EM-T-7A - BANNER ENGINEERING

Model EM-T-7A Extension Module

One- or two-channel control for use with a Primary Safety Device

Printed in USA P/N 54208B0B

Features

• Extension Module provides additional safety outputs for a Primary Safety Device

(for example, an E-stop Safety Module or a 2-hand control module), if controlled

and monitored by this device

• Features four 6-amp switching channels for connection to control-reliable machine

power interrupt circuits

• Four redundant output channels

• Contact status outputs are provided for connection to the Primary Safety Device’s

monitoring input

• 24V dc operation

• Housed in a narrow, 22.5 mm (0.9") DIN-rail-mountable module

• Convenient plug-in terminal blocks

• Design complies with standards UL 991 and EN 60204

Description

The model EM-T-7A Extension Module provides additional forced-guided (positive-

guided) relay contacts for a Primary Safety Device, such as an E-stop Safety Module or

a two-hand-control module. Controlled by the safety outputs of the Primary Safety

Device, the EM-T-7A Extension Module provides four redundant outputs. These outputs

may be connected to control-reliable machine power interrupt circuits. Each of the four

Extension Module outputs is a series connection of two forced-guided relay contacts

(K1 and K2 in Figure 3).

The outputs of the Extension Module follow the action of the safety outputs from the

Primary Safety Device which control it, within a switching delay time of approximately

20 milliseconds. The Extension Module’s four outputs are each rated for up to 250V

ac/dc at up to 6A.

The Extension Module offers an output circuit at terminals Y1 and Y2 which provides

K1 and K2 contact status information for connection to the monitoring input of the

Primary Safety Device (see Figure 3). This monitoring circuit prevents the Primary

Safety Device from being reset if contacts of either K1 or K2 of the Extension Module

fail in a shorted condition.

The Extension Module has indicators for input power (green), and status of internal

relays (K1 and K2, both green) (see Figure 1). There are no adjustments and no user-

serviceable parts. See page 6 for information regarding repair service.

WARNING . . . This Extension Module is not a point-of-operation guarding device, as defined by OSHA

regulations. It is necessary to install point-of-operation guarding devices, such as safety light curtains and/or

hard guards, to protect personnel from hazardous machinery. Failure to install point-of-operation guards on

hazardous machinery could lead to serious injury or death.

Extension Module – Model EM-T-7A

page 2

Banner Engineering Corp. • Minneapolis, U.S.A.

Website: http://www.baneng.com • Tel: 888.373.6767

IMPORTANT NOTICE . . . Read this page before proceeding!

Banner Engineering Corp. has made every effort to provide complete application, installation, operation, and maintenance

instructions. In addition, any questions regarding the use or installation of this Banner Extension Module should be directed to

the factory applications department at the telephone numbers or addresses shown on the back cover.

The user shall ensure that all machine operators, maintenance personnel, electricians, and supervisors are thoroughly familiar

with and understand all instructions regarding the installation, maintenance, and use of this Extension Module, and with the

machinery it controls.

The user and any personnel involved with the installation and use of this Extension Module must be thoroughly familiar with

all applicable ANSI/NFPA standards. The standards, listed below, directly address the use of Primary Safety Devices, by

which the Extension Module can be controlled. 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 Extension Module in any particular application are satisfied. Extreme care is urged that all legal requirements have been met

and that all installation and maintenance instructions contained in this manual are followed.

U. S. Standards Applicable to Use of Primary Safety Devices

ANSI B11 Standards for Machine Tools “Safety Requirements for the Construction, Care and Use”

Available from: Safety Director

AMT – The Association for Manufacturing Technology

7901 Westpark Drive

McLean, VA 22101-4269

Tel.: 703-827-5266

NFPA 79 “Electrical Standard for Industrial Machinery (1997)”

Available from: National Fire Protection Association

1 Batterymarch Park, P.O. Box 9101

Quincy, MA 02269-9101

Tel.: 800-344-3555

ANSI/RIA R15.06 “Safety Requirements for Industrial Robots and Robot Systems”

Available from: Robotic Industries Association

900 Victors Way, P.O. Box 3724

Ann Arbor, MI 48106

Tel.: 734-994-6088

European Standards Applicable to Use of Primary Safety Devices

EN 292-1 “Safety of Machinery – Basic Concepts, General Principles for Design

Part 1: Basic Terminology, Methodology”

EN 292-2 “Safety of Machinery – Basic Concepts, General Principles for Design

Part 2: Technical Principles and Specifications”

EN 60204-1 “Electrical Equipment of Machines: Part 1: General Requirements”

Also, request a type “C” standard for your specific machinery.

