GM-FA-10J Gate Monitoring Safety Module - Allied … Gate Monitoring Safety Module ... Global Engineering Documents 15 Inverness Way East ... (green) Input 1 Active (green) Fault

Printed in USA 11/09 P/N 60998 rev. E

GM-FA-10J Gate Monitoring Safety Module24V ac/dc operation, 1- or 2-Channel Input

Features

• Monitorsoneortwosafetyswitchesforacontactfailureorwiringfault

• Twooutputswitchingchannelsforconnectiontocontrol-reliablepowerinterruptcircuits

• Autoresetormonitoredmanualreset

• DesigncomplieswithstandardsUL991,ISO14119,andISO13849-1(EN954-1) (SafetyCategory2,3or4)

• Foruseinfunctionalstopcategory0applicationsperNFPA79 andIEC60204-1

• 6ampsafetyoutputcontacts

• Plug-interminalblocks

• Ifterminalblocksareswapped,Moduleremainsfunctionalwithnolossofsafetyfunction

Emergency Stop Device 29YL

Overview

TheGM-FA-10JGateMonitorSafetyModule(the“SafetyModule”)isusedtoverifytheproperoperationofcodedmagneticsafetyswitchesandpositive-openingsafetyswitchesbymonitoringanormallyopen(N.O.)andanormallyclosed(N.C.)contactfromeachswitch.Itcanalsobeusedtomonitorandverifythecorrectstateoftworedundantcurrent-sourcingPNPsignals.(OnePNPsourcemustbeNormallyOFFandtheotherNormallyConductingforeachinputchannel.)Inatypicalapplication,twosafetyswitches(individuallymounted)indicatetheopenorclosedstatusofagate,moveableguard,orbarrier(allcalled“guards”throughoutthisdocument).

TwofunctionsoftheSafetyModuleare:

1.TomonitorthecontactsandwiringofsafetyswitchesforcertainfailuresandtopreventthemachinefromrestartingiftheswitchortheModulefails,and

2.Toprovidearesetroutineafterclosingtheguardandreturningtheinputstotheir“closed”condition.Thisresetfunctionmayberequiredbymachinesafetystandards.

TheSafetyModulemonitorseachswitchforcomplementaryswitching;eachchannelmusthaveoneopen(OFF)inputandoneclosed(conducting)inputatalltimes.Theseinputsmustalwaysbeinoppositestatesandmustswitchstatewithin1secondofeachother.Channel1hasa“guardclosed”conditionwhenS11/S13isclosedandS11/S12isopen.Similarly,Channel2hasa“guardclosed”conditionwhenS21/S23isclosedandS21/S22isopen(seeFigures2and3).TheSafetyModulealsowilldetectandproperlyrespondtoashortcircuitbetweenthechannelsandashortcircuittoothersourcesofpower.TheSafetyModulewillopenthesafetyoutputswithin35millisecondsoftheswitchingofeitherchannelwhentheguardopens.

Whentheguardcloses,debouncelogicintheSafetyModule’sinputsincreasesthereliabilityandrepeatabilityofsuccessfullyresettingtheSafetyModuleandreducesthenecessityofre-cyclingtheguard.Thisfeaturecanresultinincreasedefficiencyofthemachine,eveniftheguardismisalignedorvibrationispresent.

Original Instructions

Gate Monitoring Safety Module – Model GM-FA-10J

2 P/N 60998 rev. E

Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164


Important ... read this page before proceeding!

The user is responsible for satisfying all local, state, and national laws,rules,codes,andregulationsrelatingtotheuseofthisproductanditsapplication.Pleasedirectanyquestionsregardingtheuseorinstallationofthisproducttothefactoryapplicationsdepartmentatthetelephonenumbersoraddressshownonbackcover.

The user is responsibleformakingsurethatallmachineoperators,maintenancepersonnel,electricians,andsupervisorsarethoroughlyfamiliarwithandunderstandallinstructionsregardingtheinstallation,maintenance,anduseofthisproduct,andwiththemachineryitcontrols.TheuserandanypersonnelinvolvedwiththeinstallationanduseofthisproductmustbethoroughlyfamiliarwithallapplicableANSI/NFPAstandards,someofwhicharelistedbelow.BannerEngineeringCorp.makesnoclaimregardingaspecificrecommendationofanyorganization,theaccuracyoreffectivenessofanyinformationprovided,ortheappropriatenessoftheprovidedinformationforaspecificapplication.

Certificate of Adequacy

ThisSafetyModuledatasheet(p/n60998)satisfiestherequirementsofMachineryDirective2006/42/EC,Section1.7.4—instructions.

Applicable U. S. StandardsANSIB11 StandardsforMachineTools

Availablefrom: SafetyDirector AMT–TheAssociationforManufacturingTechnology 7901WestparkDrive McLean,VA22102-4269 Tel.:703-827-2900

ANSINFPA79 ElectricalStandardforIndustrialMachinery

Availablefrom: NationalFireProtectionAssociation 1BatterymarchPark,P.O.Box9101 Quincy,MA02269-9101 Tel.:800-344-3555

ANSI/RIAR15.06 SafetyRequirementsforIndustrialRobotsandRobotSystems

Availablefrom: RoboticIndustriesAssociation 900VictorsWay,P.O.Box3724 AnnArbor,MI48106 Tel.:734-994-6088

Applicable International Standards ISO12100-1&-2 SafetyofMachinery–BasicConcepts,General

Principals(EN292-1&-2)forDesign,Part1:BasicTerminology,MethodologyandPart2:TechnicalPrinciplesandSpecifications

IEC60204-1 ElectricalEquipmentofMachines:Part1:GeneralRequirements

ISO13849-1 SafetyofMachinery–SafetyRelatedPartsofControlSystems

ISO13855(EN999) SafetyofMachinery–ThePositioningofProtectiveEquipment

ISO14119(EN1088) SafetyofMachinery–InterlockingDevicesAssociatedwithGuards

Also,requestatype“C”standardforyourspecificmachinery.

Availablefrom: GlobalEngineeringDocuments 15InvernessWayEast Englewood,CO80112-5704 Tel.:800-854-7179


P/N 60998 rev. E 3Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164


WARNING . . .

It must not be possible for personnel to reach any hazard point through an opened guard (or any opening) before hazardous machine motion has completely stopped.Pleasereferencetheappropriatestandards(seepage2)forinformationondeterminingsafetydistancesandsafeopeningsizesforyourguardingdevices.

S21A1

S11 S13

S23 S21 S22

13 23 Y1

Y2 14 24 A2

K1

K2

14 24

MachineSafety

GM-FA-10J

Power

Fault

In 1

In 2

Output

Power ON(green)

Input 1Active (green)

Fault (red)

Input 2Active (green)

OutputsActive (green)

S12 S13 S11

Y12313 A1

A2 2414Y2

S22 S21 S23

Figure 1. GM-FA-10J features and terminal locations

Safety Circuit Integrity and ISO 13849-1 Safety Circuit Principles Safetycircuitsinvolvethesafety-relatedfunctionsofamachinethatminimizethelevelofriskofharm.Thesesafety-relatedfunctionscanpreventinitiation,ortheycanstoporremoveahazard.Thefailureofasafety-relatedfunctionoritsassociatedsafetycircuitusuallyresultsinanincreasedriskofharm.

Theintegrityofasafetycircuitdependsonseveralfactors,includingfaulttolerance,riskreduction,reliableandwell-triedcomponents,well-triedsafetyprinciples,andotherdesignconsiderations.

