Models AT-GM-13A and AT-HM-13A, for use with two actuating devices
For the latest technical information about this product, including specifications, dimensions, and wiring, see www.BannerEngineering.com
Features
• Diverse-redundant microcontrollers
• Supplies power and monitors two Banner STB Self-Checking Optical Touch But-
tons, or two mechanical push buttons
• Four redundant, forced-guided (mechanically linked) output contacts rated at 6 A
• Two auxiliary solid-state outputs (NPN and PNP), plus auxiliary N.C. relay output
• Feedback input monitors external machine control elements
• Five indicator LEDs for Power, Fault, Input 1, Input 2, and Output
• 24V dc plus 115V ac or 230V ac operation, depending on model
• DIN-rail-mountable 45 mm-wide housing with removable terminal blocks
• 500 ms (max.) simultaneity requirement for touch-/push-button operation
Description
A DUO-TOUCH SG Two-Hand Control Safety Module may be used with:
• Two Banner STB Self-Checking Optical Touch Buttons, each with one normally open and one normally closed relay output contact, or
• Two Banner STB Self-Checking Optical Touch Buttons, each with two current-sourcing PNP outputs, or
• Two mechanical push buttons with one normally open and one normally closed contact each (Form C contact)
If the machine operator removes one or both hands from the actuating device(s), the Duo-Touch SG relays de-energize, causing the
output contacts to open. The relays will not re-energize until both actuating devices are deactivated and then simultaneously reactivated.
The Duo-Touch SG Two-Hand Control Kit system has been designed to meet:
• Type IIIC requirements of ISO 13851 (EN 574) Safety of Machinery – Two-Hand Control Devices, and
• Category 4 requirements of ISO 13849-1 (EN 954-1) Safety of Machinery – Safety-Related Parts of Control Systems – Part 1: Gener-
al Principles of Design
The Safety Module’s output signal consists of four sets of redundant, forced-guided (mechanically linked) contacts (see Figures in Electri-
cal Installation on page 8). 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.
DUO-TOUCH SG Safety Module LED Indicators (see Figure 1)
Power On: ON when power is applied Output Status: ON if both relays (K1 and K2) are energized
Flashing if feedback error has occurred
Fault: ON if simultaneity is not met or external
wiring fault
Flashing when internal fault condition is
detected
Input 1 (2) Status: ON if touch button is activated
OFF when button is not activated
Flashing if external wiring fault is detected
WARNING: Point-of-Operation Guarding
When properly installed, a two-hand control device provides protection only for the hands of the machine
operator. It may be necessary to install additional safeguarding, such as safety light screens, addition-
al two-hand controls, and/or hard guards, to protect all individuals from hazardous machinery.
Failure to properly guard hazardous machinery can result in a dangerous condition which could
lead to serious injury or death.
DUO-TOUCH® SG Two-Hand Control Modules
P/N 67241 Rev. D 11/22/2011
Important . . . Read This Before Proceeding!
In the United States, the functions that the Banner DUO-TOUCH SG Two-Hand Control Module is intended to perform are regulated by
the Occupational Safety and Health Administration (OSHA). Whether or not any particular DUO-TOUCH SG Two-Hand Control Module
installation meets all applicable OSHA requirements depends upon factors that are beyond the control of Banner Engineering Corp.
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 addi-
tion, 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 su-
pervisors 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 sys-
tems. 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 mainte-
nance instructions contained in this manual are followed.
U.S. Application Standards
ANSI B11.0 Safety of Machinery; General Requirements and Risk Assessment
ANSI NFPA 79 Electrical Standard for Industrial Machinery
ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems
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.)