EN 418 “Safety of Machinery – Emergency Stop Equipment Functional Aspects, Principles for Design”

Available from: Global Engineering Documents

15 Inverness Way East

Englewood, CO 80112-5704

Tel.: 800-854-7179

Extension Module – Model EM-T-7A

page 3

Banner Engineering Corp. • Minneapolis, U.S.A.

Website: http://www.baneng.com • Tel: 888.373.6767

Supply Protection Circuitry

Application Notes There are no adjustments and no user-serviceable parts. See page 6 for information regarding repair service.

Protected against transient voltages and reverse polarity

Output Configuration Four output channels:

Each channel is a series connection of two forced-guided (positive-guided) relay contacts –

AgNi, gold-flashed

Contact ratings:

Maximum voltage: 250V ac/dc

Maximum current: 6 A ac/dc

Minimum current: 30 mA @ 24V dc

Maximum power: 1500VA, 200 W

Mechanical life: 50,000,000 operations

Electrical life: 100,000 at full resistive load

Feedback contact rating (Y1-Y2): 24V dc @ 0.5A

NOTE: Transient suppression is recommended when switching inductive loads. Install suppressors

across load. Never install suppressors across output contacts (see Warning, page 5).

Output Response Time 20 milliseconds maximum (if channel u-k fails, maximum response time is 200 milliseconds)

Status Indicators 3 green LED indicators:

Power ON

K1 energized

K2 energized

Input Requirements Inputs from Primary Safety Device must each be capable of switching 30 to 250mA @ 13 to 28V dc.

Construction Polycarbonate housing.

Mounting Mounts to standard 35 mm DIN-rail track.

Vibration Resistance 10 to 55Hz @ 0.35 mm displacement per IEC 68-2-6

Operating Temperature 0° to +50°C (+32° to 122°F)

Supply Voltage and Current A1-A2: 24V dc, +/-15%, 10% maximum ripple

Model EM-T-7A Specifications

Environmental Rating Rated NEMA 1, IEC IP20. Extension Module must be installed inside an enclosure rated NEMA 3 (IEC

IP54), or better.

Machine

Safety

EM-T-7A

A1 Y1 K1

23 33 43

Power

Ch.1

Ch.2

UY2A2

14 24 34 44

118.0 mm

(4.65")

84.0 mm

(3.31")

22.5 mm

(0.89")

Figure 2. Extension Module enclosure dimensions

Machine

Safety

EM-T-7A

A1 Y1 K1

23 33 43

Power

Ch.1

Ch.2

UY2A2

14 24 34 44

Input Power

K1 Energized

K2 Energized

Figure 1. EM-T-7A status indicators

Certifications

Extension Module – Model EM-T-7A

page 4

Banner Engineering Corp. • Minneapolis, U.S.A.

Website: http://www.baneng.com • Tel: 888.373.6767

Installation

Primary Safety Device Requirements

Model EM-T-7A Extension Module is driven by one or two safety output channels of a

Primary Safety Device. The design of the Primary Safety Device must meet OSHA and

ANSI control reliability requirements. The EM-T-7A must be used ONLY with Primary

Safety Devices which have a dedicated input for feedback monitor contacts (see hookup

diagrams).

Each output channel of the Primary Safety Device must meet the following

requirements:

• Include two (or more) redundant, normally open forced-guided (positive-guided)

contacts,

• Be self-monitored to result in a safe (open) condition in the event of a contact failure,

and

• Be capable of switching 30 to 250 mA at 13 to 28V dc.

Mechanical Installation

The model EM-T-7A Extension Module must be installed inside an enclosure. It is not

designed for exposed wiring. It is the user’s responsibility to house the Extension Module in

an enclosure with NEMA 3 (IEC IP54) rating, or better.

Dimensions of the Extension Module are shown in Figure 2; it mounts directly to standard

35mm DIN rail.

Electrical Installation

As the Extension Module can be used with many different Primary Safety Devices and can

interface to a multitude of machine control configurations, it is not possible to give exact

wiring instructions for the output contacts. The following guidelines are general in nature.

The output contacts of the Extension Module have no delay function. They will open within

20 milliseconds from the time that the controlling contacts coming from the Primary

Safety Device open.

IMPORTANT: Review the following discussion of one-channel and two-channel control

before connecting the Extension Module to its Primary Safety Device.

CAUTION . . .

Dangerous Voltages

Always disconnect all power from the

Extension Module, the Primary Safety

Device, and from the machine being

controlled before making any wire

connections. Electrical installation and

wiring must be made by qualified

personnel and must comply with the NEC

(National Electrical Code), EN 60204-1

and -2, and all applicable local standards

and codes.

WARNING . . . Not for

Use As a Stand-Alone

Safety Relay

1) DO NOT connect E-stop switches,

2-hand-control switches, safety

interlock switches, or similar devices

directly to this Extension Module.

2) ALWAYS connect terminals Y1 and Y2

of this Extension Module to the

monitoring input of the Primary

Safety Device that controls it (see

Figure 3).