Dependingonthelevelofriskassociatedwiththemachineoritsoperation,anappropriatelevelofsafetycircuitperformance(i.e.,integrity)mustbeincorporatedintoitsdesign.StandardsthatdetailsafetyperformancelevelsincludeANSI/RIAR15.06IndustrialRobots,ANSIB11MachineTools,OSHA29CFR1910.217MechanicalPowerPresses,andISO13849-1(EN954-1)Safety-RelatedPartsofaControlSystem.

Safety Circuit Integrity LevelsSafetycircuitsinInternationalandEuropeanstandardshavebeensegmentedintocategories,dependingontheirabilitytomaintaintheirintegrityintheeventofafailure.ThemostrecognizedstandardthatdetailssafetycircuitintegritylevelsisISO13849-1(EN954-1),whichestablishesfivelevels:CategoriesB,1,2,3,andthemoststringent,Category4.

IntheUnitedStates,thetypicallevelofsafetycircuitintegrityhasbeencalled“controlreliability.”Controlreliabilitytypicallyincorporatesredundantcontrolandself-checkingcircuitryandhasbeenlooselyequatedtoISO13849-1Categories3and4(seeCSAZ432andANSIB11.TR4).

IftherequirementsdescribedbyISO13849-1aretobeimplemented,ariskassessmentmustfirstbeperformedtodeterminetheappropriatecategory,inordertoensurethattheexpectedriskreductionisachieved.Thisriskassessmentmustalsotakeintoaccountnationalregulations,suchasU.S.controlreliabilityorEuropean“C”levelstandards,toensurethattheminimumlevelofperformancethathasbeenmandatediscompliedwith.

Fault ExclusionAnimportantconceptwithinthecategoryrequirementsofISO13849-1isthe“probabilityoftheoccurrenceofthefailure,”whichcanbedecreasedusingatechniquetermed“faultexclusion.”Therationaleassumesthatthepossibilityofcertainwell-definedfailure(s)canbereducedtoapointwheretheresultingfault(s)canbe,forthemostpart,disregarded-thatis,“excluded.”

Faultexclusionisatooladesignercanuseduringthedevelopmentofthesafety-relatedpartofthecontrolsystemandtheriskassessmentprocess.FaultexclusionallowsthedesignertodesignoutthepossibilityofvariousfailuresandjustifyitthroughtheriskassessmentprocesstomeettheintentrequirementsofCategory2,3or4.SeeISO13849-1/-2forfurtherinformation.

ConfigurationTheSafetyModulemaybeconfiguredviaDIPswitchesfortwo-channel(redundantswitchesonasingleguard),orone-channeloperation(individualswitchesontwoguards).Intwo-channeloperation,eachchannelmustswitchwithin3-secondsimultaneityoftheotherwhentheguardcloses.Ifnot,theguardmustbere-openedandcloseduntilthetimingrequirementismet.Whentheguardopens,thetwochannelsoperateconcurrently(bothchannelsmustswitch,butwithoutthetimingrequirement).

Inone-channeloperation,eachchanneloperatesindividually,excepttoresetthedevice(inwhichcasebothguardsmustbeclosed).Ifonlyoneswitchisbeingmonitored,theclosedinputoftheunusedchannelmustbejumpered(S11/S13orS21/S23).

Theresetfunctionhastwooptions,selectedbyDIPswitch:AutomaticresetorMonitoredManualreset.SeeFigure7forconfigurationinformation.

WARNING . . . Safety Categories

Thelevelofsafetycircuitintegritycanbe greatlyimpactedbythedesignandinstallationofthesafetydevicesandthemeansofinterfacingofthosedevices.A risk assessment must be performed to determine the appropriate safety circuit integrity level or safety category as described by ISO 13849-1 (EN 954-1) to ensure that the expected risk reduction is achieved and that all relevant regulations and standards are complied with.


4 P/N 60998 rev. E



TheresetinputalsocanbeusedforanExternalDeviceMonitoring(EDM)circuit.TheEDMcircuitconsistsofanormallyclosed,force-guidedcontactfromeachdevicebeingcontrolledbytheSafetyModule,allwiredinserieswiththeResetbutton(ifused)andterminatedatterminalsY1andY2.SeeFigure6forfurtherinformation.

TheoutputoftheSafetyModuleconsistsoftworedundantoutputswitchingchannels,eachofwhichistheseriesconnectionoftwoforced-guidedrelaycontacts(K1andK2inFigure6).Eachoftheswitchingoutputsisratedforupto250Vacatupto6amps.

Safety Switch RequirementsThefollowinggeneralrequirementsandconsiderationsapplytotheinstallationofinterlockedgatesandguardsforthepurposeofsafeguarding.Inaddition,theusermustrefertotherelevantregulationsandbesuretocomplywithallnecessaryrequirements.

Hazardsguardedbytheinterlockedguardmustbepreventedfromoperatinguntiltheguardisclosed;astopcommandmustbeissuedtotheguardedmachineiftheguardopenswhilethehazardispresent.Closingtheguardmustnot,byitself,initiatehazardousmotion;aseparateproceduremustberequiredtoinitiatethemotion.Thesafetyswitchesmustnotbeusedasamechanicalorend-of-travelstop.

Theguardmustbelocatedanadequatedistancefromthedangerzone(sothehazardhastimetostopbeforetheguardisopenedsufficientlytoprovideaccesstothehazard),anditmustopeneitherlaterallyorawayfromthehazard,notintothesafeguardedarea.Theguardalsoshouldnotbeabletoclosebyitselfandactivatetheinterlockingcircuitry.Theinstallationmustpreventpersonnelfromreachingover,under,aroundorthroughtheguardtothehazard.Anyopeningsintheguardmustnotallowaccesstothehazard(seetheappropriatestandard).Theguardmustbestrongenoughanddesignedtoprotectpersonnelandcontainhazardswithintheguardedareathatcanbeejected,droppedoremittedbythemachine.

Thesafetyswitches,actuators,sensorsandmagnetsusedwiththeSafetyModulemustbedesignedandinstalledsothattheycannotbeeasilydefeated.Theymustbemountedsecurely,sothattheirphysicalpositioncannotshift,usingreliablefastenersthatrequireatooltoremove.Mountingslotsinthehousingsareforinitialadjustmentonly;finalmountingholesmustbeusedforpermanentlocation.

Coded Magnetic Safety Switches: Similartopositive-openingsafetyswitches,codedmagneticswitchesusedwiththeSafetyModulemustprovideonenormallyclosedcontactandonenormallyopencontact(typicallyafour-wireswitch).(SeeBannerSafetyCatalogorpage15formoreinformation.)The sensor and its magnet must be mounted a minimum distance of 15 mm (0.6″) from any magnetized or ferrous materials for proper operation.Ifeitherthesensorormagnetismountedonamaterialthatcanbemagnetized(aferrousmetal,suchasiron),theswitchingdistancewillbeaffected.Althoughthesensorandmagnetarecodedtominimizethepossibilityoffalseactuation,theyshouldnotbeusedwithinknownfieldsofhigh-levelelectromagneticradiation.

Dependingonthemodelofsensorandmagnetused,theinstallationmustbedesignedtoprovidethecorrectdirectionofapproach(seepage17).The speed of approach must be fast enough to meet the simultaneity-monitoring period of 1.0 second, approximately equal to or greater than 0.1 m (4″) per second.Ifthesimultaneityrequirementisnotmet,theSafetyModulecannotberesetandwillnotcloseitssafetyoutputcontacts.

