Printed in USA 12/04 P/N 47550 rev. E
DUO-TOUCH
® – Two-Hand Control Modules
Models AT-FM-2A, AT-AM-2A, and AT-BM-2A, for Use with Two Actuating Devices
Features
• Two redundant, forced-guided (mechanically linked) output contacts rated at 4 A
• One auxiliary N.C. relay output rated at 0.5 A
• Feedback input for monitoring external machine control elements
• Four indicator LEDs for Power, Input 1, Input 2, and Fault
• 24V ac/dc, 115V ac, or 230V ac operation, depending on model
• DIN-rail-mountable 45-mm-wide housing
• 500 ms (max.) simultaneity requirement for touch-/push-button operation
Description
A DUO-TOUCH Two-Hand Control Safety Module may be used with:
• Two Banner OTB Optical Touch Buttons, each with one normally open relay output
contact, or
• Two Banner OTB Optical Touch Buttons, one with current-sourcing PNP output, and
one with current-sinking NPN output, or
• Two mechanical push buttons, each with one normally open contact
If the machine operator removes one or both hands from the actuating device(s),
the DUO-TOUCH 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 (SSI input channels closed).
The DUO-TOUCH Two-Hand Control system has been designed to meet:
• Type IIIA/B requirements of ISO 13851 (EN 574) Safety of Machinery – Two-Hand
Control Devices, and
• Category 1 and 3 requirements of ISO 13849-1 (EN 954-1) Safety of Machinery –
Safety-Related Parts of Control Systems – Part 1: General Principles of Design
The Safety Module’s output signal consists of two sets of redundant, forced-guided
(mechanically linked) contacts (see figures on page 8). Circuitry within the Safety
Module is Category 4 (per EN954-1) without consideration of the inputs. This circuitry
monitors the 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,
the DUO-TOUCH Two-Hand Control
Safety Module provides protection only
for the hands of the machine operator.
It may be necessary to install additional
safeguarding, such as safety light screens
and/or hard guards, to protect personnel
from hazardous machinery.
Failure to properly guard hazardous
machinery can result in a dangerous
condition which could lead to serious
injury or death.
!
LISTED LISTED
Presence
Sensing
Device
10Y8
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
2 P/N 47550 rev. E
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Important ... read this page before proceeding!
In the United States, the functions that the Banner DUO-TOUCH 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 Two-Hand Control Module
installation meets all applicable OSHA requirements depends upon factors that are beyond the control of Banner
Engineering Corp. These factors include the specific ways the safety module is applied, installed, wired, operated, and maintained.
Banner Engineering Corp. has attempted to provide complete application, installation, operation, and maintenance instructions. In
addition, we suggest that any questions regarding the use or installation of this two-hand control safety system be directed to the
factory applications department at the telephone numbers or address shown on the back cover of this manual.
The user of this Two-Hand Control Safety Module must ensure that all machine operators, maintenance personnel, electricians, and
supervisors are thoroughly familiar with and understand all instructions regarding the installation, maintenance, and use of this
system, and with the machinery upon which it is installed.
The user and any personnel involved with the installation and use of this Safety Module must be thoroughly familiar with all
applicable OSHA regulations and ANSI standards. The regulations and standards, listed below, directly address the use of two-hand
control systems. Banner Engineering Corp. makes no claim regarding a specific recommendation of any organization, the accuracy
or effectiveness of any information provided, or the appropriateness of the provided information for a specific application.
The user has the responsibility to ensure that all local, state, and national laws, rules, codes, and regulations relating to the use of
this Two-Hand Control Module are satisfied. Extreme care is urged that all legal requirements are met and that all installation and
maintenance instructions contained in this manual are followed.
