SI-HG80DQDR - BANNER ENGINEERING

SI-HG80 Series Safety Interlock Switches encapsulated in a load-bearing hinge

• Safety switch is integrated and encapsulated into a load-bearing hinge, providing a

high degree of protection from intentional defeat

• Identical in appearance to non-switching blank hinge (see Accessories on page 6)

• Switch components concealed inside the hinge are protected from mechanical impact,

providing superior performance to actuator-activated safety switches; rated IEC IP67

• Hinge operates to a full 180° range of motion; safety switching point (guard-closed po-

sition) is adjustable over the full 0–180°operating range

• Hinge can support an axial load of 750 N and more than 1,000 N in radial direction

• When properly interfaced or used with an appropriate controller, two SI-HG80D..

switches can achieve safety category 4, per ISO 13849 (EN 954-1)

• Robust zinc die-cast housing is corrosion resistant

• Typical applications include:

• Hinged covers and guards to machines

• Hinged doors and gates in safety fencing systems

• Modular aluminum framing

Inline QD Fitting Right-angle QD Fitting

Model QD Connection Contact Configuration

(Closed State)

Contact Configuration

(Open State) Switching Diagram

SI-HG80DQD Inline QD Fitting

13 24

134 2

1-2Safety

Operating

Angle

3°

10°

SI-HG80DQDR Right-angle QD Fitting

Note: Terminal #3 is non-safety.

Switching Diagram Key

Contacts: Open Closed Transition

Important Information Regarding the Use of Safety Switches

In the United States, the functions that Banner safety switches are intended to perform are regulated by the Occupational Safety and

Health Administration (OSHA). Whether or not any particular safety switch installation meets all applicable OSHA requirements depends

upon factors that are beyond the control of Banner Engineering Corp. These factors include the details of how the safety switches are

applied, installed, wired, operated, and maintained.

Banner Engineering Corp. has attempted to provide complete application, installation, operation, and maintenance instructions. This in-

formation is found in the instruction manual packaged with each safety switch. In addition, we suggest that any questions regarding the

use or installation of safety switches be directed to the factory applications department at the telephone numbers or address shown

below.

Hinge Wing Safety Interlock Switches

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Banner Engineering Corp. recommends that safety switches be applied according to the guidelines set forth in international (ISO/IEC)

standards listed below. Specifically, Banner Engineering Corp. recommends application of these safety switches in a configuration which

meets safety category 4, per ISO 13849 (EN954-1).

In addition, the user of Banner safety switches has the responsibility to ensure that all local, state, and national laws, rules, codes, and

regulations relating to the use of Banner safety switches in any particular application are satisfied. Extreme care is urged that all legal

requirements have been met and that all installations and maintenance instructions are followed.

Application Assistance

Toll Free: 1-888-3-SENSOR (1-888-373-6767)

Email: sensors@bannerengineering.com

9714 Tenth Avenue North

Minneapolis, MN 55441

U.S. Regulations Applicable to Use of Banner Safety Switches

OSHA Code of Federal Regulations: Title 29, Parts 1900 to 1910

Available from: Superintendent of Documents, Government Printing Office, P.O. Box 371954, Pittsburgh, PA 15250-7954, Tel:

202-512-1800

U.S. Standards Applicable to Use of Banner Safety Switches

ANSI B11 Standards for Machine Tools Safety

Contact: Safety Director, AMT – The Association for Manufacturing Technology, 7901 Westpark Drive, McLean, VA 22102, Tel.:

703-893-2900

Applicable European and International Standards

ISO/TR 12100-1 (EN 292-1 & -2) Safety of Machinery – Basic Concepts, General Principles for Design

ISO 13852 (EN 294) Safety of Machinery—Safety Distances to Prevent Danger Zones Being Reached by the Upper Limbs

ISO 13853 (EN 811) Safety of Machinery—Safety Distances to Prevent Danger Zones Being Reached by the Lower Limbs

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 14119 (EN 1088) Interlocking Devices Associated with Guards – Principles for Design and Selection

IEC 60204-1 Electrical Equipment of Machines Part 1: General Requirements

IEC 60947-5-1 Low Voltage Switchgear – Electromechanical Control Circuit Devices

Contact: Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5704, Tel.: 800-854- 7179

Mechanical Installation

WARNING: Hazard Point

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.

Please reference OSHA CFR 1910.217 and ANSI B11 standards for information on determining safety

distances and safe opening sizes for your guarding devices.