Positive-Opening Interlocking Switches: SafetyinterlockswitchesusedwiththeSafetyModulemustsatisfyseveralrequirements.Eachswitchmustprovideelectricallyisolatedcontacts:atminimum,onenormallyclosed(N.C.)contactornormallyconductingsourceandonenormallyopen(N.O.)contactornormallyOFFsourcetointerfacewiththeModule.

Thecontactsmustbeof“positive-opening”design,withoneormorenormallyclosedcontactsratedforsafety.Positive-openingoperationcausestheswitchtobeforcedopen,withouttheuseofsprings,whentheswitchactuatorisdisengagedormovedfromitshomeposition(seetheBannerSafetyCatalogforexamples).Inaddition,theswitchesmustbemountedina“positivemode,”tomove/disengagetheactuatorfromitshomepositionandopenthenormallyclosedcontact,whentheguardopens.




Switch Hookups, Typical ApplicationsRequirementsvarywidelyforthelevelofcontrolreliabilityorsafetycategory(perISO13849)intheapplicationofinterlockedguards.WhileBannerEngineeringalwaysrecommendsthehighestlevelofsafetyinanyapplication,itistheresponsibilityoftheusertosafelyinstall,operateandmaintaineachsafetysystemandcomplywithallrelevantlawsandregulations.TheapplicationsshowninFigures2,3,and4meetorexceedtherequirementsforcontrolreliabilityandSafetyCategory3or4,perISO13849(EN954-1).

Mechanical Installation

RoutetheswitchcabletotheSafetyModulelocation.TheSafetyModuleisnotdesignedforexposedwiring;houseitinanenclosurewithaNEMA3(orIECIP54)rating,orbetter.TheSafetyModulemaybemounteddirectlyontostandard35mmDINrail.

Heat Dissipation ConsiderationsForreliableoperation,theusermustensurethattheoperatingspecificationsarenotexceeded.Theenclosuremustprovideadequateheatdissipation,sothattheaircloselysurroundingtheModuledoesnotexceedthemaximumoperatingtemperaturestatedintheSpecifications.Methodstoreduceheatbuild-upincludeventing,forcedairflow(e.g.,exhaustfans),adequateenclosureexteriorsurfacearea,andspacingbetweenmodulesandothersourcesofheat.

Electrical Installation

EachSafetyModuleispoweredby24Vac/dc(atlessthan150mA).TheSafetyModule,inturn,suppliespowertoeachswitch.

ItisnotpossibletogiveexactwiringinstructionsforaSafetyModulewhichinterfacestoamultitudeofmachinecontrolconfigurations.Thefollowingguidelinesaregeneralinnature.

TheSafetyModulehasnodelayfunction.Itsoutputrelaycontactsopenwithin35millisecondsafterasafetyinputopens.ThisclassifiestheSafetyModuleasfunctionalstop“Category0”,asdefinedbyANSINFPA79andIEC/EN60204-1.

Connection of Power to the Safety ModuleTheSafetyModulerequiresa24Vac/dcsupplyvoltage(seeSpecifications).Useextremecautionwheneverinstallingacpower.Useaminimumof16to18AWGwireforpowerandoutputconnections.Useaminimumof20AWGwireforallotherterminalconnections.Ahand-operatedsupplydisconnectandover-currentprotection(e.g.,acircuitbreaker)mustbeprovidedperANSINFPA79andIEC/EN60204-1.

SeeFigures2through6forconnectionofsafetyswitches.

Monitoring Series-Connected Safety Switches Whenmonitoringtwoindividuallymountedsafetyswitches(asshowninFigures2,3,and4),afaultyswitchwillbedetectedifitfailstoswitchastheguardopens.Inthiscase,theGateMonitorModulewillde-energizeitsoutputrelaysanddisableitsresetfunctionuntiltheinputrequirementsaremet(i.e.,thefaultyswitchisreplaced).However,whenaseriesofinterlockingsafetyswitchesismonitoredbyasingleSafetyModule,thefailureofoneswitchinthesystemmaybemaskedornotdetectedatall(refertoFigures5and6).

Series-connectedinterlockswitchcircuitsdonotmeetISO13849(EN954-1)SafetyCategory4andmaynotmeetControlReliabilityrequirementsbecauseofthepotentialforaninappropriateGateMonitorresetorapotentiallossofthesafetystopsignal.Amultipleconnectionofthistypeshouldnotbeusedinapplicationswherelossofthesafetystopsignaloraninappropriateresetcanleadpotentiallytoseriousinjuryordeath.Thefollowingtwoscenariosassumetwopositive-openingsafetyswitchesoneachguard:

WARNING . . . Shock Hazard

Always disconnect power from the Safety Module and all power from the machine being controlled before making any connections or replacing any component. ElectricalinstallationandwiringmustbemadebyqualifiedpersonnelandmustcomplywiththeNEC(NationalElectricalCode),ANSINFPA79orIEC60204-1,andallapplicablelocalstandardsandcodes.


6 P/N 60998 rev. E



1. Masking of a failure.Ifaguardisopenedbutaswitchfailstoopen,theredundantsafetyswitchwillopenandcausetheSafetyModuletode-energizeitsoutputs.Ifthefaultyguardisthenclosed,bothSafetyModuleinputchannelsalsoclose,butbecauseonechanneldidnotopen,theSafetyModulewillnotreset.However,ifthefaultyswitchisnotreplacedandasecond“good”guardiscycled(openingandthenclosingbothoftheModule’sinputchannels),theModuleconsidersthefailuretobecorrected.Withtheinputrequirementsapparentlysatisfied,theModuleallowsareset.Thissystemisnolongerredundantand,ifthesecondswitchfails,mayresultinanunsafecondition(i.e.,theaccumulationoffaultsresultsinthelossofthesafetyfunction).

2.Non-detection of a failure.Ifagoodguardisopened,theSafetyModule de-energizesitsoutputs(anormalresponse).Butifafaultyguardisthenopenedandclosedbeforethegoodguardisre-closed,thefailureonthefaultyguardisnotdetected.Thissystemisnolongerredundantandmayresultinalossofsafetyifthesecondsafetyswitchfailstoswitchwhenneeded.

Thesystemsineitherscenariodonotinherentlycomplywiththesafetystandardrequirementsofdetectingsinglefaultsandpreventingthenextcycle.Inmultiple-guardsystemsusingseries-connectedsafetyswitches,itisimportanttoperiodicallycheckthefunctionalintegrityofeachinterlockedguardindividually.Operators, maintenance personnel, and others associated with the operation of the machine must be trained to recognize such failures and be instructed to correct them immediately.

OpenandcloseeachguardseparatelywhileverifyingthattheGateMonitoroutputsoperatecorrectlythroughoutthecheckprocedure.Followeachgateclosurewithamanualreset,ifneeded.Ifacontactsetfails,theSafetyModulewillnotenableitsresetfunction.IftheSafetyModuledoesnotreset,aswitchmayhavefailed;thatswitchmustbeimmediatelyreplaced.

Thischeckmustbeperformedandallfaultsmustbecleared,ataminimum,duringperiodiccheckouts.If the application can not exclude these types of failures and such a failure could result in serious injury or death, then the series connection of safety switches must not be used.

Connection to the Guarded Machine Themachineinterfacehookupdiagram(Figure7)showsagenericconnectionoftheModule’stworedundantoutputcircuitstomachineprimarycontrolelementsMPCE1andMPCE2.Amachineprimarycontrolelementisanelectricallypowereddevice,externaltotheModule,whichstopstheguardedmachinerybyimmediatelyremovingelectricalpowertothemachineand(whennecessary)byapplyingbrakingtodangerousmotion.ThestopisaccomplishedbyremovingpowertotheactuatorcoilofeitherMPCE.