U. S. Standards Applicable to Use of Two-Hand Control Systems
ANSI B11 Standards for Machine Tools “Safety Requirements for the Construction, Care and Use”
Available from: Safety Director
AMT – The Association for Manufacturing Technology
7901 Westpark Drive
McLean, VA 22102
Tel.: 703-893-2900 Fax: 703-893-1151
NFPA79 “Electrical Standard for Industrial Machinery”
Available from: National Fire Protection Association
1 Batterymarch Park, P.O. Box 9101
Quincy, MA 02269-9101
Tel.: 800-344-3555
ANSI/RIA R15.06 “Safety Requirements for Industrial Robots and Robot Systems”
Available from: Robotic Industries Association
900 Victors Way, P.O. Box 3724
Ann Arbor, MI 48106
Tel.: 734-994-6088
International Standards Applicable to Use of Two-Hand Control Systems
ISO/TR12100-1 & -2 “Safety of Machinery – Basic Concepts, General Principles for Design, Part 1: Basic Terminology, Methodology”, and
(EN292-1 & -2) “Part 2: Technical Principles and Specifications”
IEC/EN60204-1 “Electrical Equipment of Machines: Part 1: General Requirements”
Also, request a type “C” standard for your specific machinery.
ISO13849-1 (EN954-1) “Safety of Machinery – Safety Related Parts of Control Systems”
ISO13855 (EN999) “Safety of Machinery – The Positioning of Protective Equipment”
ISO13851 (EN574) “Safety of Machinery – Two-Hand Control Devices”
Available from: Global Engineering Documents
15 Inverness Way East
Englewood, CO 80112-5704
Tel.: 800-854-7179
!
P/N 47550 rev. E 3
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Appropriate Applications
The DUO-TOUCH 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 on page 6).
Simultaneous use of both hands is required, meaning that both buttons must be
actuated within a very short time span. The time span is specified by ANSI/RIA R15.06,
ANSI/NFPA79, and ISO 13851 (EN 574) as not more than 500 ms, even under single-
fault conditions. This requirement reduces the possibility of intentional defeat and
unintended initiation of the machine cycle.
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.
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 Figure 3.
NOTE: Two-hand control and two-hand trip safeguarding protect only the operator’s
hands. Additional safeguarding may be required. The user must refer to the
relevant standards for additional requirements for the application of two-hand
control and two-hand trip devices when used for safeguarding.
Part-Revolution Clutched Machinery
A two-hand control safety module can be used for the following functions: “inch”
(jog), “single-stroke,” or “continuous” (run). Two-hand control safety modules are
recognized as a means of protecting the machine operator when the hand controls
are safely located and protected from false operation (see Mechanical Installation on
pages 4-5 and Separation Distance on page 6) and when properly interfaced to the
machine (see Electrical Installation on page 7) to control the required stopping action.
Full-Revolution Clutched Machinery
A two-hand control safety module used to initiate the cycle of a full-revolution clutched
machine is known as a “two-hand trip device.” Two-hand trip devices are recognized
as a means of protecting the machine operator when the hand controls are safely locat-
ed and protected from false operation (see Mechanical Installation on pages 4-5 and
Separation Distance on page 6) and when properly interfaced to the machine (see
Electrical Installation on pages 6-7) to prevent accidental cycle initiation.
Figure 1. AT-..M-2A status indicators
CAUTION ... Not an
Anti-Repeat Control Device
Anti-repeat control is not
a function of the AT-..M-2A Two-Hand
Control Safety Module. The user of this
device must provide a suitable means of
anti-repeat control for any single-stroke or
single-cycle machines.
!
WARNING ...
Avoid Hazardous
Installations
The user has the
responsibility to satisfy all local, state,
and national laws, rules codes, and
regulations relating to the use of safety
equipment in any application. It is extremely
important to be sure that all appropriate
agency requirements have been met
and that all installation and maintenance
instructions contained in the appropriate
manuals are followed.
!
Power
ON Indicator
Fault
Indicator
K1 and K2
Energized
Indicators
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
4 P/N 47550 rev. E
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Theory of Operation
The input circuit of the DUO-TOUCH Safety Module requires simultaneous actuation
(within 0.5 seconds of each other) of both two-hand control actuators to generate an
output signal.
