models im-t-9a and im-t-11a interface modules

Models IM-T-9A and IM-T-11A Interface ModulesInterface Modules for use with a Primary Safety Device

Printed in USA 11/02 P/N 62822 rev. B

Interface Module Features

• Interface Modules provide isolated safety output contacts for a Primary SafetyDevice (for example, a safety light screen or safety control module) which has solid-state or hard contact outputs and external device monitoring (EDM)capability.

• Model IM-T-9A features three normally open 6 amp redundant-output channels.

• Model IM-T-11A features two normally open redundant-output channels and onenormally closed non-safety auxiliary output channel, all rated at 6 amps.

• Normally closed outputs for connection to the Primary Safety Device’s monitoringinput.

• 24V dc operation

• 22.5 mm (0.9") DIN-rail-mountable housing

• Convenient plug-in terminal blocks

Interface Module Description

Interface Modules IM-T-9A and IM-T-11A operate on 24V dc inputs and provideisolated redundant output channels for interfacing dc safety controls (such as safetylight screens or other safety control modules) to ac safety circuits. These modules canalso be used to increase the switching current capacity of safety controls with lowcurrent output rating (see Figures 6, 8, and 9).

The outputs of the Interface Module will follow the action of the safety outputs from thePrimary Safety Device which control it, within a 20 millisecond switching delay time.The Interface Module’s normally open outputs each are rated for up to 250V ac/dc at upto 6 amps.

The Interface Modules offer two normally closed output contacts, Y1-Y2 and Y3-Y4,which provide K1 and K2 status information for connection to the External DeviceMonitoring (EDM) input of the Primary Safety Device (see Figures 5 through 9). Thismonitoring circuit allows the Primary Safety Device to detect failures of the InterfaceModule.

Two green indicator LEDs on the front of each Interface Module indicate the outputstatus of internal relays K1 and K2.

WARNING . . . This Interface Module is not a point-of-operation guarding device, as defined by OSHAregulations. It is necessary to install point-of-operation guarding devices, such as safety light screens and/orhard guards, to protect personnel from hazardous machinery. Failure to install point-of-operation guards onhazardous machinery could lead to serious injury or death.

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WARNING . . .Use Only withindependently testedand safety-certifiedsafety light screensor safety controlmodules.

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Interface Modules – Models IM-T-9A and IM-T-11A

2 P/N 62822 rev. B

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

IMPORTANT NOTICE . . . Read this page before proceeding!Banner Engineering Corp. has made every effort to provide complete application, installation, operation, and maintenanceinstructions. In addition, any questions regarding the use or installation of this Banner Interface Module should be directed to thefactory 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 familiarwith and understand all instructions regarding the installation, maintenance, and use of this Interface Module, and with themachinery it controls.

The user and any personnel involved with the installation and use of this Interface Module must be thoroughly familiar withall applicable ANSI/NFPA standards. The standards, listed below, directly address the use of Primary Safety Devices, bywhich the Interface Module can be controlled. Banner Engineering Corp. makes no claim regarding a specificrecommendation of any organization, the accuracy or effectiveness of any information provided, or the appropriateness ofthe 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 ofthis Interface Module in any particular application are satisfied. Extreme care is urged that all legal requirements have been metand 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 Technology7901 Westpark DriveMcLean, VA 22102Tel.: 703-893-2900Fax: 703-893-1151

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

Available from: National Fire Protection Association1 Batterymarch Park, P.O. Box 9101Quincy, MA 02269-9101Tel.: 800-344-3555

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

Available from: Robotic Industries Association900 Victors Way, P.O. Box 3724Ann Arbor, MI 48106Tel.: 734-994-6088

European Standards Applicable to Use of Primary Safety Devices

ISO 12100-1 (EN 292-1) “Safety of Machinery – Basic Concepts, General Principles for DesignPart 1: Basic Terminology, Methodology”

ISO 12100-2 (EN 292-2) “Safety of Machinery – Basic Concepts, General Principles for DesignPart 2: Technical Principles and Specifications”

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

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

Available from: Global Engineering Documents15 Inverness Way EastEnglewood, CO 80112-5704Tel.: 800-854-7179

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P/N 62822 rev. B 3Banner Engineering Corp. • Minneapolis, MN U.S.A.

www.bannerengineering.com • Tel: 763.544.3164

Models IM-T-9A and IM-T-11A Specifications

Supply Protection Circuitry Protected against transient voltages.