TosatisfytheSafetyCategory4requirementsofISO13849(EN954-1),eachMPCEmustofferanormallyclosed,forced-guidedmonitorcontact.OnenormallyclosedmonitorcontactfromeachMPCEiswiredinseriestotheY1-Y2feedback/resetinput(seeFigure7).Inoperation,ifoneoftheswitchingcontactsofeitherMPCEfailsintheshortedcondition,theassociatedmonitorcontactwillremainopen,preventingtheresetoftheModule.

External Device MonitoringTosatisfytherequirementsofControlReliability(OSHAandANSI)andCategory3and4ofISO13849-1(EN954-1),themachineprimarycontrolelements(MPCEs)musteachofferanormallyclosed,forced-guided(mechanicallylinked)monitorcontact.ConnectonenormallyclosedmonitorcontactfromeachmasterstopcontrolelementinseriestoY1andY2(seehookupdrawings).

Inoperation,ifoneoftheswitchingcontactsofeitherMPCEfailsintheenergizedcondition,theassociatedmonitorcontactwillremainopen.Therefore,itwillnotbepossibletoresettheSafetyModule.IfnoMPCE-monitorcontactsaremonitored,ajumpermustbeinstalledbetweenterminalsY1andY2(dottedline),asshowninthehookupdrawings.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.

WARNING . . . Mutiple Switching Devices

Whenever two or more switches are connected to the same Safety Module:•Contacts of the corresponding pole

of each switch must be connected together in series. Never connect the contacts of multiple emergency-stop switches in parallel to one Module. SuchaparallelconnectiondefeatstheswitchcontactmonitoringabilityoftheModuleandcreatesanunsafeconditionwhichcouldresutinseriousinjuryordeath.

•Each switch must be individually actuated (engaged), then re-armed and the Safety Module reset. ThisallowstheModuletocheckeachswitchanditswiringtodetectfaults.

Failure to test each switch individually in this manner could result in undetected faults and create an unsafe condition which could result in serious injury or death. Thischeckmustbeperformedduringperiodiccheckouts.



Figure 2. Hookup to two 4-wire coded magnetic safety switches

Guard

Mechanicalstop

Mechanicalstop

open

S12 S13S11

S23 S22S21

Guard #1

NOTE: Guard shown in closed position.

Figure 3. Hookup to two positive-opening safety interlock switches

Two-Channel Monitoring Configured for two-channel monitoring of one guard. This application is considered to meet or exceed requirements for Control Reliability and Safety Categories 3 and 4 per ISO 13849-1 (EN954-1).

Mechanical stop

Guard #1open

Guard #2open

BlueGray

Black

Brown

SI-MAG..SM SI-MAG..MM

SI-MAG..SM SI-MAG..MM

Mechanical stop

BlueGray

Black

Brown

NOTE: If only one magnetic safety switch is used, select 1-channel input and jumper S23 to S21.

S12 S13S11

S23 S22S21

One-Channel Monitoring Configured for one-channel monitoring of either one or two guards. This application is considered to meet or exceed requirements for Control Reliability and Safety Categories 3 and 4 per ISO 13849-1 (EN954-1).

S12 S13

S23 S22

NOTE: If PNP current-sourcing signals are used, the GM-FA-10J and the current-sourcing devices must be powered from the same DC supply and Common (Com).

A1

A2

+24V dc

0V

+24V dc

+24V dc

N.O.

N.C.

N.O.

N.C.

0V

0V

Figure 4. Hookup to two complementary current-sourcing PNP devices


8 P/N 60998 rev. E


Figure 5. Alternate hookup for one-channel monitoring of multiple guards

Blu

e

Gra

y

Bla

ck

Bro

wn

Blu

e

Gra

y

Bla

ck

Bro

wn

Blu

e

Gra

y

Bla

ck

Bro

wn

Blu

e

Gra

y

Bla

ck

Bro

wn

Blu

e

Gra

y

Bla

ck

Bro

wn

Blu

e

Gra

y

Bla

ck

Bro

wn

S12 S13S11

S23 S22S21

SI-MAG..SM SI-MAG..SM SI-MAG..SM

Guard #1 Guard #2 Guard #n

SI-MAG..SM SI-MAG..SM SI-MAG..SM

Guard #3 Guard #4 Guard #n+1

NOTE: Switch/magnet pairs shown in closed position.

Mechanical stop

Mechanical stop

SI-MAG..MMSI-MAG..MM SI-MAG..MM

SI-MAG..MM SI-MAG..MM SI-MAG..MM

One-Channel Monitoring Configured for one-channel monitoring of multiple guards with single switches at each guard (see Warning). Up to 10 Banner magnetic switches may be connected to each channel in this series/parallel method.

(If other than Banner magnetic switches are used, a total resistance of 270 Ohms between S11/S13, S11/S12, S21/S22 and S21/S23 must not be exceeded.)

Guard #1 Guard #2 Guard #3 Guard #n

NOTE: Guards shown in closed position.

S12 S13S11

S23 S22S21

Guard #4

Figure 6. Alternate hookup for two-channel monitoring of multiple guards

Two-Channel Monitoring Configured for two-channel monitoring of multiple guards with two safety switches mounted individually on each guard (see Warning).

The number of mechanical switches is limited by the max. resistance of 270 ohm between S11/S13, S11/S12, S21/S22 and S21/S23. The total resistance is calculated by adding the resistance of all guard switch contacts and the resistance of the cables that connect the switches and the switches to the module.

WARNING . . . Not a Safety Category 4 Application

When monitoring multiple guards with a series connection of multiple safety interlock switches, a single failure may be masked or not detected at all.

When such a configuration is used, procedures must be performed regularly to verify proper operation of each switch. See“MonitoringSeries-ConnectedSafetySwitches”(page6)formoreinformation.

WARNING . . . Not a Safety Category 4 Application

When monitoring multiple guards with a series connection of multiple safety interlock switches, a single failure may be masked or not detected at all.

When such a configuration is used, procedures must be performed regularly to verify proper operation of each switch. See“MonitoringSeries-ConnectedSafetySwitches”(page6)formoreinformation.




Overvoltage Category II and III Installations (EN 50178 and IEC 60664-1)TheSafetyModuleisratedforOvervoltageCategoryIIIwhenvoltagesof1Vto150Vac/dc areappliedtotheoutputrelaycontacts.ItisratedforOvervoltageCategoryIIwhenvoltagesof151Vto250Vac/dcareappliedtotheoutputrelaycontactsandnoadditionalprecautionsaretakentoattenuatepossibleovervoltagesituationsinthesupplyvoltage.TheModulecanbeusedinanOvervoltageCategoryIIIenvironment(withvoltagesof151Vto250Vac/dc)ifcareistakeneithertoreducethelevelofelectricaldisturbancesseenbytheModuletoOvervoltageCategoryIIlevelsbyinstallingsurgesuppressordevices(e.g.,arcsuppressors),ortoinstallextraexternalinsulationinordertoisolateboththeSafetyModuleandtheuserfromthehighervoltagelevelsofaCategoryIIIenvironment.