All mounting hardware is supplied by the user. Fasteners must be of sufficient strength to guard against breakage. Use of permanent

fasteners or locking hardware is recommended to prevent loosening or displacement of the actuator and the switch body. The mounting

holes in the switch body and the actuator accept M6 screws (see Dimensions on page 5).

Ensure that excessive force is not exerted by the weight and swing of the guard, gate, or door (see Specifications on page 5).

Position blank hinges (if used) and the hinge switch(es) on the guard or gate while it is in its fully closed and latched position. Verify that

the axis of rotation is identical for all hinges used. (Typically, this can be accomplished by using a straight edge along the long flat edge to

ensure the switch bodies are parallel.) After the mounting hardware is secure, check the rotation of the guard or gate for misalignment

and binding.

NOTE: A safety switch must be installed in a manner that discourages tampering or defeat.

Hinge Wing Safety Interlock Switches

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CAUTION:

End Stops.

Do not use the switch as an end stop. The operating angle of the switch must be limited by outer end

stops.

Setting the Switch Point

CAUTION:

Remove Set Screw Head.

Shear off the hexagonal head of

the set screw after it is set, and

before using the switch. If not, the

safe activation of the switch can

not be ensured.

Figure 1. Hinge switch with set screw head in place

1. Ensure the hinge switches (and blind hinges, if used) are properly mounted and the guard or gate swings freely throughout its range

of motion without binding. If binding is noticed, repeat the mechanical installation procedures.

2. Place the guard in its closed and latched position.

After the switch point is set, it cannot be changed. Before proceeding, verify the installation is correct and the resulting switching

action is what is expected.

3. Tighten the hexagonal set screw head with a 13 mm open-ended wrench (rotate clockwise when switch is mounted vertically and the

nut is on top). See Figure 1. Hinge switch with set screw head in place on page 3.

4. Continue tightening until the set screw head shears completely off the switch. When the screw head shears off, the switch point is

set.

Electrical Installation

CAUTION: Electrical Installation

Two safety switches must be used for each interlock guard to achieve control reliability or Safety

Category 4 (per ISO 13849-1, EN 954-1) of a machine stop circuit. Use of only one safety switch per

interlock guard is not recommended.

In addition, normally-closed safety contacts from each of the two safety switches should be connected to

the two separate inputs of a 2-channel safety module or safety interface. This is required to provide moni-

toring for safety switch contact failure, and to provide the necessary reset routine, as required by IEC

60204-1 and NFPA 79 machine safety standards.

Hinge Wing Safety Interlock Switches

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WARNING: Series Connection of Safety Interlock Switches

Monitoring multiple guards with a series connection of safety interlock switches may result in a failure be-

ing masked or not detected at all. When such a configuration is used, periodic checks must be performed

regularly to verify proper operation. All failures must be immediately corrected ( e.g. immediately replacing

a failed switch), or the loss of the safety stop signal or an inappropriate reset could lead to serious injury or

death.

As shown, a normally-closed safety contact (i.e., a safety contact

that is closed when the actuator is engaged) from each of two

safety switches per interlock guard must connect to a 2-channel

safety module or safety interface to achieve a control reliable inter-

face to the master stop control elements of a machine. Examples

of appropriate safety modules include 2-channel emergency stop

(E-stop) safety modules and gate monitor safety modules.

Two functions of the safety module or safety interface are to:

1. provide a means of monitoring the contacts of both safety

switches for contact failure, and to prevent the machine from

restarting if either switch fails; and

2. provide a reset routine after closing the guard and returning

the safety switch contacts to their closed position. This pre-

vents the controlled machinery from restarting by simply

closing the guard. This necessary reset function is required

by ANSI B11 and NFPA 79 machine safety standards.

Use only the positively driven, normally closed safety contact (be-

tween pins 1 and 2) from each switch for connection to the safety

module. A typical use is to communicate with a process controller.

Refer to the installation instructions provided with the safety mod-

ules for more information regarding the interface of the safety mod-

ule to the machine stop control elements.

Safety Switch

Input Channel

2-channel Safety Module

(2-channel E-stop Module

2-channel Gate Monitor Module, etc.)

Single gate

or guard

Figure 2. Hinge Wiring to Safety Module

Connect two redundant safety switches per interlock guard to an

appropriate 2-channel input safety module.

Refer to the installation instructions provided with the safety mod-

ule for information regarding the interface of the safety module to

the machine stop control elements.

Periodic Checks

A designated person should perform the following safety switch checks at each shift change or machine setup.

