Category III installations with applied voltages from 151 V to 250 V AC/DC applied to the output contact(s):
the AT-FM-10K may be used under the conditions of a higher overvoltage category where appropriate overvoltage reduction is
provided. Appropriate methods include:
• An overvoltage protective device
• A transformer with isolated windings
• A distribution system with multiple branch circuits (capable of diverting energy of surges)
• A capacitance capable of absorbing energy of surges
• A resistance or similar damping device capable of dissipating the energy of surges
When switching inductive AC loads, it is good practice to protect the AT-FM-10K outputs by installing appropriately-sized arc
suppressors. However, if arc suppressors are used, they must be installed across the load being switched (for example, across the
coils of external safety relays), and never across the AT-FM-10K’s output contacts.
Product Support and Maintenance
Initial Checkout Procedure
To perform the initial checkout, it is necessary to view the red Fault LED and the four green status indicators: Power, Input
1, Input 2 and Output. Proceed with caution around open wiring.
CAUTION:
• Disconnect power prior to checkout
• Dangerous voltages might be present along the module wiring barriers whenever power to the machine
control elements is on.
• Before performing the initial checkout procedure, disconnect all power from the machine to be
controlled. Exercise extreme caution whenever machine control power is or might be present. Always
disconnect power to the machine control elements before opening the enclosure housing of the module.
WARNING:
• External Device Monitoring (EDM)
• Creating a hazardous situation could result in serious injury or death.
• If the system is configured for “no monitoring,” it is the user’s responsibility to ensure this does not
create a hazardous situation.
1. Verify that the two actuating devices are properly connected to the Module.
2. Apply power to the Safety Module and to the actuating devices, if applicable.
3. Verify that only the Power indicator is ON. If any of the other Safety Module indicators are ON, disconnect the power to the
Safety Module and check all wiring. Do not continue this checkout procedure until the cause of the problem is corrected.
4. Activate both hand controls simultaneously (within 0.5 seconds), and hold them engaged. Input 1 and Input 2 indicators
should come ON. Release both hand controls simultaneously. Output indicator should go OFF.
5. Again, activate the two hand controls simultaneously, and hold them engaged. Input 1, Input 2, and Output indicators should
come ON. Release one hand control, while holding the other engaged. One of the indicators should remain ON. The Output
indicator should go OFF. Re-activate the hand control which was just released. The Output indicator should remain OFF.
Release both hand controls. Input 1 and Input 2 indicators should then be OFF.
6. Activate only one hand control and hold it engaged. Input 1 (Input 2) indicator should come ON. After more than 1/2 second,
activate the second hand control. Input 1 and 2 indicators should remain ON, while Output indicator remains OFF.
7. Remove power from the Safety Module and disconnect the monitor contact feedback loop at terminals Y1 and/or Y2. Reapply power to the Safety Module. Activate both hand controls simultaneously. Output indicator LED should remain OFF.
If the Safety Module passes all of these tests, reconnect the output wires at terminals 13/14 and 23/24. Do not attempt to use the
Safety Module until all of the tests are passed.
Daily Checkout Procedure
To be Performed at every Power-up, Shift Change, and Tooling/Machine Setup Change
The daily checkout must be performed by a Designated Person, appointed and identified in writing by the employer, or by a
Qualified Person (see below).
WARNING:
• External Device Monitoring (EDM)
• Creating a hazardous situation could result in serious injury or death.
• If the system is configured for “no monitoring,” it is the user’s responsibility to ensure this does not
create a hazardous situation.
P/N 64137 Rev. J
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9
AT-FM-10K Two-Hand Control Module
1. Verify that all point-of-operation guards are in place and operating properly.
2. Verify that the two actuating devices must be simultaneously engaged to actuate the machine.
3. For single-cycle machines: Verify that maintained engagement of the two actuating devices results in only one machine
cycle.
For part-revolution clutch machinery: Verify that release of either actuating device results in the immediate arrest of the
machine motion.
4. Verify that the distance from each actuating device to the closest hazard point is not less than the calculated safety distance.
Semi-Annual Checkout Procedure
To be Performed at Six-Month Intervals
This semi-annual checkout must be performed by a Qualified Person (a person who, by possession of a recognized degree
or certificate of professional training, or who, by extensive knowledge, training, and experience, has successfully
demonstrated the ability to solve problems relating to the installation, maintenance and use of the Safety System). Keep a
copy of the test results on or near the machine.
WARNING:
• External Device Monitoring (EDM)
• Creating a hazardous situation could result in serious injury or death.
• If the system is configured for “no monitoring,” it is the user’s responsibility to ensure this does not
create a hazardous situation.
1. Perform the daily checkout procedure.
2. Perform the initial checkout procedure.
3. Calculate the separation distance, and verify that the actuating devices are far enough away from the nearest hazard point.
Relocate the actuating devices, if necessary.
4. Verify that the actuating devices are positioned to require the use of both hands for operation, and are protected from false
or inadvertent operation.
5. Inspect the machine controls and the connections to the Safety Module to ensure that wiring is correct and that no
modifications have been made which could adversely affect the System.
Repairs
Do not attempt any repairs to the Safety Module. It contains no field-replaceable components. Return it to the factory for warranty
repair or replacement.
WARNING:
• Do not abuse the module after failure—If an internal fault has occurred and the module will not reset,
do not tap, strike, or otherwise attempt to correct the fault with a physical impact to the housing.
• Failure to follow these instructions could result in serious injury or death.
• An internal relay might have failed in such a manner that its replacement is required. If the module is not
immediately replaced or repaired, multiple simultaneous failures might accumulate such that the safety
function cannot be guaranteed.