For Overvoltage Category III installations with applied voltages from 151V to 250V ac/dc applied to the output contact(s):theSafetyModulemaybeusedundertheconditionsofahigherovervoltagecategorywhereappropriateovervoltagereductionisprovided.Appropriatemethodsinclude:

•Anovervoltageprotectivedevice

•Atransformerwithisolatedwindings

•Adistributionsystemwithmultiplebranchcircuits(capableofdivertingenergyofsurges)

•Acapacitancecapableofabsorbingenergyofsurges

•Aresistanceorsimilardampingdevicecapableofdissipatingtheenergyofsurges

Whenswitchinginductiveacloads,itisgoodpracticetoprotecttheSafetyModuleoutputsbyinstallingappropriately-sizedarcsuppressors.However,ifarcsuppressorsareused,theymustbeinstalledacrosstheloadbeingswitched(e.g.,acrossthecoilsofexternalsafetyrelays),andneveracrosstheSafetyModule’soutputcontacts(seeWarningonpage7).

*

*

* Arc Suppressor, see Warning

A1 Y1

24V ac/dc

MACHINECONTROL

RESET

S12 S13S11

S23 S22S21

2313

Y2 A22414

K1

K2

0V ac/dc

MPCE2Monitoring Contactsor Jumper

MPCE1 MPCE1

For AutomaticReset, connectdirectly and configure DIPswitches

MPCE2

Figure 7. Hookup to the guarded machine

WARNING . . . Interfacing MPCEs

NEVER wire an intermediate device(s) (e.g., PLC, PES, PC), between the Safety Module outputs and the machine primary control element (MPCE) it switches, in such a manner that in the event of a failure there is the loss of the safety stop command, OR in such a manner that the safety function can be suspended, overridden, or dereated, unless accomplished with the same or greatr degree of safety. Wheneverforced-guided,mechanicallylinkedrelaysareaddedasintermediateswitchingdevices,anormallyclosedforced-guidedmonitorcontactfromeachrelaymustbeaddedtotheseriesfeedbackloopbetweenSafetyModuleterminalsY1andY2.

WARNING . . . Wiring of Arc Suppressors

If arc suppressors are used, they MUST be installed as shownacrossthecoilofthemachineprimarycontrolelements(MPCE1andMPCE2).NEVER install suppressors directly across the output contacts of the Safety Module.Itispossibleforsuppressorstofailasashortcircuit.IfinstalleddirectlyacrosstheoutputcontactsoftheSafetyModule,a short-circuited suppressor will create an unsafe condition which could result in serious injury or death.


10 P/N 60998 rev. E



Configuration

Manual Reset and Reset Switch Connection Theresetswitchmustbecapableofreliablyswitching15to30Vdcat5to50mA.AsshowninFigure7,theresetswitchconnectsbetweenterminalsY1andY2oftheModule.Theresetswitchmustbelocatedoutsideof–andnotaccessiblefrom–theareaofdangerousmotion,anditmustbepositionedsotheswitchoperatorcanseeallareasofdangerousmotionduringtheresetprocedure(seeWarning).

ToconfiguretheModuleforManualReset,setswitchesS1.2andS2.2inbanksAandBtoOFF.Theresetswitchmaybeanymechanicalnormallyopenswitch,butshouldbeamomentaryswitchoratwo-positionkeyedswitch.ToresettheModule,bothguardsmustbeclosed,atwhichtimetheoutputLEDwillflash(signalingthattheresetswitchmustbecycled).Thisactionisamonitoredmanualreset(open-closed-open),wherethe“closed”phaseisapproximately0.25to2secondslong.

Automatic Reset ModeToconfiguretheModuleforAutomaticReset,setswitchesS1.2andS2.2inBanksAandBtoON.IfnoMPCEcontactsaremonitored,installajumperbetweenterminalsY1andY2(seeFigure7).TheSafetyModulewillreset(anditsoutputswillenergize)assoonastheguardsreturntotheirclosedposition.

AutomaticResetisusefulforsomeautomatedprocesses.However, if Automatic Reset is used, an alternate means must be provided to prevent resumption of hazardous machine motion until an alternate reset procedure is performed.ThealternatemeansmustincludeaResetswitch,locatedoutsidetheareaofdangerousmotion,andpositionedsothattheswitchoperatorcanseeallareasofdangerousmotionduringtheresetprocedure.

1-Channel or 2-Channel InputTheSafetyModulemaybeconfiguredfor1-channel(“singlechannel”)or2-channel(“dualchannel”)operationbysettingDIPswitchesS1.1andS2.1inBanksAandB.In1-channeloperation(S1.1andS2.1–ON),theinputchannelsfunctionindependently.Thetwoguardscanbemonitoredindividually,butbothchannelsmustbeintheclosedpositionfortheSafetyModuletobereset.

In2-channeloperation(S1.1andS2.1–OFF)theinputchannelsmustfunctiontogether.Bothchannelsmustswitchwithina3-secondsimultaneityoftheotherwhentheguardcloses.Ifnot,theguardmustbere-openedandcloseduntilthetimingrequirementismet.Whentheguardopens,thechannelsfunctionconcurrently(bothmustopen,butwithoutthetimingrequirement).

Ineitherconfiguration,the“closed”inputsofeachchannelmustbeclosedbeforetheSafetyModulecanbereset(continuityS11toS13andS21toS23).Ifin1-channelmodeandmonitoringonlyoneswitch,ajumpermustbeinstalledattheunusedinput(e.g.,S21toS23;seeFigure2).

Figure 8. DIP switch configuration settings for reset mode and 1- or 2-channel operation

S21A1

S11 S13

S23 S21 S22

13 23 Y1

Y2 14 24 A2

K1

K2

14 24

MachineSafety

GM-FA-10J

Power

Fault

In 1

In 2

Output

DIPSwitch

Bank "A"S1.1S1.2

DIPSwitch

Bank "B"S2.1S2.2

S1.1/S2.1 OFF* – 2-Channel ON – 1-Channel

S1.2/S2.2 OFF* – Manual Reset ON – Auto Reset

* Factory Default

NOTE: Corresponding DIP switches in Banks A and B must be set identically.

OFFON

Shownwithterminalblocksremoved

WARNING . . . Reset Routine Required

U.S.andinternationalstandardsrequirethataresetroutinebeperformedafterclearingthecauseofastopcondition(e.g.,arminganE-stopbutton,closinganinterlockedguard,etc.).Allowing the machine to restart without actuating the normal start command/device can create an unsafe condition which could result in serious bodily injury or death.

WARNING . . . Reset Switch Location

The reset switch must be accessible only from outside, and in full view of, the hazardous area. Reset switches must also be out of reach from within the safeguarded space, and must be protected against unauthorized or inadvertent operation (e.g.,throughtheuseofringsorguards).Ifanyareasarenotvisiblefromtheresetswitch(es),additionalmeansofsafeguardingmustbeprovided.Failure to do so could result in serious bodily injury or death.




Initial Checkout Procedure

1. Removepowerfromthemachineprimarycontrolelements(MPCEs).

2. Closeallmonitoredguards.IftheModuleiswiredto1-channelinput,thesecondinput(S21/S23orS11/S13)mustbejumperedifunused.

3.Applyinputpower(only)totheGateMonitorModuleatterminalsA1andA2(seeFigure7).ThefollowingLEDsshouldcomeON: Power Input1 Input2

IfthePowerLEDcomesON,buteitherorbothInputLEDsarenotON,disconnectinputpowerandcheckthewiringoftheconnectedswitch(es)and/orthejumper.Checkifthejumperisinstalledcorrectlyontheunusedinput.Returntostep2afterthecauseoftheproblemhasbeencorrected.

4. If the Module is set to 1-channel operation:AfterthePower,Input1,andInput2LEDsallareON,openandcloseallconnectedguardsoneatatime.Wheneachindividualguardopens,thecorrespondingInputLEDmustturnOFF,andwhentheguardclosesitsLEDmustcomeONagain.

