Pull Wire and Trip Switch PDF

Revised 14.2.
2012
Contents
Safe-T-Pull (STP-M-C-2) 2
Lanyard Options Guide 4
Safe-T-Pull (stainless Steel) 8
Safe-T-Drift 10
Safe-T-Drift (Stainless Steel) 12
Safe-T-Rip 14
Safe-T-Rip (Stainless Steel) 16
Pull-Safe 18
CS-P Collide Safe 20
Safe-T-Curve 22
Safe-T-Lanyard 24
Safe-T-Lanyard (Vectran) 25
Safe-T-Pull Sign 26
AKLS clamping wedge 28
LWS Lanyard Wire Support 29
Emergency Stop Pullwire Labels 32
Conveyor Products
Leveltec Switches
Miscellaneous Products
Installation & Setting instructions
Standards & Certifcations
Mercury Tilt Switch LP04-S2 34
Mercury Tilt Switch LP04-R 36
Snap Action Tilt Switch LP01 38
Thermo Tilt Switch 40
FT-1000 H.Duty Float Switch 42
FT-2000 H.Duty Float Switch 44
Cable Accessories 46
Viking Nut 48
Sounders & Strobes 49
Lanyard Rope (Calculating lengths) 50
Safe-T-Lanyard (How do they work) 51
Safe-T-Pull (Installation) - new series 52
Safe-T-Pull (wiring digram) 53
Safe-T-Pull (Installation) - old series 55
Safe-T-Pull (Stainless Steel) 56
Safe-T-Drift (Horizontal) 57
Safe-T-Drift (Vertical) 57
Safe-T-Drift (Micro Switch Install) 58
Safe-T-Rip (wiring diagram) 59
Safe-T-Rip (Installation) 60
Safe-T-Rip (wiring diagram) 61
Pull-Safe (Installation) 62
Safe-T-Pull (Standards) 63
Safe-T-Pull (Lanyard Risk Assessment) 66
Safe-T-Drift (Standards) 70
Safe-T-Rip (Standards) 72
Pull-Safe (Standards) 74
2
R&D Technology - Material Handling Catalogue
Safe-T-Pull (STP-M-C-2)
Product Information
Tripping occurs under the following conditions:
(a) One or both trip wires are removed
(b) One or both trip wires are overtensioned
(c) One or both trip wires are activated
(d) Manual trip via reset knob.
The switch cannot be reset unless both trip wires are attached and correctly tensioned,
Manual reset via the external reset knob is required after a trip has occurred.
Tamper Proof Switch Plate Mechanism.
Absolute simplicity in initial setup and adjustment.
Robust non-metallic enclosure.
Simple design ensures low maintenance.
Stainless steel internal compression type springs.
Pull rods 316 stainless steel.
Pull rods have spring loaded external dust protecting boots so the pull rod is always covered for extra seal protection.
Double lip oil seals on pull rods and reset operator for secure dust and weather protection to IP 67.
Non-metallic pull rod bushings.
Positive drive action switching contacts provides mechanical forcing of the trip contacts.
Complies to AS/NZS 3947.5.5: 2000 IEC 60947-5.5: 1997
Three fail safe trip mechanism to ensure safety.
Internal switch connections are fully shrouded for added safety during inspection.
Switches have forced open double break, double make Gold Flashed/Silver contacts for reliable low voltage signalling.
Cam design compensates for pull wire expansion/contraction up to 30mm either side of the set point. Eliminates nuisance tripping
due to vibration.
Pull forces to actuate trip @ 60Nm (6Kg) 90 to pull wire axis and 90Nm (9Kg) along pull wire axis.
Padlock facility provided as standard.
Photograph shows optional
Signal Flag tted.
STP-M-C-2 brochure - Rev A
SAFE - T - PULL
The Pull Wire Switch has been tested to the requirements of AS 1755 - 2000.
Features
Switch features 3 Fail Safe
Trip Modes designed for
high performance levels.
3
www.rdtechnology.com.au
Manufactured in
Australia by
Max 4no + 4nc contacts,
External signal flag,
External light,
Single sided operation, right hand or left hand,
316 stainless steel mounting feet,
Two x M20 stainless steel armoured cable glands,
Gold Plated Fail Safe Contacts.
Matched stainless steel compensation springs for
remote end attachment. P/N STP-E60
To comply with AS1755 - 2000 Clause 2.7.9.1 (f ).
A matched compensation spring must be fitted to
the remote end of the Pull Wire to allow tripping
in both directions.
VARIATIOS
ECLOSLRE SPECIFICATIOS
High Impact PBT/PC
Non Corrosive Material.
U.V Stabilised. (See Valox Specs Sheet)
Flame retarded ASTM.UL94.V-0 (1.6mm)
Resists splash and spillage of most hydrocarbon solvents,
mild acids and strong alkali. (See Valox Specs Sheet)
ISTALLATIO
One centrally mounted switch for every 200m
of pull wire. Consult AS1755 - 2000
for mechanical installation.
SWITCH SETTIGS
Adjust each pull wire until there
is 100mm from the end of the
pull rod to the switch housing.
ORDERIG DETAILS
Standard Switch with 2 NO 2 NC
S.P.D.T Fail Safe Contacts ....................................... STPMC2
With 316 stainless steel mounting feet and
2 NO 2 NC S.P.D.T Fail Safe Contacts ..... STPME2
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4 NO and 4 NC contacts ............................................. 4
External signal flag .............................................................. F
External strobe light ........................................................... S vo|ts
& co|or
Left hand operation only ............................................... LH
Right hand operation only .......................................... RH
Two x M20 stainless steel
armoured cable glands ...................................................... ACGS
Matched SS Compensation Spring .................... STPE60
270
26.5
26.5
175
25
MOUNTING HOLES
4 x 9mm DIA.
TO SUIT 8mm BOLTS.
2 x M20 CONDUIT HOLES
25
120
100
SET POSITION
ADDITIONAL ENTRIES AVAILABLE
132.5
227
INTERNAL
DIMENSIONS
160
26.5
26.5
50
175 200
26.5
85
31
S
W
I
T
C
H