Output Configuration IM-T-9A: 3 normally open output channelsIM-T-11A: 2 normally open output channels and 1 normally closed auxiliary output channel.Each normally open output channel is a series connection of contacts from two forced-guided (positive-guided) relays, K1-K2.The normally closed contact 31-32 is a parallel connection of contacts from K1-K2.Contacts: AgNi, 5 µm gold-platedLow Current Rating:Caution: The 5 µm gold-plated contacts allow the switching of low current/low voltage. In these low-

power applications, multiple contacts can also be switched in series (e.g., “dry switching”).To preserve the gold plating on the contacts, the following max. values should not be exceeded at any time:

Min. voltage: 1V ac/dc Max. voltage: 60VMin. current: 5 mA ac/dc Max. current: 300 mAMin. power: 5 mW (5 mVA) Max. power: 7 W (7 VA)

High Current Rating:If higher loads must be switched through one or more of the contacts, the minimum and maximum valuesof the contact(s) changes to:

Min. voltage: 15V ac/dc Max. voltage: 250V ac/dcMin. current: 250 mA ac/dc Max. current: 6 AMin. power: 5 W (5 VA) Max. power: 200 W (1,500 VA)

Mechanical life: 50,000,000 operationsElectrical life: 150,000 operations (typical, @ 200 W (1,500 VA) switched power, resistive load)Feedback contact rating (Y1-Y2, Y3-Y4):

Min. voltage: 1V ac/dc Max. voltage: 60VMin. current: 5 mA ac/dc Max. current: 300 mAMin. power: 5 mW (5 mVA) Max. power: 7 W (7 VA)

Note: Transient suppression is recommended when switching inductive loads. Install suppressorsacross load. Never install suppressors across output contacts (see Warning, page 6).

Input Voltage and Current 24V dc, +/-15% no polarity, 10% maximum ripple; 50 mA per input channelPower consumption: approximately 2.4 W

Output Response Time 20 milliseconds maximum

Status Indicators 2 green LED indicators:K1 energizedK2 energized

Construction Polycarbonate housing.

Environmental Rating Rated NEMA 1, IEC IP20. Interface Module must be installed inside an enclosure rated NEMA 3 (IECIP54), or better.

Mounting Mounts to standard 35 mm DIN-rail track.

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

Operating Conditions Temperature: 0° to +50°C (+32° to 122°F)Max. Relative Humidity: 90% @ 50°C (non-condensing)Heat Dissipation Considerations: See “Mechanical Installation” on page 5.

Application Notes There are no adjustments and no user-serviceable parts. See page 11 for information regarding repair service.

Certifications Approvals are in process.


4 P/N 62822 rev. B


Definitions

Final Switching Device (FSD): The component of the machine’s safety-related controlsystem that interrupts the circuit to the machine primary control element (MPCE) whenthe output signal switching device (OSSD) goes to the OFF-state.

Output Signal Switching Device (OSSD): The component of the electro-sensitiveprotective equipment (ESPE) connected to the control system of the machine which,when the sensing device is actuated during normal operation, responds by going to theOFF-state.