If the Module is set to 2-channel operation:AfterthePower,Input1,andInput2LEDsallareON,opentheguard;bothswitchesmustopenwithin3seconds,andbothInputLEDsmustturnOFF.IftheredFaultLEDcomesON,simultaneitybetweentheswitchesorwithinoneswitch(betweenitsNOandNCcontacts)wasnotmet.Checkallwiringandtheswitches.

If the Module is set to Auto Reset:(Y1/Y2closedandDIPswitchessettoAutoReset),theoutputLEDwillcomeONassoonasbothInputLEDsareON(outputcontacts13/14and23/24close).

If the Module is set to Manual Monitored Reset:theOutputLEDshouldcomeONonlyifInput1and2LEDsareONandtheResetbuttonconnectedtoY1andY2wentfromopentoclosedandbacktoopenposition.

5. Repeatstep4individuallyforeachguardthatisbeingmonitored.

6. Closetheguard.ApplypowertothemachinecontrolelementsandperformthePeriodicCheckoutProcedureonpage12.

NOTE:MakesurethatbothInput1and2LEDsareONonly when ALL connected guards are closed.IftheguardsareclosedandtheInputLEDsareOFF,theguardswitchesmaybewiredincorrectly,whichcouldresettheModuleinappropriately(safetyoutputcontactscloseassoonasoneoftheconnectedguardsopens).

Donotcontinueoperationuntilallchecksarecompletedandallproblemsarecorrected.SeetheWarningonpage12,andRepairandTroubleshootingonpages18and19forfurtherinformation.

To remove a terminal block, insert a small screwdriver into the slot as shown, and pry to loosen.

When reinserting the block, take care to slide the dovetail on the terminal block into the slot on the frame.

Figure 9. Removal of terminal blocks

CAUTION . . . Disconnect Power Prior to Checkout

Before performing the initial checkout procedure, make certain all power is disconnected from the machine to be controlled.DangerousvoltagesmaybepresentalongtheE-stopSafetyModulewiringbarrierswheneverpowertothemachinecontrolelementsisON.Exercise extreme caution whenever machine control power is or may be present. Always disconnect power to the machine control elements before opening the enclosure housing of the Safety Module.

WARNING . . . Multiple Safety Devices

When two or more safety devices are used, each device must be individually actuated, causing a STOP or open-contact condition, then reset/rearmed and the Safety Module reset (ifusingmanualresetmode).Thisallowsthemonitoringcircuitstocheckeachdeviceanditswiringtodetectfaults.Failure to test each device in this way could result in undetected faults and create an unsafe condition. This could result in serious bodily injury or death.


12 P/N 60998 rev. E



Periodic Checks

Ateachshiftchangeormachinesetup,aDesignatedPerson*shoulddothefollowingchecksonallsafetyswitches:

1.Breakageordamageoftheswitch,sensor,actuator,ormagnet.

2.Goodalignmentbetweentheswitchandactuatororsensorandmagnet.

3.Confirmationthattheswitchesarenotbeingusedasanend-of-travelstop.

4.Looseningofthemountinghardware.

5.Verificationthatitisnotpossibletoreachanyhazardpointthroughanopenedguard(oranyopening)beforehazardousmachinemotionstopscompletely.

6.OpenandcloseeachguardseparatelywhileverifyingthattheGateMonitoroutputsoperatecorrectlythroughoutthecheckprocedure.Followeachgateclosurewithamanualreset,ifneeded.Ifacontactsetfails,theSafetyModulewillnotenableitsresetfunction.IftheSafetyModuledoesnotreset,aswitchmayhavefailed;thatswitchmustbeimmediatelyreplaced.

Inaddition,aQualifiedPerson*shoulddothefollowingonaperiodicschedule(determinedbytheuser,basedupontheseverityoftheenvironmentandthefrequencyofswitchactuations):

1.Inspecttheelectricalwiringforcontinuityanddamage.

2.Confirmthatwiringconformstotheinstructionsgiveninthisinstallationmanual.

Donotcontinueoperationuntilallchecksarecompletedandallproblemsarecorrected.SeeRepairandTroubleshootingonpages18and19forfurtherinformation.

*ADesignatedPersonisidentifiedinwritingbytheemployerasbeingappropriatelytrainedtoperformaspecifiedcheckoutprocedure.AQualifiedPersonpossessesarecognizeddegreeorcertificateorhasextensiveknowledge,training,andexperiencetobeabletosolveproblemsrelatingtosafetyswitchinstallation.

WARNING . . . Do Not Use Machine Until System Is Working Properly

Ifallofthesecheckscannotbeverified,donotattempttousetheguardedmachineuntilthedefectorproblemhasbeencorrected.

Attempts to use the guarded machine under such conditions could result in serious bodily injury or death.




Supply Voltage and Current 24Vdc±15%@150mA(SELV-ratedsupplyaccordingtoENIEC60950,NECClass2)24Vac±15%@150mA,50-60Hz+/-5%(NECClass2-ratedtransformer)Power consumption: approx.3VA/3W TocomplywithULandCSAstandards,theisolatedsecondarypowersupplycircuitintheinstallationmustincorporateamethodtolimittheovervoltageto0.8kV.

Supply Protection Circuitry Protectedagainsttransientvoltagesandreversepolarity

Overvoltage Category Output relay contact voltage of 1V to 150V ac/dc: CategoryIII Output relay contact voltage of 151V to 250V ac/dc: CategoryII(CategoryIII,ifappropriateovervoltagereductionisprovided,asdescribedonpage9.)

Pollution Degree 2

Output Configuration Eachnormallyopenoutputchannelisaseriesconnectionofcontactsfromtwoforced-guided(mechanicallylinked)relays,K1-K2.Contacts:AgNi,5µmgold-platedLo w Current Rating:The5µmgold-platedcontactsallowtheswitchingoflowcurrent/lowvoltage.Inthese

low-powerapplications,multiplecontactscanalsobeswitchedinseries(e.g.,“dryswitching”). To preserve the gold plating on the contacts, do not exceed the following max. values at any time: Min. voltage: 1Vac/dc Max. voltage:60V Min. current:5mAac/dc Max. current:300mA Min. power:5mW(5mVA) Max. power:7W(7VA)Hi gh Current Rating:Ifhigherloadsmustbeswitchedthroughoneormoreofthecontacts,theminimum

andmaximumvaluesofthecontact(s)changesto:

Mechanical life: ≥50,000,000operationsElectrical life (switching cycles of the output contacts, resistive load): 150,000cycles@900VA; 1,000,000cycles@250VA;2,000,000cycles@150VA;5,000,000cycles@100VANOTE: Transient suppression is recommended when switching inductive loads. Install suppressors

across load. Never install suppressors across output contacts (see Warning, page 9).

Output Response Time 35msmax.

Input Requirements Eachswitchorsensormusthaveanormallyclosedcontactandanormallyopencontactcapableofswitching20to50mA@15to30Vdc.

Reset switch:20mA@12Vdc,hardcontactonly

Max. external resistance between terminals S11/S12, S11/S13, S21/S22 and S21/S23: 270ohmseach.

Simultaneity Monitoring 2-Channel operation:3seconds1-Channel operation: infinite

Status Indicators 1 red LED:Fault(see“Troubleshooting,”page18)4 green LEDs:Power–powerissuppliedtoSafetyModuleChannel1–inputssatisfied(guardclosed)Channel2–inputssatisfied(guardclosed)Output–K1andK2energized,safetyoutputsclosed

Construction Polycarbonatehousing.RatedIECIP20

Mounting Mountstostandard35mmDINrailtrack.SafetyModulemustbeinstalledinsideanenclosureratedNEMA3(IECIP54),orbetter.