P
L
A
T
E
101
DIMESIOS
GEERAL CHARACTERISTICS
REMOTE ED
Forced Open Snap Action Switches
4 5 0 1 L U , 8 5 0 1 6 N E / C E I h t i w y l p m o C
Rated Insulation voltage Ui V 250V
Rated impulse withstand volt. Uimp V 1500
Rated thermal current lth A 8
Rated operating current le: ac 8A - 250V resistive load,
d a o l e v i t c u d n i V 0 5 2 - A 3
Ambient temperature C -25 +85
Electric shock protection Class II
2 s s a l c n o i t u l l o P
0 1 l a c i n a h c e M s e l c y c e f i L
6
, electrical 5x10
5
Termination type 6.3 x 0.8 faston terminal
R&D Technology Pty Ltd Specialised Engineering Products
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
E: sales@rdtechnology.com.au
website: www.rdtechnology.com.au
4
Easily tailored to suit your business...!
Product Information
Lanyards -
Option Guide
Lanyard options brochure - Rev A
4 x 20mm conduit entries as an option
Lanyard Options Guide
5
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Simply contact R&D Technology to obtain the product that suits you...!!
Note: all information is subject to change & images are for illustration purposes only.
Lanyards - Options Guide
Product Features
Simple design ensuring low maintenance
Robust non-metallic enclosure
Stainless steel internal compression type springs
Pull rods 316 stainless steel
Pull rods have external dust protecting boots for
seal protection
Double lip oil seals on pull rods and reset operator
for secure dust and weather protection to IP 67
General Product Information
Pull wire switch is designed for the use of material
handling conveyor systems.
a. One or both trip wires are removed
b. One or both trip wires are overtensioned
c. One or both trip wires are activated
d. Manual trip via reset knob
Self Resetting Option
Standard unit with 316 stainless steel mounting feet
(Model STP-MB)
Ordering Details
Standard switch STP-MC
With 316 stainless steel mounting feet STP-MB
2 NO and 2 NC contacts -2
External signal ag -F
External strobe light -S + volts
& Colour
Left hand operation only -LH
Right hand operation only -RH
Two x M20 stainless steel armoured
cable glands
-ACGS
Matched SS Compensation Spring STP-H60
Add to Cat No. for variations
The standard switch cannot be reset unless both
trip wires are attached and correctly tensioned.
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
6
Audio visual alarm switch
wired to terminals, complete
with override button wired
back to terminals
Audio visual pre-start warning
with monitoring bug and termi-
nals, Pre-wired to six pin socket
Visual indication complete
with remote isolation switch
V
A
R
I
O
U
S

O
P
T
I
O
N
S
Pre start audio visual alarm
switch wired to terminals
Monitoring bug and
switches wired back to
Terminals, with two contacts
7
Basic non-tension unit,
ftted with non-tension blocks
Visual indication and stainless
steel mounting feet
Monitoring bug and switch-
es wired back to
terminals and sockets
Non tension unit with
monitoring bug and switches
wired back to terminals with
three contacts
Non tension with audio
visual pre-start warning,
pre-wired with sockets and
external signal ag
8
Safe-T-Pull (stainless Steel)
Product Information
(a) One or both trip wires are removed
(b) One or both trip wires are overtensioned
(c) One or both trip wires are activated
The switch cannot be reset unless both trip wires are attached and correctly tensioned,
Tamper Proof Switch Plate Mechanism.
2mm 316 Electro Polished Stainless Steel enclosure.
Stainless steel internal compression type springs.
Pull rods 316 stainless steel.
Pull rods have spring loaded external dust protecting boots so the pull rod is always covered for extra seal protection.
Double lip oil seals on pull rods and reset operator for secure dust and weather protection to IP 67.
Non-metallic pull rod bushings.
Positive drive action switching contacts provides mechanical forcing of the trip contacts.
Complies to AS/NZS 3947.5.5: 2000 IEC 60947-5.5: 1997
Three fail safe trip mechanism to ensure safety.
Internal switch connections are fully shrouded for added safety during inspection.
Switches have forced open double break, double make Gold Flashed/Silver contacts for reliable low voltage signalling.
Cam design compensates for pull wire expansion/contraction up to 30mm either side of the set point. Eliminates nuisance tripping
due to vibration.
Pull forces to actuate trip @ 60Nm (6Kg) 90 to pull wire axis and 90Nm (9Kg) along pull wire axis.
Photograph shows optional Signal Flag tted.
STP-SSB-2 Brochure - Rev A
SAFE - T - PULL
The Pull Wire Switch has been tested to the requirements of AS 1755 - 2000.
Features
Switch features 3 Fail Safe
Trip Modes designed for
high performance levels.
9
Manufactured in
Australia by
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
VARIATIONS REMOTE END
Max 4no + 4nc contacts,
External signal flag,
External lights,
Single sided operation, right hand or left hand,
Gold Plated Fail Safe Contacts.
Matched stainless steel compensation springs for
remote end attachment. P/N STP-E60
To comply with AS1755 - 2000 Clause
2.7.9.1 (f ). A matched compensation spring
must be fitted to the remote end of the Pull
Wire to allow tripping in both directions.
CAT No. STP-SSB
175
ELECTRIC CONTROL PRODUCTS
MADE IN AUSTRALIA
RESET
TRIP
SET
EMERGENCY STOP
130.5
Internal Dimension
26.5
272.5
224
Internal Dimension
120
9.0 Mounting
Holes x 4
26.5
100
SET POSITION
2 x M25 Conduit entries
Extra entries available
200 175
175
56
Internal Dimension
98.5
54.5
S
W
I
T
C
H