These and other standards are available from:
OSHA Documents: http://www.osha.gov (Tel: 202.512.1800)
American National Standards Institute (ANSI): http://www.ansi.org (Tel: 212.642.4900)
Robotics Industries Association (RIA): http://www.robotics.org (Tel: 734.994.6088)
National Fire Protection Association (NFPA): http://www.nfpa.org (Tel: 800.344.3555)
NSSN National Resource for Global Standards : http://www.nssn.org/ (Tel: 212.642.4980)
IHS Standards Store: http://www.global.ihs.com/ (Tel: 303.397.7956, 800.854.7179)
Document Center: http://www.document-center.com/home.cfm (Tel: 650.591.7600)
DUO-TOUCH® SG Two-Hand Control Modules
2 www.bannerengineering.com - tel: 763-544-3164 P/N 67241 Rev. D
Appropriate Applications
S12
A1 A2 B1 B2
13 14 23 24
S11
Y30 Y31 Y32 Y33 51 52
S13
Z1 Z2 Y1 Y2
33 34 43 44
S21S22 S23
Powe r
Faul t
In 1
In 2
Output
Power ON
(green)
Input 1 Status
(green)
Internal Fault (red)
Input 2 Status
(green)
Output Status
(green)
K1 K2
K1
K251 52
Figure 1. AT-xM-13A Status Indicators
The DUO-TOUCH SG Two-Hand Control Safety Module may be used as an ini-
tiation 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 haz-
ard 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 intention-
al defeat and unintended initiation of the machine cycle.
When used in single-cycle or single-stroke mode, the machine control must pro-
vide 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.
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 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. Install activation devices so that they are
protected to prevent defeat or inadvertent actuation (STB Touch Buttons shown) on page 5.
NOTE: Two-hand control and two-hand trip safeguarding protect only the operator’s hands. Additional safe-
guarding 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 page 4 and Separation Distance on page 6) and when properly
interfaced to the machine (see Electrical Installation on page 8) 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 located and
protected from false operation (see Mechanical Installation on page 4 and Separation Distance on page 6) and when properly
interfaced to the machine (see Electrical Installation on page 8) to prevent accidental cycle initiation.
DUO-TOUCH® SG Two-Hand Control Modules
P/N 67241 Rev. D www.bannerengineering.com - tel: 763-544-3164 3
Theory of Operation
The input circuit of the DUO-TOUCH SG 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 illustrates that an output signal from the DUO-TOUCH SG Safety Module occurs only if switch #1 (SW1) and switch
#2 (SW2) are actuated within 0.5 seconds of each other. The output signal drops within 35 milliseconds following the release of either
switch. The device output does not re-energize until both hand controls are disengaged, and then simultaneously re-actuated. This logic
reduces the possibility of defeating the two-hand control by tying down one or both hand controls.
Power
< 0.5 s < 0.5 s Feedback Open SW1 tied down SW2 tied down
Feedback
Loop*
SW1
SW2
Output
> 0.5 s
Figure 2. DUO-TOUCH SG Safety Module AT-xM-13A timing diagram
* Feedback loop can remain closed at all times (if jumpered), when no monitoring contacts are available.
Mechanical Installation
Installation of the DUO-TOUCH SG Safety Module
The Module must be installed inside a NEMA 3 (IEC IP54) rated, or better, enclosure. It is not designed for exposed wiring. See Dimen-
sions on page 13 for Safety Module Dimensions. The device mounts directly onto a standard 35 mm DIN rail.
CAUTION: Hand Controls
The environment in which hand controls are installed must not adversely affect the means of ac-
tuation. 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.
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 Speci-
fications on page 12 . 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.
DUO-TOUCH® SG Two-Hand Control Modules
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Installation of Hand Controls
Each actuating device typically requires a normally open and a normally closed (e.g.,
Form C or SPDT) hard contacts, each capable of reliably conducting 20 mA at 12V dc.
For complementary PNP operation, model STBVP.. touch buttons must be used to en-
sure proper functionality.
Standards require that the actuating devices be mounted to protect them from acci-
dental or unintentional operation. Use shields, covers, rings, collars, dividers, or simi-
lar 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 hand controls must be arranged far enough apart so that the operator cannot op-
erate 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.
Ergonomic principles should be considered to avoid unnecessary fatigue in the instal-
lation of the hand controls. See ISO13851 (EN574) Two-Hand Control, ANSI
B11.TR1–Ergonomic Guidelines, and EN894–Safety of Machinery–Ergonomic Re-
quirements–Control Actuators for further information.
The figure to the right shows two examples for mounting Banner’s STB Touch But-
tons. 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.
Side Mount
Top Plate Shield
Field Covers
Top Mount
Figure 3. Install activation devices so that
they are protected to prevent defeat or inad-
vertent actuation (STB Touch Buttons
shown)
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 re-
quired by OSHA regulations to arrange and protect hand controls to minimize possibility of defeat
or accidental actuation.
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 by-
passed
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.