This Extension Module does not have the

circuitry required to perform a self-check. A

single fault inside the unit or in external

devices like switches or E-Stop buttons

connected to the unit can go undetected

and create an unsafe condition. Failure to

properly connect this Extension Module to

a control-reliable Primary Safety Device

could result in serious injury or death.

Extension Module – Model EM-T-7A

page 5

Banner Engineering Corp. • Minneapolis, U.S.A.

Website: http://www.baneng.com • Tel: 888.373.6767

WARNING . . .

Use of Arc Suppressors

If arc suppressors are used,

they MUST be installed as shown across

the actuator coil of the master stop

control elements (MSC1 to MSC4).

NEVER install suppressors directly

across the output contacts of the

Extension Module. It is possible for

suppressors to fail as a short circuit. If

installed directly across the output

contacts of the Extension Module, a

short-circuited suppressor will create an

unsafe condition which could result in

serious injury or death.

WARNING . . .

Maintain Control Reliability

NEVER wire an intermediate

device (e.g., a programmable logic

controller/ PLC), other than a safety

relay, between any safety output of the

Extension Module and the master stop

control element it switches. To do so

sacrifices the control reliability of the

control-to-machine interface, and creates

an unsafe condition which could result in

serious injury or death. Whenever a

safety relay is added as an intermediate

switching device, a normally-closed

forced-guided monitor contact of that

relay must be added to the series

feedback loop.

(Reference ANSI B11.1 – 1988,

Appendix B4)

23 33 43

14 24 34 44

EM-T-7A

+24

V dc

Machine Control Circuit

Primary

Safety

Device

Monitoring Contact

Feedback Input

Monitoring Contact

Feedback Input

A1 KY1

MSC1

MSC Monitor Contacts

MSC2 MSC3 MSC4

MSC1

MSC2

MSC3

MSC4

Machine

Master Stop

Control Elements

*Arc Suppressors

(See Warning)

U Y2

Figure 3. Generalized EM-T-7A Hookup for One-Channel Control

NOTE:

This hookup is general in

nature. Your specific hookup

may vary significantly,

depending on the Primary

Safety Device used and the

machine control configuration.

One-Channel Control (Figure 3)

One-channel control affords simplicity of wiring. However, one-channel wiring requires

eliminating the possibility of an unsafe failure of the control wires (which connect the

output of the Primary Safety Device to the input of the Extension Module). One of the

ways to reduce the probability of such failure is to locate the Primary Safety Device

adjacent to the Extension Module in the same enclosure.

The output of the Primary Safety Device must consist of two or more series-connected,

normally open contacts, coming from forced-guided safety relays. These contacts

must be monitored for failure by the Primary Safety Device. In addition, a single contact

failure cannot prevent normal stopping action, and a successive cycle cannot be

initiated until the failure has been corrected. An example of this type of output is any

single output channel of a Banner E-stop safety module.

Extension Module – Model EM-T-7A

page 6

Banner Engineering Corp. • Minneapolis, U.S.A.

Website: http://www.baneng.com •Tel: 888.373.6767

Two-Channel Control (Figure 4)

Two-channel control allows the Primary Safety Device to detect an unsafe failure of the

control wires. Two-channel control should be used whenever unsafe failure of the

control wires cannot be eliminated.

The outputs of the Primary Safety Device must each be normally open, forced-guided

contacts from redundant safety relays. These contacts must be monitored for failure by

the Primary Safety Device. In addition, a single contact failure cannot prevent normal

stopping action, and a successive cycle cannot be initiated until the failure has been

corrected.

Connection to the Machine to be Controlled

The hookup diagrams in Figures 3 and 4 show a generic connection of the four safety

output channels of the Extension Module to Master Stop Control Elements MSC1

through MSC4. A Master Stop Control Element is defined as an electrically powered

device, external to the Extension Module, which stops the machinery being controlled

by immediate removal of electrical power to the machine and (when necessary) by

applying braking to dangerous motion (reference ANSI B11.19, section 5.2: “Stop

Control”). To achieve control reliability, two redundant MSCs are required to control

each machine hazard.

23 33 43

14 24 34 44

EM-T-7A

+24

V dc 0

V dc

Machine Control Circuit

Primary

Safety

Device

Monitoring Contact

Feedback Input

Monitoring Contact

Feedback Input

A1 KY1

MSC1

MSC Monitor Contacts

MSC2 MSC3 MSC4

MSC1

MSC2

MSC3

MSC4

Machine

Master Stop

Control Elements

*Arc Suppressors

(See Warning)

U Y2 A2

Figure 4. Generalized EM-T-7A Hookup for Two-Channel Control

NOTE:

This hookup is general in

nature. Your specific hookup

may vary significantly,

depending on the Primary

Safety Device used and the

machine control configuration.