The timing diagram in Figure 2 illustrates that an output signal from the DUO-TOUCH
Safety Module occurs only if switches #1 and #2 (SW1 and SW2) are actuated within
0.3 seconds of each other (300 ms typical, not more than 500 ms under single-fault
conditions). The output signal drops within 25 milliseconds following the release of
either switch. The device output does not reenergize until both hand controls are dis-
engaged, and then simultaneously re-actuated. This logic reduces the possibility of
defeating the two-hand control system by tying down one or both actuators.
Mechanical Installation
The DUO-TOUCH Safety Module must be installed inside a NEMA 3 (IEC IP54) rated, or
better, enclosure. It is not designed for exposed wiring. Safety Module dimensions are
shown in Figure 6. The device mounts directly onto standard 35 mm DIN rail.
Heat Dissipation Considerations
For reliable operation, the user must 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 (page 11). 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.
Power
< 300 ms
(Typ.)
< 300 ms > 300 ms Feedback Open
(Red LED ON)
SW1 tied down SW2 tied down
Feedback
Loop*
SW1
SW2
Output
Figure 2. DUO-TOUCH Safety Module AT-..M-2A timing diagram
P/N 47550 rev. E 5
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Installation of Hand Controls
Each actuating device requires a normally open (e.g., SPST) hard contact capable of
reliably conducting 20mA at 12V dc. For solid-state operation, model OTBVN6.. and
OTBVP6.. touch buttons must be used to ensure proper functionality.
Standards require that the actuating devices be mounted to pro tect them from
ac ci den tal or unintentional operation. Use shields, covers, rings, collars, dividers, or
similar protection to pre vent ac ci den tal switch actuation and to discourage use of
forearms or elbows. European standard ISO13851 includes a detailed discussion of
ap proach es to pro tec tion of hand controls.
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, not less than
550 mm/21.7" in a straight line, per ISO13851).
Figure 3 shows two examples for mounting Banner’s OTB 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.
The hand controls must be arranged far enough apart so that the operator cannot
operate both hand controls using only one hand. Typically, this distance is not less
than 550 mm (21.7"), but using guards or an alternate mounting arrangement can
allow a shorter distance, per ISO13851 (EN574). This standard also recommends that
the hand control be arranged on a horizontal (or nearly horizontal) surface that is not
less than 1,100 mm (43.3") above the floor.
Employ ergonomic principles to avoid unnecessary fatigue in the use of the hand
controls. See ISO13851 (EN574) Two-Hand Control, ANSI B11.TR1–Ergonomic
Guidelines, and EN894–Safety of Machinery–Ergonomic Requirements–Control
Actuators for further information.
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 responsibility of the user 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.
CAUTION ... Install
Hand Controls to Prevent
Accidental Actuation
Total protection for the two-hand control
system from “defeat” is not possible.
However, regulations require the user
to arrange and protect hand controls to
minimize possibility of defeat or accidental
actuation.
!
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.
!
Figure 3. Protect activation devices in order
to prevent defeat or inadvertent
actuation
Side Mount
Top Plate Shield
Field Covers
Top Mount
1,100 mm (43.3")*
1,100 mm (43.3")*
* Minimum clearance,
per EN 574:1996 Chapter 8.5
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
6 P/N 47550 rev. E
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Separation Distance
Both hand controls must be located 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,” and may be calculated as
follows:
For Part-Revolution Clutch Machinery
Where the machine and its controls allow the machine to stop motion during the
hazardous portion of the machine cycle, use the following formula:
Ds = K x (Ts + Tr + Th)
For Full-Revolution Clutch Machinery
Where the machine and its controls are designed to complete a full machine cycle,
once activated, use the following formula:
Ds = K x (Tm + Tr + Th)
For both formulas:
Ds = the separation distance in millimeters or inches,
K = 1600 mm (63") per second (the hand speed constant currently accepted by
OSHA; see NOTE 1)
Ts = the stop time (in seconds) of the machine, measured from the applica-
tion of the “stop” signal to the final ceasing of all motion, including stop
times of all relevant control elements, and measured at maximum machine
velocity (see NOTE 2)
Tr = 0.025 seconds (the response time of the Safety Module as measured from
the time either hand disengages a hand control)
Th = the response time of the slowest hand control (from the time when a hand
disengages that control until the switch opens; see NOTE 3)
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 1.5 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
where:
N = number of clutch engaging points per revolution
Tcy = time (in seconds) necessary to complete one revolution of the crankshaft
Electrical Installation
Because the DUO-TOUCH Safety Module interfaces to many types of machine controls,
it is not possible to give exact wiring instructions here. The following guidelines are
general in nature.