P
L
A
T
E
25 25
INSTALLATION
One centrally mounted switch for every 200m
of pull wire. Consult AS1755 - 2000
for mechanical installation.
SWITCH SETTINGS
Adjust each pull wire until there
is 100mm from the end of the
pull rod to the switch housing.
ENCLOSURE SPECIFICATIONS
2mm 316 Electro Polished Stainless Steel.
DIMENSIONS
ORDERING DETAILS
Standard Switch with 2 NO 2 NC
S.P.D.T Fail Safe Contacts .................................. STPSSE2
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4 NO and 4 NC contacts .......................... 4
External signal flag .............................................. F
External strobe light ......................................... S vo|ts & co|or
External tripped indicator light LED vo|ts
(only Red Available)
Left hand operation only ............................ LH
Right hand operation only ....................... RH
Matched SS Compensation Spring ............ STPE60
GENERAL CHARACTERISTICS
Forced Open Snap Action Switches
4 5 0 1 L U , 8 5 0 1 6 N E / C E I h t i w y l p m o C
Rated impulse withstand volt. Uimp V 1500
Rated operating current le: ac 8A - 250V resistive load,
d a o l e v i t c u d n i V 0 5 2 - A 3
2 s s a l c n o i t u l l o P
0 1 l a c i n a h c e M s e l c y c e f i L
6
, electrical 5x10
5
10
Safe-T-Drift
Product Information
Made in Western Australia
BELT MI SALI GNMENT SWI TCH
The Heavy Duty
Belt Misalignment Switch, is made for
applications requiring a unit which caters
for high speed belt applications, having
a pre-warn trip contact and a final trip
contact, both individually adjustable.
Dual operation ( ie. right hand/left hand
is also available) . Its unique spring /
cam operator ensures long, trouble free
operation, in the most severe environmental
situations.
FEATURES
Switch Unit:
Robust UV stable, flame retardant (V0
rating) PBT/PC non corrosive plastic
enclosure to IP67.
All external fixings etc. are 316
Stainless Steel.
Operating shaft bearings are UV stable,
flame retardant PBT/PC plastic, for
long maintenance free operation.
Operating shaft sealing via a double lip
oil seal, with external dust protecting
boot.
90 full movement of operating arm
with easily adjustable switching points
from 5 to 75.
Standard unit has both ALARM &
TRIP micro switches, each with 1no
+1nc change over contacts
Micro switches pre wired to tunnel
terminals.
Roller Arms:
Solid or sprung shaft roller mounting
arms, available either vertical or
horizontal.
Rollers are Stainless Steel, 50mm
diameter with high speed sealed ball
bearings.
Arms are fully adjustable through 360.
Conveyor Bel t
Mi sal i gnment
Swi tch
Photograph displays vertical
roller arm fitted.
Order as separate item.
Conformity
11
Newcastle P: +61 2 4962 1282 F: + 61 2 4962 1522
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4962 1522
Regional QLD P: +61 7 4952 3833 F: + 61 7 4952 3866
Manufactured in
Australia by:
IP67, UV stable, high impact, chemical resistance,
flame retardant (V0) PBT/PC material.
DIMENSIONS
ORDERING DETAILS
NOTE: Order Switch Unit and Roller Arm
Standard Switch STD-P
Dual Switching STD-P-D
Standard Switch w/- spec Terminals STD-P-K
Dual Switching w/- spec Terminals STD-P-D-K
Horizontal Roller Arm STD-HA
Horizontal Sprung Roller Arm STD-HASR
Vertical Roller Arm STD-VA
Vertical Sprung Roller Arm STD-VASR
Other variations available: See price list
SWITCHING CAPACITY PER LOAD (REFERENCE VALUES)
Model Voltage
Non-Inductive Load Inductive Load
Resistive Load Lamp Load Inductive Load Motor Load
NC NO NC NO NC NO NC NO
V-15 250 VAC 15 A 2A 10 A 3 A
8 VDC 15A 4 A 10 A 6 A
30 VDC 10 A 4 A 10 A 4 A
125 VDC 0.6 A 0.1 A 0.6 A 0.1 A
250VDC 0.3 A 0.05 A 0.3 A 0.05 A
Standard Switch STD-P
Adjustable Switching Cams
Alarm
Switch
Standard
Tunnel
Terminals
5mm
Earth Stud
Trip
Switch
13
4 x M6
Mounting
Holes
20mm
Conduit
105
161
28
60
33.5
11
48
32
47
84
BELT
MI SALI GNMENT
SWI TCH
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
12
Product Information
BELT MISALIGNMENT SWITCH
The Heavy Duty
Belt Misalignment Switch, is made for
applications requiring a unit which
caters for high speed belt applications,
having a pre-warn trip contact and a
final trip contact, both individually
adjustable.
Dual operation (ie. right hand / left
hand is also available). Its unique
spring /cam operator ensures long,
trouble free operation, in the most
severe environmental situations.
FEATURES
Switch Unit:
316 2mm electro polished stainless
steel enclosure to IP67.
All external fxings etc. are 316
Stainless Steel.
Operating shaft bearings are UV
stable, fame retardant (V0 rated)
PBT/PC plastic, for long maintenance
free operation.
Operating shaft sealing via a double
lip oil seal, with external dust
protecting boot.
90 full movement of operating arm
with easily adjustable switching
points from 5 to 75.
Standard unit has both ALARM &
TRIP micro switches, each with 1no
+1nc change over contacts
Micro switches pre wired to tunnel
terminals.
Roller Arms:
Solid or sprung shaft roller mounting
arms, available either vertical or
horizontal.
Rollers are Stainless Steel, 50mm
diameter with high speed sealed ball
bearings.
Arms are fully adjustable through
360.
Conveyor Belt
Misalignment
Switch
Photograph displays
vertical
roller arm fitted.
Conformity
For more information
please turn overleaf.
Safe-T-Drift SS brochure- Rev A Safe-T-Drift (Stainless Steel)
13
Newcastle P: +61 2 4014 1000 F: + 61 2 4014 4099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Manufactured in
Australia by:
BELT
MISALIGNMENT
SWITCH
2mm 316 electro polished stainless steel.
DIMENSIONS
ORDERING DETAILS
NOTE: Order Switch Unit and Roller Arm
Standard Switch STD-SSB
D - B S S - D T S g n i h c t i w S l a u D
Standard Switch w/- spec Terminals STD-SSB-K
Dual Switching w/- spec Terminals STD-SSB-D-K
Horizontal Roller Arm STD-HA-SS
Horizontal Sprung Roller Arm STD-HASR-SS
Vertical Roller Arm STD-VA-SS
Vertical Sprung Roller Arm STD-VASR-SS
Other variations available:
SWITCHING CAPACITY PER LOAD (REFERENCE VALUES)
Model Voltage
d a o L e v i t c u d n I d a o L e v i t c u d n I - n o N
Resistive Load Lamp Load Inductive Load Motor Load
NC NO NC NO NC NO NC NO
V-15 250 VAC 15 A 2A 10 A 3 A
8 VDC 15A 4 A 10 A 6 A
30 VDC 10 A 4 A 10 A 4 A
125 VDC 0.6 A 0.1 A 0.6 A 0.1 A
250VDC 0.3 A 0.05 A 0.3 A 0.05 A
Adjustable Switching Cams
Switch STD-SSB-D (Shown)
Alarm
Switch
Standard
Tunnel
Terminals
5mm
Earth Stud
Trip
Switch
13
4 x M6
Mounting
Holes
20mm
Conduit
11
106
163
18.5
60
34
48
32
47
84
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
14
Product Information
CONVEYOR BELT TEAR DETECTOR
The heavy duty Belt
Rip Detector is magnetically or mechanically
operated, utilising the inherent reliability of
Reed Switches or Micro Switches. The Reed
Switches are encapsulated in a robust, non
metallic enclosure.
Various trip tensions can be achieved by
simple external adjustment.
An external santoprene rubber boot assists
in excluding dust and dirt from the plug and
magnetic socket assembly.
FEATURES
UV stable, flame retardant (V0 rated) PBT/PC