118.0 mm(4.65")

84.0 mm(3.31")

22.5 mm(0.89")

MachineSafety

IM-T-9A

13S1 S2 Y1

23 33

K1

K2

Y2

Ch.1

Ch.2

Y3 S3 S4Y4 14 24 34

Figure 2. Interface Module enclosure dimensions

Figure 1. Interface Module status indicators

K2

MachineSafety

IM-T-9A

13S1 S2 Y1

23 33

K1

K2

Y2

Ch.1

Ch.2

Y3 S3 S4Y4 14 24 34

13S1 S2 Y1

31 23

K1

K2

Y2

Ch.1

Ch.2

Y3 S3 S4Y4 14 32 24

MachineSafety

IM-T-11A

K1 Energized

K2 Energized

IM-T-9A IM-T-11A




WARNING . . . Not forUse As a Stand-AloneSafety Module

1) DO NOT connect E-stop switches,2-hand-control switches, safetyinterlock switches, or similardevices directly to this InterfaceModule.

2) ALWAYS connect terminalsY1-Y2 and Y3-Y4 of this InterfaceModule to the monitoring input ofthe Primary Safety Device thatcontrols it (see Figures 4 through 9).

This Module does not have the circuitryrequired to perform a self-check. Asingle fault inside the unit or in externaldevices (like switches or E-stop buttons)can go undetected and create an unsafecondition. Failure to properly connectthis Interface Module to a control-reliable Primary Safety Device couldresult in serious injury or death.

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Primary Safety Device Requirements

Interface Modules IM-T-9A and IM-T-11A are driven by two safety output channels of aPrimary Safety Device. The design of the Primary Safety Device must meet OSHA andANSI control reliability requirements. These Interface Modules must be used only withPrimary Safety Devices which have External Device monitoring capability (see Figures 5through 9 and the Warning on page 10).

Each output channel of the Primary Safety Device must:

• Include one normally open forced-guided (positive guided) contact (FSD), or

• Include one solid-state 24V dc sourcing safety output (OSSD), and

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

• Be capable of switching 50 mA @ 24V dc ± 15%.

NOTE: As OSSD solid-state outputs on Primary Safety Devices very often are pulsed, itis possible that the relay coils will produce an audible buzzing. This relay buzzingdoes not affect the function of the Interface Module, as long as the pulse widthis below 500 µs (microseconds) and the duty cycle (t1) is greater than 500.

t2

Mechanical Installation

The Interface Modules must be installed inside an enclosure. They are not designed forexposed wiring. It is the user’s responsibility to house the Interface Modules in anenclosure with NEMA 3 (IEC IP54) rating or better.

Dimensions of either Interface Module are shown in Figure 2; they mount directly tostandard 35 mm DIN rail.For reliable operation, the user must ensure that the operating specifications are notexceeded. The enclosure must provide adequate heat dissipation, so that the air closelysurrounding the Module does not exceed its maximum operating temperature. Methodsto reduce heat build-up include venting, forced airflow (e.g., exhaust fans), adequateenclosure exterior surface area, and spacing between modules and other sources ofheat. (See Specifications, Operating Conditions: Temperature.)

t1

1

2

2

+24V dc

0V dc

> 500t

t

t(500µs max.)

Figure 3. Requirements for pulsed output signals from a Primary Safety Device


6 P/N 62822 rev. B


Electrical Installation

As the Interface Modules can be used with many different Primary Safety Devices and caninterface to a multitude of machine control configurations, it is not possible to give exactwiring instructions for the output contacts. The following guidelines are general in nature.

The output contacts of the Interface Module have no delay function. They will open within20 milliseconds from the time that the controlling contacts coming from the PrimarySafety Device open.

WARNING . . .Use of Arc Suppressors

If arc suppressors areused, they MUST be installed acrossthe actuator coil of the machine primarycontrol elements (MPCE1, MPCE2).NEVER install suppressors directlyacross the output contacts of theInterface Module. It is possible forsuppressors to fail as a short circuit. Ifinstalled directly across the outputcontacts of the Interface Module, ashort-circuited suppressor will create anunsafe condition which could result inserious injury or death.

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CAUTION . . .Dangerous Voltages

Always disconnect all power from theInterface Module, the Primary SafetyDevice, and the machine beingcontrolled before making any wireconnections. Electrical installation andwiring must be made by qualifiedpersonnel and must comply with theNEC (National Electrical Code), EN60204-1 and -2, and all applicable localstandards and codes.