Connection of Input Switches
The actuation devices are connected to the DUO-TOUCH module as shown in Figures
5 a, b, and c. SW1 and SW2 must both be isolated normally-open switches capable of
reliably switching up to 20 mA, at 12V dc. If hand controls have metal housings, the
housings must be connected to protective earth ground.
If OTB Touch Buttons with PNP/NPN outputs are used, the System must be
connected as shown in Figure 5b. Electronic actuation devices other than OTB Touch
Buttons must share the same voltage supply with the Safety Module (see Electronic
Hand Control WARNING on page 7).
WARNING ...
Location of Touch
Button Controls
Hand controls must be mounted at 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.
!
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 0.10 seconds for Th:
K = 1600 mm (63") per second,
Ts = 0.50 seconds (measured by a stop-time
measuring device)
Tr = 0.025 seconds
Th = 0.10 seconds
Ds = K x (Ts + Tr + Th)
= 1600 mm (or 63") (0.50 + 0.025 + 0.10)
= 1000 mm (39.4")
In this example, both hand controls must
be located no closer than 1000 mm (39.4")
from the nearest hazard point.
NOTES:
1) The OSHA-recommended hand speed
constant K has been determined by various
studies, and although these studies indicate
speeds of 1600-2500 mm/sec (63"/sec to
over 100"/sec), they are not conclusive deter-
minations. The employer should consider all
factors, including the physical ability of the
operator, when determining the value of K to
be used.
2) 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.
3) Th is usually insignificant for purely mechanical
switches. However, Th should be considered
for separation distance calculation when using
electronic or electromechanical (i.e., powered)
hand controls. In this example, OTB response
time = 0.10 seconds.
P/N 47550 rev. E 7
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Connection of Power to the DUO-TOUCH Safety Module
The Safety Module requires a 24V dc, 115V ac or 230V ac supply voltage (see
Specifications on page 11). Use extreme caution whenever installing ac power. Use a
minimum of 16 to 18 AWG wire for power and output connections. A hand-operated
supply disconnect (e.g. a circuit breaker) must be provided (per NFPA79 and IEC/
EN60204).
Connection to the Machine to be Controlled
Figure 5d shows a generic connection of the Safety Module’s two 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 motion so that it is the last (in time)
to operate when motion 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.
The connection of the safety outputs must be in such a manner that the stop command
issued by the AT-..M-2A 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. If interposing relays are used, they must be of mechanically
linked (forced-guided) design and monitored by the MPCE Monitoring Circuit (X1/X2).
As shown in Figure 5d, a normally-closed, mechanically linked monitor contact from
each of the two MPCEs must be connected in series across terminals X1 and X2.
This allows the Safety Module to monitor the state of the MPCEs, and to prevent a
successive machine cycle, if an MPCE fault is detected. There is a timing requirement
associated with the operation of X1 and X2 inputs. The monitoring contacts of external
relays must close within 200 ms following deactivation of the AT-..M-2A outputs. If this
requirement is not met or an internal fault is detected, the unit enters a lockout mode
(indicated by Fault LED ON Red). A power cycle is required to exit the lockout. See
Figure 4 and Caution on page 10.