non corosive enclosure to IP67.
All external fixings etc. are 316 Stainless Steel.
Dust boot on socket assembly.
Socket can be mounted on either side, top or rear
of enclosure. (as per Cat No.)
Two x 20mm stainless steel amoured cable glands
available.
Two 20mm conduit entries.
Label attachment lug on lid.
Switches pre-wired to terminals.
Conveyor
Belt Tear
Detector
Conformity
Galvanized Pig Tail,
Polypropylene Rope
Grips, PVC Coated
Stainless Steel Wire
Rope and Stainless
Steel Turnbuckle
included as standard.
(Stainless Steel Pig
Tail Available.)
Safe-T-Rip brochure- Rev A
Safe-T-Rip
15
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 7 4014 9099
Manufactured in
Australia by:
Tensions:
No. 1:
Highest
tension
No. 4:
Lowest
tension
1 2 3 4
0
45
90
Move stainless steel
spring clip for Socket
detachment tensions.
Refer to installation sheet
for kgf information.
10mm
See install instructions for more detail.
DIMENSIONS
and
INSTALLATION
ORDERING DETAILS and ELECTRICAL DATA
e v i t c u d n I t n e r r u C d e h c t i w S
CAT No. Switch Device
Contact
Switched Power Switched Voltage Max. Resistive AC Loads (Power Typical Application
Confguration
) 4 . 0 r o t c a F . x a M ) S M I (
STR-P1 ............ * Dry Reed Switch S.P.S.T. 12w 230V AC 230V DC 1A Not suitable PLC & Control Circuits
STR-P2 ............ * Dry Reed Switch S.P.D.T. 5w 175V AC 175V DC 0.25 Not suitable PLC & Control Circuits
STR-P3 ............ * Dry Reed Switch 2 x S.P.D.T. 5w 175V AC 175V DC 0.25 Not suitable PLC & Control Circuits
STR-P4 ........... * Micro Switch 1 x S.P.D.T. N/A 250V AC 250V DC 15A 10A at 250V AC General AC or DC
03.A at 250V DC Control Circuits
STR-P5 ............ * Micro Switch 2 x S.P.D.T. N/A 250V AC 250V DC 15A 10A at 250V AC General AC or DC
STR-P6 ............ * Micro Switch 3 x S.P.D.T. N/A 250V AC 250V DC 15A 10A at 250V AC General AC or DC
Enclosure Specifications
High Impact PBT/PC Non Corrosive
Material
UV Stable (See Valox Specs Sheet)
Flame Retardent ASTM:UL94-V0
(1.6mm) Resist Splash and Spillage
of Most Hydrocarbon Solvents, Mild
Acids and Strong Alkali.
(See Valox Specs Sheet)
13mm
Right
hand
operation
Back
operation
105mm
161mm
4 x M6
Mounting Holes
53mm
60mm
60
mm
34mm
60mm
57.5
mm
47mm
95mm
Top operation
28 mm
Stainless steel armoured
cable entry glands 2 x M20 .....................
Tunnel rail mount terminals .....................
Example: STR P1RH
...................
Socket Positions Variations Add to CAT No.
. o N T A C o t d d A
-RH Right hand operation
-LH Left hand operation
-BK Back operation
-TP Top end operation
Example: STR P 1
...................
- K
- RH
- ACGS
- K
SPARES: Socket, 3 metres of Wire Rope and 2 x Rope Grips......................Part No. STR- SOC
For Extra Rope Length, Add Meters e.g.. STR-SOC-4 (4m of Wire )
33.5
mm
20mm Conduit
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
16
Product Information
CONVEYOR BELT TEAR DETECTOR
The heavy duty Belt
Rip Detector is magnetically or mechanically
operated, utilising the inherent reliability of
Reed Switches or Micro Switches. The Reed
Switches are encapsulated in a robust, non
metallic enclosure.
Various trip tensions can be achieved by
simple external adjustment.
An external santoprene rubber boot assists
in excluding dust and dirt from the plug and
magnetic socket assembly.
FEATURES
316 2mm electro polished stainless steel
enclosure to IP67.
All external fixings etc. are 316 Stainless Steel.
Dust boot on socket assembly.
Socket can be mounted on either side, top or rear
of enclosure. (as per Cat No.)
Two 20mm conduit entries.
Switches pre-wired to terminals.
Screw cup fittings for lid, to prevent
screwdriver slip.
Conveyor
Belt Tear
Detector
Stainless Steel Pig
Tail, Polypropylene
Rope Grips, PVC
Coated Stainless
Steel Wire Rope
and Stainless Steel
Turnbuckle included
as standard.
Conformity
Safe-T-Rip SS brochure - Rev A Safe-T-Rip (Stainless Steel)
17
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 7 4014 9099
Manufactured in
Australia by:
ORDERING DETAILS and ELECTRICAL DATA
e v i t c u d n I t n e r r u C d e h c t i w S
CAT No. Switch Device
Contact
Switched Power Switched Voltage Max. Resistive AC Loads (Power Typical Application
Confguration
) 4 . 0 r o t c a F . x a M ) S M I (
STR-SSB1 ....... * Dry Reed Switch S.P.S.T. 12w 230V AC 230V DC 1A Not suitable PLC & Control Circuits
STR-SSB2 ........ * Dry Reed Switch S.P.D.T. 5w 175V AC 175V DC 0.25 Not suitable PLC & Control Circuits
STR-SSB3 ....... * Dry Reed Switch 2 x S.P.D.T. 5w 175V AC 175V DC 0.25 Not suitable PLC & Control Circuits
STR-SSB4 ....... * Micro Switch 1 x S.P.D.T. N/A 250V AC 250V DC 15A 10A at 250V AC General AC or DC
Enclosure Specifications
2mm 316 Electro Polished
Stainless Steel.
Socket Positions Variations Add to CAT No.
. o N T A C o t d d A
-RH Right hand operation
-LH Left hand operation
-BK Back operation
-TP Top end operation
Example: STR P 1
...................
Tunnel rail mount terminals .....................
Example: STR P1RH
...................
- K
- RH
- K
SPARES: Socket, 3 metres of Wire Rope and 2 x Rope Grips......................Part No. STR - SOC
For Extra Rope Length, Add Meters e.g.. STR-SOC-4 (4m of Wire )
Tensions:
No. 1:
Highest
tension
No. 4:
Lowest
tension
1 2 3 4
0
45
90
Move stainless steel
spring clip for Socket
detachment tensions.
Refer to installation sheet
for kgf information.
DIMENSIONS
and
INSTALLATION
13mm
Left hand
operation
Back
operation
11
mm
10mm
See install instructions for more detail.
105mm
161mm
20mm Conduit
4 x M6
Mounting Holes
53mm
60mm
60
mm
34mm
60mm
57.5
mm
47mm
96.5mm
Top operation
34
mm
27mm
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
18
Product Information
PULL WIRE SWITCH