DUO-TOUCH® SG Two-Hand Control Modules
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Separation Distance
WARNING: Location of Touch Button Controls
Hand controls must be mounted a safe distance from moving machine parts, as determined by the
appropriate standard. It must not be possible for the operator or other non-qualified persons to relocate
them. Failure to establish and maintain the required safety distance could result in serious injury or
death. so that the machine’s safety-related control system interrupts the circuit to the machine pri-
mary control element(s), resulting in a non-hazardous condition.
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 follow-
ing 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 inches
K= 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 application 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= 0.035 seconds (the response time of the Safety Module as measured from the time a stop is signalled by either hand con-
trol)
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 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
where:
N = number of clutch engaging points per revolution
Tcy = time (in seconds) necessary to complete one revolution of the crankshaft
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Example Separation Distance (Ds) Calculation
The following example illustrates the use of the formula to calculate separation distance for a part-revolution clutch machine. This
example uses 0.50 seconds as a typical value for Ts and 0.02 seconds for Th:
K= 63" per second
Ts= 0.50 seconds (measured by a stop-time measuring device)
Tr= 0.035 seconds
Th= 0.02 seconds
Ds= K x (Ts + Tr + Th)
= 63" (0.50 + 0.035 + 0.02)
= 35"
In this example, both hand controls must be located no closer than 36" from the nearest hazard point.
NOTE:
1. The OSHA-recommended hand speed constant K has been determined by various studies, and
although these studies indicate speeds of 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, STB response time = 0.02 seconds.
DUO-TOUCH® SG Two-Hand Control Modules
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Electrical Installation
Because the DUO-TOUCH SG Safety Module interfaces to many types of machine controls, it is not possible to give exact wiring instruc-
tions here. The following guidelines are general in nature.
CAUTION: Disconnect Power Before Wiring
Before making any wire connections, make certain all power is disconnected from the Safety Mod-
ule and the machine to be controlled.
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.
Dangerous voltages may be present along the Safety Module wiring barriers whenever power to the ma-
chine control elements is ON. Exercise extreme caution whenever machine control power is or may
be present. Always disconnect power to the machine control elements before opening the enclo-
sure housing of the Safety Module.
STB2
Brown
Yell ow
Yell ow
Black
Black
Blue
Wh it e
Wh it e
Z1
Z2
S12
S11
S13
S22
S21
S23
STB1
AT-GM- 13A
AT-HM- 13A
+ – + –
Figure 4. Hookup to two STB touch but-
tons with contact outputs
Logi c
STB2
+ –
STB1
+ –
Logi c
Brown
Black
Black
Blue
Wh it e
Wh it e
Z1
Z2
S12
S11
S13
S22
S21
S23
AT-GM- 13A
AT-HM- 13A
Figure 5. Hookup to two STB touch but-
tons with PNP (sourcing) outputs
Z1
Z2
S12
S11
S13
S22
S21
S23
AT-GM- 13A
AT-HM- 13A
SW2 SW1
Figure 6. Hookup to two mechanical
push buttons with contact outputs
Connection of Input Switches
The actuation devices are connected to the DUO-TOUCH SG module as shown in Figures 4, 5, and 6. 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
up to 20 mA, at 12V dc. If hand controls have metal housings, the housings must be connected to protective earth ground.
If STB Touch Buttons are used, connect the brown and blue wires to terminals Z1 and Z2. Electronic actuation devices, including STB
Touch Buttons, must use terminals Z1 and Z2 for supply voltage.
WARNING: Use of Electronic Hand Controls
Electronic (powered) hand controls include optical touch buttons, capacitive touch buttons and similar de-
vices. When electronic hand controls are used as input switches for a Safety Module, the hand con-
trols and the Safety Module must be powered from the same voltage source. Failure to do so cre-
ates 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 Safety Module could result and may trigger machine motion. Also, electronic hand controls can-
not guarantee the state of their outputs at the time power is applied to them.
Connection of Power to the DUO-TOUCH SG Safety Module
The Safety Module requires a 24V dc, 115V ac or 230V ac supply voltage (see Specifications on page 12 ). 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 discon-
nect (e.g. a circuit breaker) must be provided (per NFPA79 and IEC/EN60204).
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Connection to the Machine to be Controlled
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 a loss of the safety stop command to the MPCEs.
To do so could result in serious bodily injury or death.
Figure 7 shows a generic connection of the Safety Module’s two redundant output contacts to machine primary control elements MPCE1
through MPCE4. An MPCE is defined as an electrically-powered element, external to the safety module, which directly controls the ma-
chine’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
(e.g., control reliability).