When MPCE monitor contacts are not available, a jumper wire must be installed
across terminals X1 and X2.
When a jumper wire is used (dotted line between X1 and X2 in Figure 5d), it is the
user’s responsibility to provide an appropriate level of safety for the means of machine
interfacing to ensure that any single MPCE component failure will not result in the loss
of safety.
When switching inductive ac loads, it is good practice to protect
the Safety Module outputs by installing appropriately-sized arc
suppressors. However, if arc suppressors are used, they must
be installed across the load being switched (e. g., across the
coils of external safety relays), and never across the Safety
Module’s output contacts (see WARNING on page 8).
CAUTION ... Disconnect
Power Before Wiring
Always disconnect all power
from the DUO-TOUCH Safety Module
and the machine being controlled before
making any wire connections.
Electrical installation of hand controls, the
DUO-TOUCH SG Safety Module, and the
interconnection to the machine control
must be made by qualified personnel and
must comply with NEC (National Electrical
Code), ANSI/NFPA79 or IEC60204-1, and
all applicable local standards.
WARNING ... Use of
Electronic Hand Controls
Electronic (powered) hand controls
include optical touch buttons, capacitive
touch buttons and similar devices. When
electronic hand controls are used as
input switches for a DUO-TOUCH Safety
Module, the hand controls and the Safety
Module must be powered from the same
voltage source. Failure to do so creates
a potentially dangerous condition, which
could result in serious injury or death.
If power is applied to the Safety Module
before power is applied to the electronic
hand controls, an output from the DUO-
TOUCH Safety Module could result and may
trigger machine motion. Also, electronic
hand controls cannot guarantee the state of
their outputs at the time power is applied
to them.
!
Power
Feedback
(X1-X2)
Input 1
Input 2
Output
200 ms
200 ms 200 ms
closed
open
EDM Error
(Red LED ON)
Lockout No Lockout –
Normal
Operation
Lockout Recovery
Figure 4. X1 and X2 Input timing requirements
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
8 P/N 47550 rev. E
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Figure 5a. Type IIIA hookup to two OTB
touch buttons with contact
outputs
Figure 5b. Type IIIA hookup to two OTB
touch buttons with PNP/NPN
outputs
Figure 5c. Type IIIB hookup to two
mechanical push buttons with
contact outputs
OTB2
Brown
Yellow
Yellow
Black
Black
Blue A1
A2
S13
S14
S23
S24
OTB1
AT-..M-2A
+–
+–
Devices
Two OTBA5..
Two OTBB5..
Two OTBVR81..
Power Connection
Model
AT-AM-2A
AT-BM-2A
AT-FM-2A
Supply Voltage
115V ac
230V ac
+24V dc
OTB2
+
–
OTB1
+
–
Brown
Black
Black
Blue
A1
A2
S13
S14
S23
S24
AT-..M-2A
n/c - white n/c - white
NPN
Sinking
PNP
Sourcing
Solid-state switches must not draw more than 25 mA each
Power Connection
Device
One OTBN6.. and one OTBP6..
One OTBN6.. and one OTBP6..
One OTBN6.. and one OTBP6..
Model
AT-AM-2A
AT-BM-2A
AT-FM-2A
Supply Voltage
115V ac
230V ac
+24V dc
A1
A2
S13
S14
S23
S24
AT-..M-2A
SW2 SW1
Power Connection
Devices
Two mechanical switches
Two mechanical switches
Two mechanical switches
Model
AT-AM-2A
AT-BM-2A
AT-FM-2A
Supply Voltage
115V ac
230V ac
+24V ac/dc
Figure 5d. Machine control circuit connections
WARNING ... Use of Arc
Suppressors
If arc suppressors are
used, they MUST be installed as shown
across the coils of the Machine Primary
Control Elements (MPCEs). NEVER install
suppressors directly across the output
contacts of the DUO-TOUCH Safety
Module. It is possible for suppressors to
fail as a short circuit. If installed directly
across the output contacts of the
DUO-TOUCH Safety Module, a
short-circuited suppressor will create an
unsafe condition which could result in
serious injury or death.