Specifications

Emergency Stop Device 29YL

Minimum: Voltage: 15Vac/dcCurrent:30mAac/dc Power:0.45W(0.45VA)

Maximum: 250Vac/24Vdc,6Aresistive B300,R300perUL508

Minimum: Voltage: 15Vac/dcCurrent:30mAac/dc Power:0.45W(0.45VA)

Maximum: 250Vac/24Vdc,6Aresistive IEC60947-5-1: AC15:230Vac,3A;DC-13:24Vdc,2A


14 P/N 60998 rev. E



S12A1

S11 S13

S23 S21 S22

13 23 Y1

Y2 14 24 A2

K1

K2

14 24

MachineSafety

GM-FA-10I

Power

Fault

In 1

In 2

Output

118.0 mm(4.65")

84.0 mm(3.31")

22.5 mm(0.89")

Figure 10. Dimensions and label

Vibration Resistance [email protected]

Operating Conditions Temperature:0°to+50°C(+32°to122°F)Maximum Relative Humidity:90%@+50°C(non-condensing)

Dimensions SeeFigure10.

Design Standards :Cat.4PLe,perENISO13849-1;SIL3perIEC61508andIEC62061

CertificationsEmergency Stop Device 29YL




Magnet / Sensor PairMagnet Sensor*

Coded Magnet Sensor Cable

Switching Distance Min. ON Max. OFF

SI-MAG1SMSI-MAG1SMCO†

SI-MAG1MMSI-MAG1MM90††

3m(10')

3mm(0.12") 14mm(0.55")

SI-MAG1MMHF 8mm(0.31") 16mm(0.63")

SI-MAG2SM SI-MAG2MM 4mm(0.16") 8mm(0.32")

SI-MAG3SM SI-MAG3MM 3mm(0.12") 7mm(0.28")

Magnetic Switch Models

*9m(30')cablesareavailableformagnetsensorsbyaddingsuffix“w/30”tothemodelnumber(e.g.,SI-MAG1SM w/30).

†CableoppositeseeFigure11b,page16)††90°orientation(seeFigure14a,page17)

Magnetic Switch SpecificationsSwitching Elements Threepole-stablereedswitches

Repeat Switching Accuracy ±0.1mm(±0.004")

Construction Epoxy-encapsulatedcircuitinpolyamidehousing

Environmental Rating NEMA4X,IECIP67

Switching Capacity [email protected](27Ωfuseresistorin-line,eachchannel)

Operating Temperature -5°to+70°C(+23°to+158°F)

ConnectionsIntegralPVC-jacketed3m(10')4-wirecable.CableO.D.is5mm(0.2").Wiresare24AWG(0.25mm²).

HardwareAllmountinghardwareissuppliedbyuser.Useofpermanentfastenersorlockinghardwareisrecommendedtopreventlooseningordisplacementoftheactuatorandswitchbody.MountingholesinthemagnetandsensoracceptM4(#6)hardware(seeFigures11,12,and13).

Application NoteThesensor/magnetpairmustbemountedaminimumdistanceof15mm(0.6”)fromanymagnetizedorferrousmaterials.MultipleSFA-IMB1(usedwithSI-MAG1..)andSFA-IMB2(usedwithSI-MAG2..)canbeusedasspacers.

Accessories


16 P/N 60998 rev. E


43 mm(1.69")

22 mm(0.87")

7 mm(0.28")

26 mm(1.02")

ø 8.3 mm(0.33") (2)

ø 4.3 mm(0.17") (2)

SensingSurface

29 mm(1.14")

13 mm(0.51")

4.5 mm(0.18")

88 mm(3.46")

78 mm(3.07")

68 mm(2.68")

4.5 mm(0.18") (3)

6.5 mm(0.26")

25 mm(0.98")

10.7 mm(0.42")

7.2 mm(0.28")2.5 mm(0.10")

13 mm(0.51")

SensingSurface

3.0 mm(0.12")

43 mm(1.69")

22 mm(0.87")

7 mm(0.28")

26 mm(1.02")

ø 8.3 mm(0.33") (2)

ø 4.3 mm(0.17") (2)

MagnetSurface

29 mm(1.14")

13 mm(0.51")

4.5 mm(0.18")

88 mm(3.46")

78 mm(3.07")

68 mm(2.68")

4.5 mm(0.18") (3)

6.5 mm(0.26")

25 mm(0.98")

10.7 mm(0.42")

7.2 mm(0.28")2.5 mm(0.10")

13 mm(0.51")

MagnetSurface

3.0 mm(0.12")

Figure 11a. SI-MAG1SM Sensor

88 mm(3.46")

78 mm(3.07")

68 mm(2.68")

4.5 mm(0.18") (3)

6.5 mm(0.26")

25 mm(0.98")

10.7 mm(0.42")

7.2 mm(0.28")

2.5 mm(0.10")

13 mm(0.51")

SensingSurface

3.0 mm(0.12")

Figure 11b. SI-MAG1SMCO Sensor Figure 11c. SI-MAG1MM/MM90/MMHF Magnet

35 mm(1.38")

34 mm(1.34")

2 mm(0.08")

SW365.2 mm

(0.2")

27.5 mm (1.06")

M30 x 1.5 mm

SensingSurface

ø 35 mm (1.38")

15 mm (0.59")

9 mm (0.35")

35 mm(1.38")

25 mm(0.98")

4.5 mm (0.18")

10.5 mm(0.41")Magnet

Surface

Figure 13a. SI-MAG3SM Sensor Figure 13b. SI-MAG3MM Magnet

Figure 12a. SI-MAG2SM Sensor Figure 12b. SI-MAG2MM Magnet

Magnetic Switch Dimensions



Direction ofMovement

Alternate Direction of Approachmovement is parallel to theplane of the sensing face

Important! The magnet mounting holes must be orientedas shown, relative to the sensor cable position.

CodedMagnet

MagnetSensor

Normal Direction of Approachmovement is perpendicular to theplane of the sensing face


Important! The magnet mounting holes must be orientedas shown, relative to the sensor cable position.

CodedMagnetMagnet

Sensor


Incorrect Magnet Orientation

CodedMagnet

MagnetSensor

“Direction of Approach” Options for Sensor/Magnet Pairs


Incorrect Direction of ApproachLabel to label approach of sensor and magnet is notpossible


Incorrect Direction of Approach90º approach of sensor and magnet is not possible

Incorrect Direction of ApproachLabel to label approach of sensor and magnet is not possible


Sensing face

CodedMagnet



MagnetSensor

Incorrect Direction of Approach90º approach of sensor and magnet is not possible




CodedMagnet

MagnetSensor





CodedMagnet

MagnetSensor

Figure 14a. Direction of Approach for SI-MAG1.. sensor/magnet pairs

Figure 14b. Direction of Approach for SI-MAG2.. sensor/magnet pairs

Figure 14c. Direction of Approach for SI-MAG3.. sensor/magnet pairs

NOTE:Forallmagnetstyleswitches,approachspeedmustbegreaterthan0.1m/stoallowforproperswitching.(Seepage4.)


18 P/N 60998 rev. E


Troubleshooting

ModelGM-FA-10JGateMonitoringSafetyModuleprovides5LEDindicators.

LED Condition Meaning

Power(green)

ON

OFF

PowerisconnectedtoterminalsA1-A2.

NopowerorlowpowertoterminalsA1-A2,orinternalpowersupplyfailure.