Photograph shows optional
Signal Flag fitted.
The pull wire switch complys with the requirements of AS1755-2000.
(a) The trip wire is removed
(b) The trip wire is overtensioned
(c) The trip wire is activated
The switch cannot be reset unless the trip wire is attached and correctly tensioned,
FEATURES
Robust non-metallic enclosure.
All external fixings are 316 Stainless Steel.
Stainless steel internal compression type spring.
Pull rod 316 stainless steel.
Pull rod has external dust protecting boot for seal protection.
Double lip oil seal on pull rod and reset operator for secure dust and weather protection to IP 67.
Non-metallic pull rod bushing.
Positive drive action from cams through to switching contacts provides mechanical forcing
of the trip contacts.
Micro switches are wired to terminals for easy wiring installation.
Cam design compensates for pull wire expansion /contraction up to 15mm either side of the set
point. Eliminates nuisance tripping due to vibration.
Conformity
Pull-Safe brochure - Rev A
Pull-Safe
19
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 7 4014 9099
Manufactured in
Australia by:
Max Two S.P.D.T. Contacts.
External signal flag.
Matched stainless steel compensation spring for remote
end attachment.
To comply with AS1755-2000. A matched compensation
spring must be fitted to the remote end of the pull wire
to allow tripping in both directions.
VARIATIONS
DIMENSIONS
INSTALLATION
One switch mounted for every
50m of pull wire.
SWITCH SETTINGS
Adjust pull wire until there is 75mm from the end
of the pull rod to the switch housing.
ORDERING DETAILS
Standard Switch with one forced open ..................................... PS-P
contact Micro Switch.
Standard Switch with a second non forced .................... PS-P-2
open contact Micro Switch for alarm purposes.
Standard Switch with second forced open .......................PS-P-3
contact Micro Switch.
Matched S/ S Compensation Spring ........................................ PS-60
External Signal Flag.......................................................................................PS-F
POSITIVE BREAK TYPE
Performance to VDE 0660, part 200 7/92
EN 60947, IEC 947.
Direct positive opening.
Long overtravel after direct positive opening.
Type A, DIN 41636.
Protection degree IP 40.
Self cleaning contacts.
TECHNICAL DATA
Permenant current 6A (max. 10A)
Breaking capacity AC 15 250 V AC/1,5A
Insulation 4kV/3
Contact type NC/NO/change over
mechanical life 10 million operations
Temperature range -40C to +85C
High Impact PBT/PC Non Corrosive Material
UV Stable (See Valox Specs Sheet)
Flame Retardent ASTM:UL94-V0 (1.6mm) Resist
Splash and Spillage of Most Hydrocarbon Solvents,
Mild Acids and Strong Alkali ( See Valox Specs Sheet)
125
30
52.5 52.5
75
161 13
33.5
20mm
Conduit
4 x M6 Mounting Holes
SET POSITION
28
11
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
20
Product Information
COLLIDE-SAFE
The switch is a IP67 rated Fail Safe Anti Collision Switch or Emergency Stop Switch.
The switch body is made from High Impact UV Stabilised PBT / PC non corrosive material, which is
resistant to splash and spillage of most hydrocarbons, mild acids and strong alkali. All external steel
fttings are 316 Stainless Steel. The is activated by pulling the Wire Rope in any
direction or the Wire being cut or removed. The Wire Rope can be up to 50m long, depending on the
application. The has a removable Socket assembly, so if the Wire is pulled too far,
then the Socket comes of leaving the Switch in a safe and unbroken condition. The
Socket assembly has a Tether Point for easy Wire retrieval and Socket resetting.
The is designed to be Fail Safe.
It will trip when: 1. The wire is pulled 3. The wire is over tensioned
2. The wire is cut or removed 4. A manual trip via the Reset Knob
The Micro switches ftted are S.P.D.T. switches either Positive Break or Snap Action. The
can be used as an over height switch for vehicles, trains or used on a Stacker/Reclaimer
so the operator is alerted that the stucture is going to hit the stock pile. The comes
with diferent Socket Assemblies for diferent applications.
Conformity
Collide-safe brochure - 030211
CS-P Collide Safe
21
VARIAIONS
Max three S.P. D.T Positive Break or Snap
Action micro Switches.
External signal fag.
Socket assembly with two Sockets.
SWITCH SETTINGS
Tension the wire so the Pull Rod is extended out
to the "Set Position", which is 100mm between
the body of the switch to the face of the socket
attachment plug.
DIMENSIONS
100
161 13
33.5
20mm
Conduit
4 x M6 Mounting Holes
SET POSITION
28
11
125
30
52.5 52.5
ORDERING DETAILS
Standard Switch with 1 x S.P.D.T. forced open .............. CS-P
Trip Contact and 10m Wire Rope kit.
Standard Switch with 1 x S.P.D.T. forced open ........ CS-P-2
Trip Contact, 1 x S.P.D.T. Snap Action alarm
contact and 10m Wire Rope kit.
Trip Contact, 1 x S.P.D.T. forced open alarm
contacts and 10m Wire Rope kit.
Trip Contact, 1 x S.P.D.T. forced open alarm
Wire lengths available in 5m increments
example: CS-P-4-25..................................................... add -15, -20 etc
10m Wire Rope kits with Socket, 3 Rope Grips, ..... CS-P-6
5mm Stainless Steel eye/eye Turnbuckle, M6 x 40 Stainless
Steel Eye Bolt and PS-60 Compensation Spring.
High Impact PBT/PC non Corrosive Material.
UV Stable (see Valox Specs Sheet).
Flame retardent ASTM:UL94-V0 (1.6mm)
Resist splash and spillage of most Hydrocarbon
Solvents, mild Acids and strong Alkali (see
Valox Specs Sheet).
ELECTRICAL SPECIFICATIONS
Switch No. Type Voltage Current
Mechanical
Operating Temp.
Endurance
CS-P (SW1) SPDT 250v 6A 1.5 million -25C to 85C
Forced Open Operating Cycle
CS-P-2 (SW1)
Snap Action
Silver Alloy
CS-P-3 (SW1/2)
Type
CS-P-4 (SW1)