!
WARNING ... Interfacing
Safety Outputs
Never wire or interface an
intermediate device (e.g., PLC, PES, PC)
that can fail in such a manner that there
is the loss of the safety stop command to
the MPCEs. To do so could result in serious
bodily injury. See page 7, Connection to the
Machine to be Controlled.
!
P/N 47550 rev. E 9
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Initial Checkout Procedure
To perform the initial checkout, it is necessary to view the Status indicators: Power, Fault,
K1 and K2. Proceed with caution around open wiring.
1) Verify that two actuating devices are properly connected to the DUO-TOUCH
Safety 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 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 one hand control and hold it engaged for 2 seconds, then release.
Repeat this step for other hand control. If the module locks out, do not continue
this checkout procedure until the cause of the problem is corrected.
5) Activate both hand controls simultaneously (within 0.3 seconds), and hold them
engaged. K1 and K2 indicators should come ON. Release both hand controls
simultaneously. K1 and K2 indicators should go OFF.
6) Again, activate the two hand controls simultaneously, and hold them engaged.
K1 and K2 indicators should come ON. Release one hand control while holding the
other engaged. One of the indicators should turn OFF. Re-activate the hand control
that was just released. The indicator that was OFF should remain OFF. Release both
hand controls. K1 and K2 indicators should then be OFF. Repeat for other hand
control.
7) Activate only one hand control and hold it engaged. K1 (or K2) indicator should
come ON. After more than 1/2 second, activate the second hand control. K1 (or K2)
indicator should remain ON, while K2 (or K1) indicator remains OFF. Repeat for
other hand control.
8) Remove power from the Safety Module and disconnect the monitor contact feed-
back loop at terminal X1 or X2. Re-apply power to the Safety Module. Activate
both hand controls simultaneously. K2 indicator LED should remain OFF, and the
Module should lock out.
If the DUO-TOUCH Safety Module passes all of these tests, reconnect the output wires
at terminals 13/14, 23/24, and 41/42. Also reconnect the monitor contact feedback
loop at terminals X1 and X2. Do not attempt to use the DUO-TOUCH Two-Hand
Control Safety Module until all of the previous tests are passed.
Periodic Checkout and Maintenance
Daily Checkout:
To be performed at every power-up, shift change, and machine setup
change. Daily checkout and checkouts after tooling and machine setup changes must
be performed by a Designated Person, appointed and identified in writing by the
employer.
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.
4) For part-revolution clutch machinery: Verify that release of either actuating device
results in the immediate arrest of the machine motion.
5) Verify that the distance from each actuating device to the closest hazard point is
not less than the calculated separation (safety) distance (see page 6).
CAUTION ... Disconnect
Power Before Checkout
Before performing the initial
checkout procedure, make certain all
power is disconnected from the machine
to be controlled. Temporarily disconnect the
wires connected to the outputs of the DUO-
TOUCH SG Safety Module at terminals 13/14,
23/24, and 41/42.
!
WARNING ... Do
Not Use System Until
Checkouts Are Verified
If all of the described
checks cannot be verified, the two-hand-
control system must not be used until
the problem has been corrected. Injury
or death to personnel may result from
attempts to use the machine under such
conditions.
!
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
10 P/N 47550 rev. E
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Semi-Annual Checkout:
To be performed at six-month intervals. This semi-annual check-
out must be performed by a Qualified Person (see definition below). A copy of the test
results should be kept on or near the machine.
1) Perform the daily checkout procedure as explained above.
2) Perform the initial checkout procedure (see page 9).
3) Calculate the separation distance (see page 6), 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 DUO-TOUCH Safety
Module to ensure that wiring is correct, as described on pages 6 through 8, and
that no modifications have been made which could adversely affect the System.
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 DUO-TOUCH Two-Hand Control Safety System.