Y2

Y1

Y3

13 14

23 24

33 34

IM-T-9A

Y4

S3

K2

S4 S2

K1

S1

Y2

Y1

Y3

13 14

23 24

IM-T-11A

Y4

S3

K2

S4 S2

K1

S1

31 32

Figure 4. Interface Module pin-outs




Safety Output

EDM1

EDM2

Safety Output

+24V dc 0V dc

Y2

Y1

Y3

+

13 14

23 24

33 34MachineControl

Feedback (optional)

IM-T-9A

PrimarySafetyDevice

Y4

MPCE1

MPCE2

MPCE2

MPCE1

S3

K2

S4

K1

K2 K1

S2

S1

+

Connection to the Machine To Be Controlled

The hookup diagrams in Figures 5 through 9 show a generic connection of two safetyoutput channels of the Interface Module to Machine Primary Control Elements MPCE1and MPCE2. A Machine Primary Control Element is an electrically powered device,external to the Interface Module, which stops the machinery being controlled byimmediately removing electrical power from the machine and (when necessary) byapplying braking to dangerous motion (reference ANSI B11.19, section 5.2: “StopControl”).

NOTE: Although this hookupshows model IM-T-9A,the hookup for modelIM-T-11A is identical.

Figure 5. Generalized hookup to a 2-channel Primary Safety Device with two current-sourcing safety outputs and two monitoring inputs


8 P/N 62822 rev. B


Figure 7. Generalized hookup to a 2-channel Primary Safety Device with twocurrent-sourcing safety outputs and one monitoring input

Safety Output

Safety Output

EDM2

EDM1

+24V dc 0V dc

Y2

Y1

Y3

13 14

23 24

33 34

MachineControl

Feedback (optional)

IM-T-9A

PrimarySafetyDevice

Y4

S3

K2

S4

MPCE1

MPCE2

MPCE2

MPCE1

S2

K1

K2 K1

S1

EDM

+24V dc 0V dc

14

23 24

Feedback (optional)

IM-T-11A

PrimarySafetyDevice

MPCE1

MPCE2

MPCE2 MPCE1

Y2

Y1

Y3

Y4

SafetyOutput

SafetyOutput

S3

K2

S4

S1

K1

S2

+

+

13

32

31

MachineControl


NOTE: Although this hookupshows model IM-T-11A,the hookup for model IM-T-9A is identical.

NOTICE regarding MPCEsTo achieve control reliability, twoMachine Primary Control Elements(MPCEs) are required to controleach machine hazard. Each MPCEmust be capable of immediatelystopping the dangerous machinemotion, irrespective of the state ofthe other. Some machines offer onlyone primary control element. Forsuch machines, it is necessary toduplicate the circuit of the singleMPCE to add a second MPCE.

MPCEs must offer at least oneforced-guided auxiliary contactwhich is wired to the monitoringcontact feedback input of thePrimary Safety Device (see hookupdiagrams).

Figure 6. Generalized hookup to a 2-channel Primary Safety Device with two hard-contactsafety outputs (FSD1 and FSD2) and two monitoring inputs

CAUTION . . .When FSD1 switches+24V dc and FSD2 switches0V dc (Figures 6 and 8), a

short circuit between the wires leading toS1, S2, S3, and S4 is detectedimmediately and K1 and K2 de-energize.However, a short circuit can result in ahigh current through the FSD1 and FSD2contacts, so the current coming from the24V dc supply connected to FSD1 andFSD2 must be fused or limited to 6 ampsmax. Otherwise, damage to the PrimarySafety Device may result.