CS-P-5 (SW1/2)

CS-P-6 (SW1/2/3)
Switch No. Type Voltage Current
Mechanical
Operating Temp.
Endurance
CS-P-2 (SW2) SPDT 125v 5A 30 million -25C to 85C
Snap Action 250v 3A Operations
CS-P-4 (SW2/3) Silver Alloy
Type
CS-P-5 (SW3)
Manufactured in
Australia by:
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
22
Product Information
PULL WIRE CORNER BRACKET
The is a
product that is designed to be
used on any pull wire system
that needs the wire/rope to
bend around any type of corner
with out becoming stuck, snagged
or pulls out like a standard pulley
may. A standard pulley is designed
mainly for yachts and straight pull
situations where the wire/rope is to be
pulled around the wheel not on an angle
to the wheels groove. When they are pulled
at an angle the wire/rope can become dislodged or
stuck in the housing as they arent designed for that type
of application.
The is designed specifically for this type of application, as the roller tube acts as
the pulley and the guides keep the wire/rope contained. When the wire/rope is pulled in a direction
that is not in line with the pulley roller the guides keep the wire/rope encapsulated so the wire/rope
cant become stuck or dislodged. The long pulley tube stop the wire/rope from becoming stuck or
dislodged even if the wire/rope becomes slack. The mounting system is designed so that it is moveable
and can mounted to any angled corner or bend, so keeping the wire/rope in the direction that it is
intended to go.
PULL WIRE
CORNER
BRACKET
Safe-T-Curve brochure - Rev A Safe-T-Curve
23
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 7 4014 9099
Manufactured in
Australia by:
189.7
139.7
24.5
41.0
42.3
57.3
83.0
97.0
143.0
50.0 Dia
ORDERING DETAILS
e p y T l a i r e t a M t e k c a r B n o i t a t n e i r O t e k c a r B o N t r a P
STC-CBI Inside Corner Mounting Bracket Zinc Plated Mild Steel
STC-CBI-SS Inside Corner Mounting Bracket 316 Stainless Steel
STC-CBO Outside Corner Mounting Bracket Zinc Plated Mild Steel
STC-CBO-SS Outside Corner Mounting Bracket 316 Stainless Steel
DIMENSIONS
Moveable Joints
Moveable Joint, so
mounting on any
angle is possible.
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
24
Product Information
LANYARD PULL WIRE ROPE
Stainless Steel Pull Wire Rope is a UV Stable Red Polyurethane coated 304
Stainless Steel 3mm ID x 5mm OD 6 x 19 construction wire rope, designed and manufactured for the
purpose of a lanyard emergency stop pull wire system.
is designed to comply with the Machinery Standards AS 4024.1604-2006 Clause
5.4.6 Actuator Colour. The actuator of the emergency stop device SHALL be coloured red.
The Actuator of a Lanyard switch is the Pull Wire thus it is made in a Red UV stable Polyurethane so to
with stand the harsh environments that the wires are placed in, without cracking of the cover or fading
of the colour. Once the is fitted to a Lanyard Switch and run
through Rope Guides and Installed as per the switch Installation Instruction, you will
then make sure your site is complying to the relevant Australian or International Standards for conveyor
Emergency Stops.
ORDERING DETAILS
Part No Description
STL-10-SS 3mm ID x 5mm OD Red 6x19. Construction UV Stable Polyurethane 304 Stainless Steel Wire Rope
LANYARD
PULL WIRE
ROPE
Safe-T-Lanyard brochure - Rev A Safe-T-Lanyard
25
Product Information
LANYARD PULL ROPE
Vectran is a UV Stable Red Polyurethane coated LCP (Liquid Crystal Polymer)
3mm ID x 5mm OD multifilament melt spun yarn rope, designed and manufactured for the purpose of a
lanyard emergency stop pull wire system.
is designed to comply with the Machinery Standards AS 4024.1604-2006 Clause
5.4.6 Actuator Colour. The actuator of the emergency stop device SHALL be coloured red.
The Actuator of a Lanyard switch is the Pull Wire thus it is made in a Red UV stable Polyurethane so to
with stand the harsh environments that the wires are placed in, without cracking of the cover or fading
of the colour. Once the is fitted to a Lanyard Switch and run
through Rope Guides and Installed as per the switch Installation Instruction, you will
then make sure your site is complying to the relevant Australian or International Standards for conveyor
Emergency Stops.
Australia
LANYARD
PULL ROPE
STL- 10- V
Safe-T-Lanyard (Vectran)
26
EMERGENCY STOP PULL WIRE SIGN
r o y e v n o c r o f n g i s p o t s y c n e g r e m e e v i t c e l f e r y l h g i h a s i e h T
lanyard switches and pull wires. It is manufactured from a high grade 3M reflective product
which a has a 10 year guarantee and is mounted to a specially designed mounting bracket which
is angled to give the operator a view of the sign at all angles. The mounting bracket is made
from either 1.2mm PGI metal or 1.2mm 304 Stainless Steel. With two 6mm mounting holes
the bracket is simple and easy to install on existing or new installations. The angle is also
designed so that when mounted as per the Australian Standards AS1755-2000 (every 30m)
they can be seen at every 15m point. The Australian Standards AS1755-2000 Clause 2.9.4 (c)
state that, Signs shall be provided at each end and every 30m along a conveyor where a pull
wire is used e.g. emergency stop.
Product Information
Safe-T-Pull Sign brochure - Rev A
Safe-T-Pull Sign
27
EMERGENCY
STOP
EMERGENCY
STOP
EMERGENCY
STOP
EMERGENCY
STOP
30 metres
DIMENSIONS
ORDERING DETAILS
Part No. Bracket Material Type Label Type
STP-ES
STP-ES-SS 304 Stainless Steel 3M Red with White reflective lettering
P
U
B
.

N
o
.

S
T
P
E
S

8
/
2
0
0
6
315mm
300mm
170mm
10mm
6.0mm hole
110mm
Newcastle P: +61 2 4014 9000 F: + 61 2 4962 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Manufactured in
Australia by:
PGI Metal (Galvanised) 3M Red with White reflective lettering
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
28
AKLS clamping wedge
Material
Wedge Carrier: One piece folded steel galvanized for corrosion
protection. Hole dimensions: 65mm long x 30mm wide.
Wedge: Two moulded polycarbonate sliding wedges with cable
grip to ensure cable is clamped, the two wedges are tted to the
carrier.
Product Information
AKLS
Insulated Cable Clamping Wedge
AKLS Brochure - Rev 051011
The insulated cable clamping wedge has been engineer
designed to grip and support cable used as the pull wire
emergency stop on a conveyor in conjunction with the
LWS wire support.
The sliding design of the two clamping wedges ensures par-
allel movement of the wedge thus applying uniform pressure
to the cable. Cables with diameters from 8.5mm to 13.5mm
to be clamped securely using the AKLS.
When the need arises the cable-clamping wedge can be re-
leased by simply pushing the two sliding wedges back in the
wedge carrier, enabling the cable to be released from the
clamping wedge.
Construction
The cable wedge is constructed of two parts. The carrier and the clamp-
ing wedge. The wedge is designed to clamp down on the cable diam-
eters 8.5mm to 13.5 mm as tension is applied to the cable.
Order code: AKLS/RD01
Standard pack quantity 10
Ma
We
prot
Wedge
grip to
carrier.
t
W
lea
we
clam
Constructio
The cable w
ing wedge. T
eters 8.5mm to
The
de
e
LW
T
a
t
t
Engineer designed to grip and support...
Simple Design Corrosion resistant Low cost High Reliability
29
LWS Lanyard Wire Support
V
A
R
I
O
U
S