Repairs
NOTE: Do not attempt any repairs to the DUO-TOUCH Two-Hand Control Module.
It contains no field-replaceable components. Return it to the factory for
warranty repair or replacement.
If it ever becomes necessary to return a DUO-TOUCH Safety Module to the factory,
please do the following:
1) Contact the Banner Factory Application Engineering Group at the address or
at the numbers listed at the bottom of the back page. 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.
WARNING ... Do
Not Use System Until
Checkouts Are Verified
If all of the described
checks cannot be verified, the two-hand-
control system must not be used until
the problem has been corrected. Injury
or death to personnel may result from
attempts to use the machine under such
conditions.
!
CAUTION ... Abuse of
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 by a physical impact to the housing.
An internal relay may have failed in such a
manner that its replacement is required.
If the Module is not immediately replaced
or repaired, multiple simultaneous failures
may accumulate such that the safety
function can not be guaranteed.
!
P/N 47550 rev. E 11
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
Supply Voltage and Current Model AT-AM-2A: 115V ac ± 15% at 100 mA
Model AT-BM-2A: 230V ac ± 15% at 50 mA
Model AT-FM-2A: 24V ac/dc ± 15% at 250 mA
Supply Protection Circuitry Protected against transient voltages and reverse polarity (dc hookup is without regard to polarity)
Output Configuration
(including Auxiliary N.C.
output 51/52)
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: 4A ac or dc (resistive load)
Maximum power: 1000 VA, 200 watts
Mechanical life: 10,000,000 operations
Electrical life: 100,000 cycles (typically @ 1.0 kVA switching power)
NOTE: Transient suppression is recommended when switching inductive loads. Install suppressors across
load. Never install suppressors across output contacts (see Warning on page 8).
Auxiliary Monitor Output (K3): One non-safety relay contact
Maximum switching voltage: 125V ac or dc
Maximum switching current: 500 mA (resistive load)
Contact Fuse Protection 6.3 A quick or 4 A slow
Output Response Time 25 milliseconds maximum
Input Requirements Outputs from actuating devices must each be capable of switching 40 to 100 mA @ 12 to 18V dc.
Simultaneity Monitoring
Period
300 milliseconds (typical)
< 500 milliseconds under single-fault conditions
Status Indicators 3 green LED indicators (see Figure 1):
Power ON
K1 energized
K2 energized
1 red LED indicator:
Fault
Housing Polycarbonate. Rated NEMA 1 (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.
Vibration Resistance 10 to 55Hz @ 0.35 mm displacement per IEC 68-2-6
Operating Conditions Temperature: 0° to +50°C (+32° to 122°F)
Maximum Relative Humidity: 90% @ +50°C (non-condensing)
Heat Dissipation Considerations: See page 4.
Dimensions See Figure 6.
Safety Category 1 and 3 per ISO 13849-1; Type IIIA/B per ISO 13851 (EN574)
(Dependent on hookup and installation of the hand controls)
Certifications
Specifications
LISTED LISTED
Presence
Sensing
Device
10Y8
Banner Engineering Corp., 9714 Tenth Ave. No., Minneapolis, MN USA 55441 • Phone: 763.544.3164 • www.bannerengineering.com • Email: sensors@bannerengineering.com
DUO-TOUCH® – Models AT-..M-2A Two-Hand Control Modules
P/N 47550 rev. E
WARRANTY: Banner Engineering Corp. warrants its products to be free from defects for one year. Banner Engineering Corp. will repair
or replace, free of charge, any product of its manufacture found to be defective at the time it is returned to the factory during the warranty
period. This warranty does not cover damage or liability for the improper application of Banner products. This warranty is in lieu of any
other warranty either expressed or implied.
DIN Mounting
Tab (Supplied)
35.0 mm
(1.38")
DIN Mounting Slot
45.0 mm
(1.77")
110.0 mm
(4.33")
75.0 mm
(2.95")
Figure 6. Module housing dimensions