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Safety Output

Safety Output

EDM

+24V dc 0V dc

14

23 24

32

MachineControl

Feedback (optional)

IM-T-11A

PrimarySafetyDevice

S3

K2

S4

MPCE1

MPCE2

MPCE2 MPCE1

Y2

Y1

Y3

Y4

K1

S2

S1

13

31

EDM

Safety Output

+24V dc 0V dc

14

23 24

33 34

MachineControl

Feedback (optional)

IM-T-9A

PrimarySafetyDevice

MPCE1

MPCE2

MPCE2 MPCE1

Y2

Y1

Y3

Y4

S3

K2

S4

S1

K1

K2 K1

S2

13

Figure 8. Generalized hookup to a 2-channel Primary Safety Device with two hard-contactsafety outputs (FSD1 and FSD2) and one monitoring input



WARNING . . .Use of Arc Suppressors

If arc suppressors areused, they MUST be installed acrossthe actuator coil of the machine primarycontrol elements (MPCE1, MPCE2).NEVER install suppressors directlyacross the output contacts of theInterface Module. It is possible forsuppressors to fail as a short circuit. Ifinstalled directly across the outputcontacts of the Interface Module, ashort-circuited suppressor will create anunsafe condition which could result inserious injury or death.

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WARNING . . .One-Channel Control

One-channel control, as shown inFigure 9, is only for use when the PSDand the Interface Module are within thesame enclosure. Refer to page 10, One-Channel Control.

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CAUTION . . .Dangerous Voltages

Always disconnect all powerfrom the Interface Module, the PrimarySafety Device, and from the machinebeing controlled before making anywire connections. Electrical installationand wiring must be made by qualifiedpersonnel and must comply with theNEC (National Electrical Code), EN60204-1 and -2, and all applicable localstandards and codes.

Figure 9. Generalized hookup to a Primary Safety Device with one redundant relay safetyoutput (one-channel control) and one monitoring input


10 P/N 62822 rev. B


To satisfy the requirements of control reliability, all MPCEs must offer at least onenormally closed forced-guided monitor contact. One normally closed monitor contactfrom each MPCE is connected to the monitoring contact feedback input of thePrimary Safety Device, as shown in Figures 5, 6, 7, 8, and 9. In operation, if the MPCEfails in the energized condition, the associated monitor contact will remain open. As aresult, the Primary Safety Device will detect the MPCE failure and prevent successivemachine cycles.

Many types of mechanisms are used to arrest dangerous machine motion. Examplesinclude mechanical braking systems, clutch mechanisms, and combinations of brakesand clutches. Additionally, control of the arresting scheme may be hydraulic orpneumatic. As a result, an MPCE may be one of several control types, including awide variety of contactors and electromechanical valves. If your machinedocumentation leaves any doubt about the proper connection points for the InterfaceModule output contacts, do not make any connections. Contact the machine builderfor clarification regarding connection to the MPCEs.

Two-Channel Control (Figures 5, 6, 7 and 8): Two-channel control allows the PrimarySafety Device to detect an unsafe failure of the control wires. Two-channel controlshould be used whenever unsafe failure of the control wires cannot be eliminated.

The outputs of the Primary Safety Device must, at minimum, comply with therequirements described on page 5. These outputs must be monitored for failure by thePrimary Safety Device. In addition, a single output failure cannot prevent normalstopping action, and a successive cycle cannot be initiated until the failure has beencorrected.

One-Channel Control (Figure 9): If the Primary Safety Device offers only oneredundant safety output, a one-channel control may be possible. However, one-channelwiring 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 InterfaceModule). One way to reduce the probability of such failure is to locate the PrimarySafety Device adjacent to the Interface Module, in the same enclosure.

The redundant safety output of the Primary Safety Device must consist of two ormore series-connected, normally open contacts, coming from forced-guided safetyrelays. These contacts must be monitored for failure by the Primary Safety Device. Inaddition, a single contact failure cannot prevent normal stopping action, and asuccessive cycle cannot be initiated until the failure has been corrected. An exampleof this type of output is any safety output channel of a Banner E-stop safety module.