If it becomes necessary to return a Safety Module to the factory:
1. Contact Banner Factory Application Engineering at the address or at
the numbers listed in this document. They will attempt to troubleshoot
the system from your description of the problem. If they conclude that
a component is defective, they will issue an RMA (Return
Merchandise Authorization) number for your paperwork, and give you
the proper shipping address.
2. Pack the component carefully. Damage which occurs in return
shipping is not covered by warranty.
10
Figure 7. To remove a terminal block, insert a small screwdriver
into the slot as shown; pry to loosen
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P/N 64137 Rev. J
AT-FM-10K Two-Hand Control Module
Specifications
Supply Voltage
24 V dc ±15% at 150 mA (use a SELV-rated supply according to EN IEC
60950, NEC Class 2)
24 V ac ±15% at 150 mA, 50-60 Hz +/- 5% (use an NEC Class 2-rated
transformer)
To comply with UL and CSA standards, the installation’s isolated secondary
power supply circuit must incorporate a method to limit the overvoltage to 0.8
kV. The use of a 500 mA slow blow fuse in series with the +24 V ac/dc is
highly recommended. The AT-FM-10K does not contain an internal fuse.
Supply Protection Circuitry
Protected against transient voltages and reverse polarity
Output Configuration
Each normally open output channel is a series connection of contacts from
two forced-guided (mechanically linked) relays, K1-K2.
Contacts: AgNi, 5 µm gold-plated
Low Current Rating: The 5 µm gold-plated contacts allow the switching of low
current/low voltage. In these low-power applications, multiple contacts can
also be switched in series (e.g., “dry switching”). To preserve the gold plating
on the contacts, do not exceed the following max. values at any time:
Voltage
Minimum
Maximum
1 V ac/dc
60 V
Current
5 mA ac/dc
300 mA
Power
5 mW (5 mVA)
7 W (7 VA)
High Current Rating: If higher loads must be switched through one or more of
the contacts, the minimum and maximum values of the contact(s) changes
to:
Minimum
Maximum
Voltage
15 V ac/dc
250 V ac / 24 V dc, 6 A resistive
Current
30 mA ac/dc
——
Power
0.45 W (0.45 VA)
——
Voltage
15 V ac/dc
250 V ac / 24 V dc, 6 A resistive
Current
30 mA ac/dc
IEC 60947-5-1; AC15: 230 V ac,
3 A; DC-13: 24 V dc, 2 A
Power
0.45 W (0.45 VA)
——
Output Response Time
35 milliseconds maximum
Input Requirements
Outputs from actuating devices must each be capable of switching 25 mA at
24V dc (nominal).
Status Indicators
4 green LED indicators: Power ON, Input 1 energized, Input 2 energized,
Output
1 red LED indicator: Fault
Construction
Polycarbonate housing. Rated IEC IP20
Mounting
Mounts to standard 35 mm DIN rail track. Safety Module must be installed
inside an enclosure rated NEMA 3 (IEC IP54), or better.
Simultaneity Monitoring Period
≤ 500 milliseconds
Pollution Degree
2
Vibration Resistance
10 to 55 Hz at 0.35 mm displacement per IEC 60068-2-6
Safety Ratings
Category 4 PLe per EN ISO 13849-1; MTTFd = 100 years
SIL 3 per IEC 61508; PFHd = 1.54 x 10-9
SIL CL 3 per IEC 62061
Type IIIc per EN ISO 13851 (when used with STBs or hard contacts)
Certifications
Banner Engineering Europe Park Lane, Culliganlaan
2F bus 3, 1831 Diegem, BELGIUM
Turck Banner LTD Blenheim House, Blenheim Court,
Wickford, Essex SS11 8YT, Great Britain
Mechanical life: 20,000,000 operations
Electrical life (switching cycles of the output contacts, resistive load): 150,000
cycles at 900 VA; 1,000,000 cycles at 250 VA; 2,000,000 cycles at 150 VA;
5,000,000 cycles at 100 VA
Operating Conditions
0 °C to +50 °C (+32 °F to +122 °F) See "Heat Dissipation Considerations."
90% at +50 °C maximum relative humidity (non-condensing)
Overvoltage Category
Output relay contact voltage of 1 V to 150 V ac/dc: Category III
Output relay contact voltage of 151 V to 250 V ac/dc: Category II (Category
III, if appropriate overvoltage reduction is provided, as described in this
document.)
P/N 64137 Rev. J
B10d Values
Voltage (V)
Current (A)
B10d
230 AC
2
100,000
230 AC
1
600,000
230 AC
0.5
1,300,000
24 DC
≤2
10,000,000
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11
AT-FM-10K Two-Hand Control Module
Dimensions
All measurements are listed in millimeters [inches], unless noted otherwise.
22.5 mm
(0.89")
118.0 mm
(4.65")
S12
A1
S11
13
23
S13
Y1
Power
13
23
14
24
Fault
K1
In 1
In 2
Output
Y2
S23
K2
84.0 mm
(3.31")
Machine
Safety
AT-FM-10K
14
24
S21
A2
S22
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. This warranty does not
cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE, COURSE OF DEALING OR
TRADE USAGE.
This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO
BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL
DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETHER ARISING IN CONTRACT OR WARRANTY,
STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR OTHERWISE.
Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any obligations or liabilities relating to any product previously
manufactured by Banner Engineering Corp. Any misuse, abuse, or improper application or installation of this product or use of the product for personal protection applications when the
product is identified as not intended for such purposes will void the product warranty. Any modifications to this product without prior express approval by Banner Engineering Corp will void
the product warranties. All specifications published in this document are subject to change; Banner reserves the right to modify product specifications or update documentation at any time.
Specifications and product information in English supersede that which is provided in any other language. For the most recent version of any documentation, refer to:
www.bannerengineering.com.
For patent information, see www.bannerengineering.com/patents.
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