NOTICE regarding MSCs

To achieve control reliability, two

redundant Master Stop Control

Elements (MSCs) are required to

control each machine hazard. Each

MSC must be capable of

immediately stopping the dangerous

machine motion, irrespective of the

state of the other. Some machines

offer only one primary control

element. For such machines, it is

necessary to duplicate the circuit of

the single MSC to add a second

MSC.

MSCs must offer at least one

forced-guided auxiliary contact

which is wired to the monitoring

contact feedback input of the

Primary Safety Device (see hookup

diagrams).

Extension Module – Model EM-T-7A

page 7

Banner Engineering Corp. • Minneapolis, U.S.A.

Website: http://www.baneng.com •Tel: 888.373.6767

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 Extension Module

wiring barriers whenever power to the

machine control elements is ON.

Exercise extreme caution whenever

machine control power is or may be

present.

To satisfy the requirements of control reliability, all MSCs must offer at least one normally

closed forced-guided monitor contact. One normally closed monitor contact from each

MSC is wired in series to the monitoring contact feedback input of the Primary Safety

Device, as shown in Figures 3 and 4. In operation, if one of the switching contacts of any

MSC fails in the shorted condition, the associated monitor contact will remain open. As a

result, it will not be possible to reset the Primary Safety Device.

Many types of mechanisms are used to arrest dangerous machine motion. Examples

include mechanical braking systems, clutch mechanisms, and combinations of brakes

and clutches. Additionally, control of the arresting scheme may be hydraulic or

pneumatic. As a result, an MSC may be one of several control types, including a wide

variety of contactors and electromechanical valves. If your machine documentation

leaves any doubt about the proper connection points for the Extension Module output

contacts, do not make any connections. Contact the machine builder for clarification

regarding connection to the MSCs.

Initial Checkout Procedure

NOTE: The Extension Module can only be used safely when its operation is controlled

via an appropriate Primary Safety Device, connected to the Extension Module

according to wiring diagrams shown in Figure 3 or 4.

Checkout procedure:

1) Remove the power controlling and switched by the machine control elements (see

Caution at left).

2) Verify that the Primary Safety Device which will be controlling the Extension

Module is operating correctly, according to its product documentation and

manufacturer’s recommendations.

3) Confirm proper connection of the Extension Module to the controlling Primary

Safety Device according to the wiring diagram (see Figures 3 and 4).

4) Verify that all four Extension Module output contacts follow exactly the operation of

the safety output contacts of the controlling Primary Safety Device, when the

Primary Safety Device is operated according to its product documentation and

manufacturer’s recommendations.

WARNING . . . MSC Monitoring

All Master Stop Control elements (MSCs), such as control relays, must be of forced-guided, captive contact design to

allow the MSC Monitoring circuit to detect unsafe failures within the master stop control elements. This monitoring

extends the safe switching point of the Primary Safety Device and the EM-T-7A Extension Module to the MSC elements. For this

monitoring to be effective, it is required that a minimum of two redundant MSCs control each hazard. This is to detect the unsafe failure

of one MSC (e.g. a welded contact), while stopping the hazard and preventing a successive machine cycle with the second MSC.

If the MSCs are the last electrically controlled device generating the hazard (i.e. not relays or contactors) and do not have forced-

guided, captive contacts to monitor, then the customer must ensure that failure or fault of any single component of the MSCs will not

result in a hazardous situation and will prevent a successive machine cycle.

NOTE: MSC Monitoring is also called External Device Monitoring (EDM), MPCE Feedback, and relay backchecking.

Extension Module – Model EM-T-7A

Banner Engineering Corp., 9714 Tenth Ave. No., Minneapolis, MN 55441 • Phone: 888.373.6767 • http://www.baneng.com • Email: sensors@baneng.com

WARRANTY: Banner Engineering Corp. warrants its products to be free from defects for one year. Banner Engineering Corp. will repair or

replace, free of charge, any product of its manufacture found to be defective at the time it is returned to the factory during the warranty period.

This warranty does not cover damage or liability for the improper application of Banner products. This warranty is in lieu of any other warranty

either expressed or implied.

Periodic Checkout

The checkout procedure described on page 7 should be performed according to the

intervals specified by the product documentation of the Primary Safety Device

controlling this Extension Module.

Repairs

Do not attempt any repairs to the EM-T-7A Extension Module. It contains no field-

replaceable components. Return the Extension Module to the factory for warranty

repair or replacement.

If it ever becomes necessary to return an Extension Module to the factory, please do

the following:

1) Contact the Banner Factory Application Engineering Group at the addresses or at

the numbers listed at the bottom of page 8. 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 Extension Module carefully. Damage which occurs in return shipping is

not covered by warranty.