Fault(red)

ON Flashing(only)

Flashing (PowerLED/flashing)

Externalfaultorconfigurationfault.ThecorrespondingfunctionLEDwillflashtoindicatetheareawherethefaulthasbeendetected.Seepage19forprobablecause.

InternalFault.Seeaboveforrepair.

DIPSwitchconfigurationfault.CheckthatswitchpositionsarethesameforbothBanksAandB.

Input 1(green)

ON

OFF

Flashing (FaultLEDON)

Guard1isclosedandtheinputsofChannel1aresatisfied.

Guard1isopenortheinputsofChannel1arenotsatisfied.

Seepage19forprobablecause.

Input 2(green)

ON

OFF


Guard2isclosedandtheinputsofChannel2aresatisfied.

Guard2isopenortheinputsofChannel2arenotsatisfied.


Output(green)

ON

OFF

Flashing


BothinternalrelaysK1andK2areenergized(13/14and23/24areclosed).

BothinternalrelaysK1andK2arede-energized(13/14and23/24areopened).

Resetrequested.CycletheResetinput(button)(open,closed,open)toenterRUNmode.


Repairs

Do not attempt any repairs to the GM-FA-10J Safety Module. It contains no field replaceable components.ReturntheInterfaceModuletothefactoryforwarrantyrepairorreplacement.

IfiteverbecomesnecessarytoreturnaSafetyModuletothefactory,contacttheBannerFactoryApplicationEngineeringGroupattheaddressornumberslistedonthebackpage.Theywillattempttotroubleshootthesystemfromyourdescriptionoftheproblem.Iftheyconcludethatacomponentisdefective,theywillissueanRMA(ReturnMerchandiseAuthorization)numberforyourpaperworkandgiveyouthepropershippingaddress.PacktheSafetyModulecarefully.Damagewhichoccursinreturnshippingisnotcoveredbywarranty.

CAUTION . . . Abuse of Module After Failure

If an Internal Fault occurs and the Module will not reset, do not tap, strike, or otherwise attempt to correct the fault by a physical impact to the housing.Aninternalrelaymayhavefailedinsuchamannerthatitsreplacementisrequired.If the Module is not immediately replaced or repaired, multiple simultaneous failures may accumulate and the safety function can not be guaranteed.



Clearing FaultsToclearafaultcondition,firstcorrecttheproblemandthencycletheinputchannelstothemodule(openandclosetheguards).WhentheFaultLEDlights,thecorrespondingFunctionLEDwillflashtoindicatetheproblem.IftheFaultLEDisflashing,referto“Repairs,”page18.NOTE:Input1:S12/S13

Input2:S22/S23

LED Fault, Probable Cause and Procedures

Power ONFault ON Input 1 FLASHING Input 2 ON or OFF Output OFF

INPUT CHANNEL 1 FAULT (S11/S12/S13) a.S13Open(guardclosed) b.S12Open(guardopen) c.S11Open(guardisopenorclosed) d.ShortbetweenS11andS12

Power ONFault ON Input 1 ON or OFF Input 2 FLASHING Output OFF

INPUT CHANNEL 2 FAULT (S21/S22/S23) a.S23Open(guardclosed) b.S22Open(guardopen) c.S21Open(guardisopenorclosed) d.ShortbetweenS21andS22

Power ONFault ON Input 1 FLASHING Input 2 FLASHING Output OFF

SHORT BETWEEN INPUT CHANNELS a.ShortbetweenS11andS21

Power ONFault ON Input 1 ON or OFF Input 2 ON or OFF Output OFF

SIMULTANEITY FAULT a.2-channelsimultaneity>3seconds(configuredfor2-channeloperation) b.Channelsimultaneity>1second (NO/NCdidnotswitchwithin1second)Seepage3fordescriptionofcomplementaryswitchingand2-channeloperation.

Power FLASHINGFault FLASHING Input 1 OFF Input 2 OFF Output OFF

DIP-SWITCH ERROR a.DIP-switchsettingsareincorrect;BankAdoesnotmatch

BankBSeepage10forDIP-switchconfiguration.

Power ONFault ON Input 1 ON Input 2 ON Output FLASHING

OPEN RESET FAULT a.Y1/Y2openwhenconfiguredforAutoResetSeepage10forManual/AutoResetinformation.

Power ONFault FLASHING Input 1 OFF Input 2 OFF Output OFF

INTERNAL FAULT (See page 18 for Repairs) a.Incorrectchecksum b.Internalrelayfailure(e.g.,weldedcontactdueto

inductiveloadarcing.)c.Lowinputpower d.Otherinternalfault


WARRANTY: BannerEngineeringCorp.warrantsitsproductstobefreefromdefectsforoneyear.BannerEngineeringCorp.willrepairorreplace,freeofcharge,anyproductofitsmanufacturefoundtobedefectiveatthetimeitisreturnedtothefactoryduringthewarrantyperiod.ThiswarrantydoesnotcoverdamageorliabilityfortheimproperapplicationofBannerproducts.Thiswarrantyisinlieuofanyotherwarrantyeitherexpressedorimplied.

BannerEngineeringCorp.,9714TenthAve.No.,Minneapolis,MN55441•Phone:763.544.3164•www.bannerengineering.com•Email:[email protected]

P/N 60998 rev. E

For more information: Contact your local Banner representative or Banner Corporate Offices around the world.

Corporate Headquarters Europe Latin America

Banner Engineering Corp.

9714TenthAve.North Mpls.,MN55441 Tel:763-544-3164 www.bannerengineering.com [email protected]

Banner Engineering Europe

ParkLaneCulliganlaan2F DiegemB-1831 BELGIUM Tel:32-24560780 Fax:32-24560789 www.bannereurope.com [email protected]

Contact Banner Engineering Corp. (US) or e-mail

Mexico: [email protected]

Brazil: [email protected]

Asia — China Asia — Japan Asia India

Banner Engineering China

Shanghai Rep Office Rm.G/H/I,28thFlr. CrossRegionPlaza No.899,LinglingRoad Shanghai200030CHINA Tel:86-21-54894500 Fax:86-21-54894511 www.bannerengineering.com.cn [email protected]

Banner Engineering Japan

Cent-UrbanBuilding 3053-23-15Nishi-Nakajima Yodogawa-Ku, Osaka532-0011JAPAN Tel:81-6-6309-0411 Fax:81-6-6309-0416

www.bannerengineering.co.jp [email protected]

Banner Engineering Asia ─ Taiwan

NeihuTechnologyPark 5F-1,No.51,Lane35,JihuRd. Taipei114TAIWAN Tel:886-2-8751-9966 Fax:886-2-8751-2966 www.bannerengineering.com.tw [email protected]

Banner Engineering India

Pune Head Quarters Office No.1001SaiCapital,Opp. ICCSenapatiBapatRoad Pune411016INDIA Tel:91-20-66405624 Fax:91-20-66405623 www.bannerengineering.co.in [email protected]

BannerEngineeringCorp.,9714TenthAve.No.,Minneapolis,MN55441•Phone:763.544.3164•www.bannerengineering.com•Email:[email protected]

EC Declaration of ConformityBannerEngineringCorp.

9714TenthAvenueNorth

Minneapolis,MN55441-5019USA

WeherewithdeclarethatGM-FA-10JGateMonitoringSafetyModuleforindustrialcontrolisinconformitywiththeprovisionsoftheMachineryDirective(Directive98/37/EEC),andallessentialHealthandSafetyRequirementshavebeenmet.

10/16/2009

R.Eagle/EngineeringManager Date

DownloadthecompleteECDeclarationofConformityasaPDFfileatwww.bannerengineering.com/ESMODULE