The connection of the safety outputs must be in such a
manner that the stop command issued by the AT-
xM-13A 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-gui-
ded) design and monitored by the MPCE Monitoring
Circuit (Y1/Y2).
As a summary, Control Reliability (OSHA
29CFR1910.217, ANSI B11, and ANSI/RIA R15.06)
and Category 3 and 4 (ISO13849-1) requirements de-
mand that a single failure does not lead to the loss of
the safety function, or does not prevent a normal or im-
mediate 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 correc-
ted. The user must refer to the relevant standard(s)
for complete information.
MPCE1 MPCE2
MPCE4 MPCE3
A2
Y1 (1)
Y2
L2/-V dc
+24V dc
+0V dc
L1/+V dc
24V dc
Connecti ons to
actuati on devices –
see Figures 4a,
4b and 4c
Z1
A1
Z2
S12
S11
S13
S22
K1 K2
13
23
14
24
S21
S23
AT-GM- 13A
AT-HM- 13A
115V ac
230V ac
33 34
43 44
51 52
Y30
Y31
Y32
Y33
B2 0V dc or for AC hookup
B1
*
*
*
*
MPCE
1
MPCE
2
MPCE
3
MPCE
4
Machine
Control
Circ uit
(1) See warni ng at left
abou t i nterfacing
safety outputs
* Arc Supp ressor – See Warning
Figure 7. Machine control circuit connections
As shown in Figure 7, a normally-closed, mechanically linked monitor contact from each of the four MPCEs must be connected in series
across terminals Y1 and Y2. 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. Monitoring MPCE contacts is one method of maintaining control reliability. When MPCE monitor
contacts are not available, a jumper wire must be installed across terminals Y1 and Y2.
When a jumper wire is used (dotted line between Y1 and Y2 in Figure 7), 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.
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
Safety Module. It is possible for suppressors to fail as a short circuit. If installed directly across the
output contacts of the Safety Module, a short-circuited suppressor will create an unsafe condition
which could result in serious injury or death.
DUO-TOUCH® SG Two-Hand Control Modules
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When switching inductive ac loads, it is good practice to protect the Safety Module outputs by installing appropriately-sized arc suppres-
sors. 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.
Initial Checkout Procedure
CAUTION: Disconnect Power Prior to Checkout
Before performing the initial checkout procedure, make certain all power is disconnected from the
machine to be controlled.
Dangerous voltages may be present along the Safety Module wiring barriers whenever power to the ma-
chine control elements is ON. Exercise extreme caution whenever machine control power is or may
be present. Always disconnect power to the machine control elements before opening the enclo-
sure housing of the Safety Module.
Temporarily disconnect the wires connected to the outputs of the DUO-TOUCH SG Safety Module at terminals 13/14, 23/24, 33/34,
43/44, Y32, and Y33.
WARNING: Do Not Use System Until Checkouts Are Verified
If all of the described checks cannot be verified, do not attempt to use the two-hand control safety
system until the defect or problem has been corrected. Attempts to use the guarded machine un-
der such conditions could result in serious bodily injury or death.
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.
1. Verify that the two actuating devices are properly connected to the DUO-TOUCH SG 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 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 indicators 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 Input indicators should remain ON. The Output indica-
tor 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 (or 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. Re-apply
power to the Safety Module. Activate both hand controls simultaneously. Output indicator LED should remain OFF.
If the DUO-TOUCH SG Safety Module passes all of these tests, reconnect the output wires at terminals 13/14, 23/24, 33/34 and 43/44,
and the monitor contact feedback loop at terminals Y1 and Y2. Do not attempt to use the DUO-TOUCH SG Two-Hand Control Safety
Module until all of the tests are passed.
Perform the Daily Checkout in Periodic Checkout and Maintenance on page 11 to verify proper operation.
DUO-TOUCH® SG Two-Hand Control Modules
10 www.bannerengineering.com - tel: 763-544-3164 P/N 67241 Rev. D
Periodic Checkout and Maintenance
WARNING: Do Not Use System Until Checkouts Are Verified
If all of the described checks cannot be verified, do not attempt to use the two-hand control safety
system until the defect or problem has been corrected. Attempts to use the guarded machine un-
der such conditions could result in serious bodily injury or death.