O
P
T
I
O
N
S
FEATURES & SPECS
LWS
Lanyard Wire Support
Date Stamped
Injection Moulded
Self Lubricating Material
10mm Internal Thread
New Design
Designed to allow lanyard wire or pull cable,
to be clipped into the LWS. Once installed, the
lanyard cannot be removed without intention-
al intervention of maintenance staff.
New Material
Self lubricating material & longer bearing
length of the LWS carrier allows conventional
PVC coated lanyard wire or pull cable to slide
freely. This greatly improves the efciency of the system and ensures compliance with AS1755
while also extending the life of the lanyard.
All threaded rods, nuts and washers are either stainless steel or galvanised for longer life. Stan-
dard lengths available are 100, 150, 200, 250 & 300mm from the centre of the wire carrier to the
end of the threaded rod. Each unit is supplied tted with two nuts, a spring washer and a at
washer to assist installation. Bolts are offered to allow direct mounting to the conveyor structure.
Bolt lengths are 20mm to 35mm supplied in 304 Stainless Steel complete with at & spring wash-
ers.
The LWS wire carrier is injection moulded. Moulded re-enforcement of the wire carrier and the
engineered overhanging tongue allow the LWS to be mounted in any orientation without allow-
ing the lanyard to become displaced.
The threaded rod has no imperfections and with the nuts and washers tted, the installer can be
assured of correct installation and adjustment.
Wire Carrier: Made from a ame retardant copolymer polypropylene compound providing
good impact strength, rigidity and UV stability.
Threaded Rod: Galvanised 10mm machine rod or 304 stainless steel are standard. Extended
length rods are available at additional cost.
Flame Retardant / UV Stable
The LWS is made from a ame retardant copolymer polypropylene compound which is UV
stabilized for extended outdoor weathering and is commonly used in outside applications such
as stadium seating and outdoor electrical enclosures. The compound has been developed to
meet the requirements of the UL 94 V-2 rating and the AS/NZS 60695.2.12:2001 (960
0
C glow wire
test) whilst providing good impact strength and rigidity.
The LWS is designed to be mounted via metal bolts or rods to conveyor structures. The LWS is also
date stamped to provide whole of life traceability.
Dont let this happen to you...
30
MOUNTING OPTIONS
LWS
LWS with Bracket
custom brackets are available on request
Receive a Bonus 15L Bucket for every lot of 50 LWS that are ordered
LWS (head only)
LWS-HEAD
LWS with Threaded Rod
LWS-150-10-GAL
GAL (Galvanised) 304SS (304 Stainless) 316SS (316 Stainless)
Thread Size (mm)
Length (mm) From centre of carrier to end of rod.
100, 150, 200, 250, 300 *other sizes available on request
LWS with Bolt
LWS-20-10-BOL
BOL (Stainless Steel Bolt)
Thread Size (mm)
Bolt Length (mm) *other sizes available on request
LWS-400-40-GAL
GAL (Galvanised) SS (Stainless Steel)
Channel Width (mm)
Channel Length (mm) *customer specied
LWS with Extension Bar
eedddd
31
LWS
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
LWS
Optional Accessories
Visual indicators such as reectors,
sounders and signs are available on request.
LWS Brochure - 211211
LWS Estop Plate Small
LWS-00200010250
LWS Estop Plate Large
LWS-00200010400
LWS Reector Red-Grn
LWS-00200010800
Re
32
Emergency Stop Pullwire Labels
Sticker Attributes
The Emergency Stop Pullwire stickers can be
easily attached to the pullwire by aligning the
red line with the pullwire and simply folding the
sticker in half. The stickers become increasingly
useful for areas where drilling to attach a sign is
not an option. Having both a standard and re-
ective alternative, they are ideal for usage in
both above and below ground applications.
Traffolyte Sign Attributes
The Traffolyte Sign is made from laminated
impact acrylic, making it highly durable. It
can be sawn, bonded and drilled as needed.
Two predrilled holes are located in the top
left and right hand corners, to
enhance the ease of installation.
The sign also has the ability to be bent which
makes the attachment to rounded surfaces
increasingly simple. These product attributes,
along with the UV stability make the Traf-
folyte Sign a reliable, long lasting label for
conveyors where a pullwire is used.
200mm
1
5
0
m
m
Standard Sticker
Part no. stpestop-sticker
Order code: LAB-00000222300
Reective Sticker
Part no. stpestop-refsticker
Emergency Stop Pullwire Labels - Rev 051011
Emergency Stop
Pullwire Labels
1
0
5
m
m
150mm
1
0
5
m
m
150mm
Product Information
Emergency Stop Pullwire labels are an essential requirement where a pullwire is in use.
The Australian Standards Conveyors- Safety Requirements AS1755-2000, states in section 2.9.4
Marking and Control Devices, subsection c) that:
Signs shall be provided at each end and every 30m
along a conveyor where a pullwire is used e.g. emergency stop.
As such, all labels supplied by R&D Technology comply
with the Australian Standards and are UV stable.
STANDARDS AS1755-2000 CONVEYOR SAFETY REQUIREMENT MENT
A
U
S
T
R
A
L
IA
N
M
A
D
E

&
O
W
N
E
D
Traffolyte Sign
Part no. stpestop-traabel
33
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
Products associated with Emergency Pullwire labels
available through R&D Technology...
D SHACKLE STP-HDDSS WIRE ROPE GRIP STP-50SS WIRE ROPE THIMBLE STP-40SS
TURNBUCKLE STP-20SS LWS-15010GAL COMPENSATION SPRING STPE60
STP-MC
Typical Lanyard arrangement
Traffolyte Sign Standard Sticker Reective Sticker
STD-P-VA
LP04-S2
Lanyard
Pull Wire
AKLS
LWS
STR
STPKIT1
Fixed End
of Pull Wire
Switch End
of Pull Wire
D-Shackle
STP-HDDSS
Compensation Spring
STPE60
Thimble
STP-40SS
Rope Grip
STP-50SS
D-Shackle
STP-HDDSS
D-Shackle
STP-HDDSS
Turnbuckle
STP-20SS
Thimble
STP-40SS
Rope Grip
STP-50SS
Products that may also be purchased are: STP MC, STD-P-VA, STR, LP04-S2 and Terminal junction boxes
LWS
34
LP04-S2 TILT
SWITCH HEAD
2
3
0
m
m

n
o
m
i
n
a
l
1" B.S.P
INTERNAL SOCKET
REINFORCED
CABLE ENTRY
EARTHED BODY
(ALL SWITCHES)
42mm
Specifcations
Mercury
Tilt Switch
Mercury Tilt Switch LP04-S2-180711
Information/images are subject to change without notice
Product Information
Proudly Australian Made
To suit Australian conditions
Model LP04-S2 Series
Engineered Australian quality,
Leveltec ask for it by name...
High bin level indication and/or control.
Plugged conveyor transfer point detection.
Plugged chute detection.
Crusher bowl level indication and/or control.
Conveyor loss of feed indication and/or control.
Conveyor belt drift indication and/or alarm.
Boom stackers.
Radial stackers.
Switch Mode
Vertical Closed
Tilted Open
Operating Angle Approx. 20 degrees from vertical
Standard Cable 3 core PVC 0.75mm
Temp rating 75C
Standard Material Steel with chrome plated nish
LP04-S2
24 VDC - 1A / 60 VDC 0.8 AMP
110 VAC - 1.5A / 240 VAC 0.8 AMP
NON INDUCTIVE
Specifcations
See over page for ordering information
Mercury Tilt Switch LP04-S2
35
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Mercury Tilt Switch LP04-S2
Ordering information
Cable Options
Accessories
Mercury Tilt Switch
Standard PVC Cable lengths in metres: 6
Longer Lengths available on request.
For Heavy duty cable option add HD prex to cable length
e.g. LP04-S2-CH/HD6
WP* - Wear Plate (Chrome plated bisalloy) or
EXT* - 130mm Extension Tube (Chrome plated)
CH (Chrome plated body) or SS (304 Stainless Steel body)
LP04-S2-CH/6-WP-HL
Heavy Duty Cable
Steel Wire Braided - 1.0mm
Order Option: HD
PVC Cable
3 Core PVC - 0.75mm
Standard Fitment on all switches
Hanger & Link
Chrome Plated
hanger with link
Wear Plate
Chrome plated
bisalloy plate
Extension Tube
130mm Chrome
plated tube
HL* - Hanger & Link (Chrome Plated)
* Only add to ordering information if accessory is required.
36
LP04 TILT
SWITCH HEAD
2
3
0
m
m

