Electrical Installation - Banner GM-FA-10J Original Instructions Manual

GM-FA-10J Gate Monitoring Safety Module

Electrical Installation

Each Safety Module is powered by 24V ac/dc (at less than 150 mA). The Safety Module, in turn, supplies power to each switch.
It is not possible to give exact wiring instructions for a Safety Module that interfaces to a multitude of machine control configurations. The
following guidelines are general in nature.
The Safety Module has no delay function. Its output relay contacts open within 35 milliseconds after a safety input opens. This classifies
the Safety Module as a functional stop "Category 0" control, as defined by ANSI NFPA 79 and IEC/EN 60204-1.
WARNING: Shock Hazard and Hazardous Energy
Always disconnect power from the safety system (for example, device, module, interfacing, etc.)
and the machine being controlled before making any connections or replacing any component.
Electrical installation and wiring must be made by Qualified Personnel and must comply with the relevant
electrical standards and wiring codes, such as the NEC (National Electrical Code), ANSI NFPA79, or IEC
60204-1, and all applicable local standards and codes.
Lockout/tagout procedures may be required. Refer to OSHA 29CFR1910.147, ANSI Z244-1, ISO
14118, or the appropriate standard for controlling hazardous energy.
Connection of Power to the Safety Module
The Safety Module requires a 24V ac/dc supply voltage (see Specifications). Use extreme caution whenever installing ac power. Use a
minimum of 16 to 18 AWG wire for power and output connections. Use a minimum of 20 AWG wire for all other terminal connections. A
hand-operated supply disconnect and over-current protection (e.g., a circuit breaker) must be provided per ANSI NFPA79 and IEC/
EN60204-1.
See
Figure 2. Wiring to two 4-wire coded magnetic safety switches
monitoring of multiple guards on page 8 for connection of safety switches.
Monitoring Series-Connected Safety Switches
When monitoring two individually mounted safety switches (as shown in
page 7 through Figure 4. Wiring to two complementary current-sourcing PNP devices
it fails to switch as the guard opens. In this case, the Gate Monitor Module will de-energize its output relays and disable its reset function
until the input requirements are met (i.e., the faulty switch is replaced). However, when a series of interlocking safety switches is moni-
tored by a single Safety Module, the failure of one switch in the system may be masked or not detected at all (refer to
wiring for one-channel monitoring of multiple guards
guards on page 8).
Series-connected interlock switch circuits do not meet ISO 13849 (EN954-1) Safety Category 4 and may not meet Control Reliability
requirements because of the potential for an inappropriate Gate Monitor reset or a potential loss of the safety stop signal. A multiple
connection of this type should not be used in applications where loss of the safety stop signal or an inappropriate reset can lead potential-
ly to serious injury or death. The following two scenarios assume two positive-opening safety switches on each guard:
1. Masking of a failure. If a guard is opened but a switch fails to open, the redundant safety switch will open and cause the Safety
Module to de-energize its outputs. If the faulty guard is then closed, both Safety Module input channels also close, but because one
channel did not open, the Safety Module will not reset. However, if the faulty switch is not replaced and a second "good" guard is
cycled (opening and then closing both of the Module's input channels), the Module considers the failure to be corrected. With the
input requirements apparently satisfied, the Module allows a reset. This system is no longer redundant and, if the second switch
fails, may result in an unsafe condition (i.e., the accumulation of faults results in the loss of the safety function).
2. Non-detection of a failure. If a good guard is opened, the Safety Module de-energizes its outputs (a normal response). But if a
faulty guard is then opened and closed before the good guard is re-closed, the failure on the faulty guard is not detected. This
system is no longer redundant and may result in a loss of safety if the second safety switch fails to switch when needed.
The systems in either scenario do not inherently comply with the safety standard requirements of detecting single faults and preventing
the next cycle. In multiple-guard systems using series-connected safety switches, it is important to periodically check the functional integ-
rity of each interlocked guard individually. 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.
Open and close each guard separately while verifying that the Gate Monitor outputs operate correctly throughout the check procedure.
Follow each gate closure with a manual reset, if needed. If a contact set fails, the Safety Module will not enable its reset function. If the
Safety Module does not reset, a switch may have failed; that switch must be immediately replaced.
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on page 7 through
Figure 2. Wiring to two 4-wire coded magnetic safety switches
on page 8 and Figure 6. Alternate wiring for two-channel monitoring of multiple
Figure 6. Alternate wiring for two-channel
on page 7), a faulty switch will be detected if
on
Figure 5. Alternate