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 iden-
tified 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 safety distance (see
Separation Distance on page 6).
Semi-Annual Checkout
To be Performed at Six-Month Intervals:
This semi-annual checkout must be performed by a Qualified Person.* A copy of test results should be kept on or near the machine.
1. Perform the daily checkout procedure (see above).
2. Perform the initial checkout procedure (see Initial Checkout Procedure on page 10).
3. Calculate the separation distance (see Separation Distance on 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 SG Safety Module to ensure that wiring is correct, as descri-
bed in Electrical Installation on page 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 SG Two-Hand Control Safety System.
DUO-TOUCH® SG Two-Hand Control Modules
P/N 67241 Rev. D www.bannerengineering.com - tel: 763-544-3164 11
Specifications
Supply Voltage and Current
A1-A2: 115V ac (AT-GM-13A) or 230V ac (AT-
HM-13A), +/- 15%; 50/60Hz
B1-B2: 24V dc, +/- 15%, 10% max. ripple
Supply Protection Circuitry
Protected against transient voltages and reverse polari-
ty
Power Consumption
Approx. 4 W/7 VA
Output Configuration
Outputs (K1 and K2): four redundant (total of eight)
safety relay (forced-guided) contacts
Contact ratings:
Maximum voltage: 250V ac or 250V dc
Maximum current:
N.O. Safety Output: 6A ac or dc (resistive load)
N.C. Auxiliary Output (51/52): 5A ac or dc (resis-
tive load)
Maximum power:
N.O. Safety Output: 1500 VA, 200 watts
N.C. Auxiliary Output (51/52): 1250 VA, 200 watts
Mechanical life: 50,000,000 operations
Electrical life: 150,000 cycles (typically @ 1.5 kVA
switching power)
NOTE: Transient suppression is recommended when
switching inductive loads. Install suppressors across
load. Never install suppressors across output contacts
(see Warning in Electrical Installation on page 8).
Auxiliary Supply Voltage (for solid-state outputs)
24V dc @ 1A (applied between Y30 and Y31)
Auxiliary Solid-State Output Current
500 mA max., short circuit protected (Y32 or Y31)
Output Response Time
35 milliseconds maximum ON to OFF
Input Requirements
Outputs from actuating devices must each be capable
of switching up to 20 mA @ 12V dc
Simultaneity Monitoring Period
≤ 500 milliseconds
Z1/Z2 Courtesy Voltage
24V dc @ 150 mA (for STB button power, separate
from Auxiliary output, unregulated)
Status Indicators
4 green LED indicators: Power ON, Input 1 ener-
gized, Input 2 energized, and Output
1 red LED indicator: Fault
Housing
Polycarbonate. Rated NEMA 1 (IEC IP20)
Mounting
Mounts to standard 35 mm DIN rail track. Safety Mod-
ule 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 Heat Dissipa-
tion Considerations on page 4
Safety Category
4 per ISO 13849-1; Type IIIC per ISO 13851 (EN574)
Certifications
UL approval is in process
DUO-TOUCH® SG Two-Hand Control Modules
12 www.bannerengineering.com - tel: 763-544-3164 P/N 67241 Rev. D
Repairs
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 man-
ner that its replacement is required.
If the Module is not immediately replaced or repaired, multiple simultaneous failures may accumu-
late such that the safety function can not be guaranteed.
NOTE: Do not attempt any repairs to the DUO-TOUCH SG 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 SG 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 http://bannerengineering.com.
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.
Dimensions
DUO-TOUCH® SG Two-Hand Control Modules
P/N 67241 Rev. D www.bannerengineering.com - tel: 763-544-3164 13
Removal of Terminal Blocks
To remove a terminal block, insert a small screwdriver into the slot and
pry to loosen.
NOTE: When reinserting the block, take
care to slide the dovetail on the terminal
block into the slot on the frame.
S12
A1 A2 B1 B2
13 14 23 24
S11
Y30 Y31 Y32 Y33 51 52
S13
Z1 Z2 Y1 Y2
33 34 43 44
S21
S22 S23
Powe r
Faul t
In 1
In 2
Output
K1 K2
K1
K2
5152
Figure 8. Removal of terminal blocks
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 (IN-
CLUDING, 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, EXPEN-
SES, 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 WAR-
RANTY, 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.
DUO-TOUCH® SG Two-Hand Control Modules