NOTICE regarding MPCEsTo achieve control reliability, twoMachine Primary Control Elements(MPCEs) are required to controleach machine hazard. Each MPCEmust be capable of immediatelystopping the dangerous machinemotion, irrespective of the state ofthe other. Some machines offer onlyone primary control element. Forsuch machines, it is necessary toduplicate the circuit of the singleMPCE to add a second MPCE.

MPCEs must offer at least oneforced-guided auxiliary contactwhich is wired to the monitoringcontact feedback input of thePrimary Safety Device (see hookupdiagrams).

WARNING . . . MPCE MonitoringAll Machine Control Primary Elements (MPCEs), such as control relays, must be of forced-guided, captive contactdesign to allow the MPCE Monitoring circuit to detect unsafe failures within the master stop control elements. Thismonitoring extends the safe switching point of the Primary Safety Device and the IM-T-9A/IM-T-11A Interface Module to

the MPCE elements. For this monitoring to be effective, a minimum of two redundant MPCEs are required to control each hazard. Thisis to detect the unsafe failure of one MPCE (e.g., a welded contact), while stopping the hazard and preventing a successive machinecycle with the second MPCE.

If the MPCEs are the last electrically controlled device generating the hazard (i.e., not relays or contactors) and they do not haveforced-guided, captive contacts to monitor (such as a solenoid), then the user must ensure that failure or fault of any singlecomponent of the MPCEs will prevent a successive machine cycle and will not result in a hazardous situation.

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

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CAUTION . . .Disconnect Power Prior toCheckout

Before performing the initial checkoutprocedure, make certain all power isdisconnected from the machine to becontrolled. Dangerous voltages may bepresent along the Safety ExtensionModule wiring barriers whenever powerto the machine control elements is ON.Exercise extreme caution whenevermachine control power is or may bepresent.

Initial Checkout Procedure

NOTE: The Interface Module can be used safely only when its operation is controlledvia an appropriate Primary Safety Device, connected to the Interface accordingto the wiring diagrams shown in Figures 5, 6, 7, 8 or 9.

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 InterfaceModule is operating correctly, according to its product documentation andmanufacturer’s recommendations.

3) Confirm proper connection of the Interface Module to the controlling PrimarySafety Device according to the wiring diagram.

4) Verify that all Interface Module output contacts follow exactly the operation of thesafety output contacts of the controlling Primary Safety Device, when the PrimarySafety Device is operated according to its product documentation andmanufacturer’s recommendations.

Periodic Checkout

The checkout procedure described above should be performed according to theintervals specified by the product documentation of the Primary Safety Devicecontrolling this Interface Module.

Repairs

NOTE: Do not attempt any repairs to IM-T-9A/IM-T-11A Interface Modules. Theycontain no field-replaceable components. Return the Interface Module to thefactory for warranty repair or replacement.

If it ever becomes necessary to return an Interface Module to the factory, please do thefollowing:

1) Contact the Banner Factory Application Engineering Group at the address or at thenumbers listed on the back cover. They will attempt to troubleshoot the systemfrom your description of the problem. If they conclude that a component isdefective, they will issue an RMA (Return Merchandise Authorization) number foryour paperwork and give you the proper shipping address.

2) Pack the Interface Module carefully. Damage which occurs in return shipping is notcovered by warranty.Figure 10. To remove terminal block, insert

a small screwdriver into the slotas shown, and pry to loosen.

When reinserting aterminal block, takecare to slide thedovetail on theterminal block into theslot on the frame.

Models IM-T-9A and IM-T-11A – Interface Modules

WARRANTY: Banner Engineering Corp. warrants its products to be free from defects for one year. Banner Engineering Corp. will repair orreplace, free of charge, any product of its manufacture found to be defective at the time it is returned to the factory during the warrantyperiod. This warranty does not cover damage or liability for the improper application of Banner products. This warranty is in lieu of anyother warranty either expressed or implied.

Banner Engineering Corp., 9714 Tenth Ave. No., Minneapolis, MN 55441 • Phone: 763.544.3164 • www.bannerengineering.com • [email protected]

P/N 62822 rev. B