A designated person is identified in writing by the employer as being appropriately trained to perform a specified checkout procedure.

1. Check the switch body for damaged or broken parts.

2. Confirm the safety switch is not being used as an end stop.

3. Verify it is not possible to reach any hazard point through an opened guard (or any opening) before hazardous machine motion has

completely stopped.

4. Verify the hinge swings freely throughout its total operating range.

5. Tighten any loosened mounting hardware.

6. Check for signs of deterioration or damage.

7. Check for signs of tampering or defeat to the switch or to the wiring interface to the machine.

Repairs

Do not attempt any repairs to the Module. It contains no field-replaceable components. Return it to the factory for warranty repair

or replacement by contacting Banner Factory Application Engineering. They will attempt to troubleshoot the system from your description

of the problem. If they conclude a component is defective, they will issue a return merchandise authorization (RMA) number for your

paperwork and give you the proper shipping address.

Pack the Module carefully. Damage that occurs in return shipping is not covered by warranty.

Hinge Wing Safety Interlock Switches

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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.

Specifications

Contact Rating

3A @ 250V ac max., 0.5 A @ 60V dc max.

2.5 kV max. transient tolerance

NEMA A300 P300

European Rating

Utilization categories: AC15 and DC13 (IEC 90497-5-1)

Ui = 250V ac

Ith = 3A

Short Circuit Protection

6 amp Slow Blow, 10 amp Fast Blow. Recommended

external fusing or overload protection.

Wire Connections

4-pin Micro-style quick-disconnect (QD) fitting. Cables

are ordered separately; see Accessories.

Weight

0.40 kg (0.88 lb)

Minimum Switching Speed

20 operations per minute

Mechanical Life

1 million operations

Force Exerted by Guard per Switch

Axial: 750 N (165 lbf) max.

Radial: 1000 N (220 lbf) max.

Operating Range

0° to 180°

Construction

Zinc Die-cast (GD-Zn)

Environmental Rating

NEMA 4, IEC IP67

Operating Conditions

Temperature: -25° to +70° C (-13° to +158° F)

Application Notes: To avoid excessive radial stress in applica-

tions containing large doors, the hinge switch should be mounted

either in pairs of two, or in conjunction with a blank hinge (see

page 7).

Certifications:

Dimensions

Model SI-HG80DQD Model SI-HG80DQDR

80.0 mm

(3.15")

64.0 mm

(2.52")

72.0 mm

(2.83")

15.0 mm (0.59")

11.0 mm (0.43")

16.0 mm (.63")

10.0 mm (0.39")

4.5 mm

(0.18")

10.0 mm

(0.39")

M12 x 1

19.0 mm

(0.75")

15.5 mm

(0.61)

4x 6.5 mm

(0.25")

2 x 10.5 mm

(0.41")

17.0 mm (0.67")

10.0 mm

(0.39")

23.6 mm

(0.93")

M12 x 1

Note: 18 mm Hole Recommended

19.0 mm

(0.75")

15.5 mmR9.0 mm

21.0 mm

(0.83")

11.5 mm

(0.45")

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Accessories

4-Pin Micro-Style Cordsets

Model Length Style Dimensions Pinout

MQEAC-406 1.83 m (6 ft)

Straight

M12 x 1

ø14.5 mm

(0.57")

42 mm Typ.

(1.65")

1 = Red/Black

2 = Red/White

3 = Red

4 = Green

MQEAC-415 4.57 m (15 ft)

MQEAC-430 9.14 m (30 ft)

MQEAC-406RA 1.83 m (6 ft)

Right-Angle

32 mm Typ.

(1.26")

M12 x 1

ø 14.5 mm

(0.57")

28 mm Typ.

(1.1")

MQEAC-415RA 4.57 m (15 ft)

MQEAC-430RA 9.14 m (30 ft)

Blank Hinge

Model Description Dimensions

SI-HG80A Same mechanical specifications as SI-HG80

Series Hinge Switches

80.0 mm

(3.15")

64.0 mm

(2.52")

72.0 mm

(2.83")

15.0 mm (0.59")

11.0 mm (0.43")

16.0 mm (.63")

10.0 mm (0.39")

4.5 mm

(0.18")

10.0 mm

(0.39")

19.0 mm

(0.75")

15.5 mm

4x 6.5 mm

(0.25")

2 x 10.5 mm

(0.41")

R9.0 mm

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.

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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.

Hinge Wing Safety Interlock Switches