n
o
m
i
n
a
l
" B.S.P
INTERNAL SOCKET
REINFORCED
CABLE ENTRY
EARTHED BODY
(ALL SWITCHES)
42mm
Specifcations
Mercury
Tilt Switch
Mercury Tilt Switch LP04R - Rev A
Product Information
Model LP04 R Series
Boom stackers.
Radial stackers.
Switch Mode
Vertical closed
Tilted Open
Cable Standard 3 core 24/020 PVC
Cable option Rubber or steel wire braided
Temp rating 75C
Material Steel, chrome plated nish
All chrome plated & stainless steel switches are supplied
with a " to " B.S.P reducing socket and B.S.P pipe
hanger & split link.
Heavy duty cable switches B.S.P pipe hanger & split
link is an optional extra.
LP04-R 24 VDC - 1.0 AMP
LP04-RA
24 VDC - 1A / 60 VDC 0.8 AMP
110 VAC - 1.5A / 240 VAC 0.8 AMP
ALL NON INDUCTIVE
Earthed Body For Safety...!
Material Option 304 grade stainless steel
Cable Lengths 4.5 metres, 7.5 metres, Heavy Duty
Specifcations
Options
Mercury Tilt Switch LP04-R
37
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Mercury Tilt Switch LP04 R
Engineered Australian Quality,
3
6
5
m
m

n
o
m
i
n
a
l
2
3
0
m
m

n
o
m
i
n
a
l
42mm
Part no. Equivalent to Cable Length
LP04-R4.5
15407 (1-201001)
S20139
4.5m
Rated: 24 VDC - 1.0 AMP
LP04-R7.5
15408 (1-201002)
S20139
7.5m
Rated: 24 VDC - 1.0 AMP
LP04-RA7.5
15407 (1-201037)
S20144
7.5m
Rated: 24 VDC - 1A / 60 VDC 0.8 AMP
110 VAC - 1.5A / 240 VAC 0.8 AMP
" HANGER B.S.P
" to " BSP reducing socket also included
38
Product Information
2
8
0
m
m

n
o
m
i
n
a
l
3
9
0
m
m

n
o
m
i
n
a
l
15mm
9
5
m
m

n
o
m
i
n
a
l
REINFORCED
CABLE ENTRY
8mm SPLIT LINK
3/4 B.S.P
PIPE HANGER
40mm
Reliable
.
Economical
.
Robust
Snap Action
Tilt Switch
Wiring Diagram
WHITE (2)
BLUE (3)
GREEN/YELLOW
Shown with
switch in
vertical
position
BROWN (1)
Snap Action Tilt Switch - Rev B
Model LP01
Boom stackers.
Radial stackers.
Contact Rating 7 ampere 250V A.C
Time Delay
Approx. 1-2 seconds standard up to
5-6 seconds available
Switch Mode
Vertical brown, white closed
Tilted brown, blue closed
Cable Standard 4 core 24/020 PVC, 6 metre length
Cable option Rubber or steel wire braided
Temp rating 75C
Material Steel, chrome plated nish
Material Option 304 grade stainless steel
All chrome plated & stainless steel switches are supplied
with a B.S.P pipe hanger & split link.
Heavy duty cable switches B.S.P pipe hanger & split
link is an optional extra.
Snap Action Tilt Switch LP01
39
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Snap Action Tilt Switch
Products associated with the Snap Action Tilt Switch
Available through R&D Technology
4
1
0
m
m

n
o
m
i
n
a
l
3
9
0
m
m

n
o
m
i
n
a
l
4
2
0
m
m

n
o
m
i
n
a
l
Model LP01 ES
Model LP01SS
Heavy duty steel chrome
plated construction.
Suitable for applications
where arduous duty is
required.
Heavy duty grade 304
stainless steel construction.
Suitable for corrosive
Environments.
Model LP01SS HD6
Model LP02FB
Light duty P.V.C body
Fitted with P.V.C ball to
increase surface area.
Suitable for ne or
powered materials.
Heavy duty grade 304
stainless steel construction.
Suitable for applications
where arduous duty is
required. Comes with a six
metre, heavy duty, steel
braided cable.
2
8
0
m
m

n
o
m
i
n
a
l
Tilt Switch Accessories
Engineered Australian Quality,
Steel Braid
Wear Plate Adaptor Cable
Chrome plated bisalloy
adaptor.
Heavy duty steel
braided cable can
be tted as an option.
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
40
Product Information
Thermo Tilt Switch - Rev B
Reliable
.
Economical
.
Robust
Thermo Tilt
Switch
Leveltec Engineering has
manufactured tilt switches
used throughout the Mining
Industry for many decades
assuring customers of not only
top quality but repeatability.
The Thermo tilt range brings
together proven tilt switch
technology and simple ro-
bust temperature switching
devices to detect both over
temperature and changed
orientation in normally static
machinery.
Thermo tilt has as standard three individual
switching outputs allowing the installer to
know what fault has occurred (whether over
temperature, tilt or a combination of both)
and then decide what action needs to be
taken. Alternative Switching arrangements
available on request.
Each unit is factory tested to conrm opera-
tion within tolerances and is supplied with easy
to understand installation instructions.
2
1
1
2
3
4
E
11mm
10mm
clearance
20mm
50mm
50mm
3
4
70
o
90
o
TILT
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sw
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Note: LTT70903-01 Internal Switching arrangement.
Alternatives available on request
Thermo Tilt Switch
41
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Mounting options for Thermo Tilt Switch
M8 or M10 Bolt (shown not supplied)
N/O 15
0
N/O 15
0
0
0
N/C
P
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r
t

N
o
.
L
T
T
7
0
9
0
3
-
0
1
1
1 5 1 0
d e g r e e s
degrees
5 0 5 1 0 1 5
15 10 5 0 5 10 15
T
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N/O 15
0
N/O 15
0
0
0
N/C
P
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t

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.
L
T
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7
0
9
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3
-
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15 10
degrees
d e g r e e s
5 0 5 10 15
1 5 1 0 5 0 5 1 0 1 5
T
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7
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-
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1
Hose Clamps not supplied.
Specifcations LTT50703-01 LTT70903-01
Casing: Stainless steel
Electronics: Passive device
Sealant: Polyurethane
Electrical: 120VAC-1A resistive / 48VDC-1A resistive
Tilt:
Sealed mercury switch (further encapsulated)
Normally Closed (N/C) in normal conditions
Thermal switches:
Sub miniature bimetal thermostat.
Normally Closed (N/C) in normal conditions
Safety: All metal parts are bonded to the earth core in cable.
Cable length: Standard cable length 3 metres (others on request)
Cable protection: Stainless steel exible conduit 1 metre from Thermo tilt (others on request)
Tilt orientation:
Contacts open Approximately 15 degrees in all
vertical planes and 15 degrees from top dead centre.
Operating
Temperature:
Alarm 1 50
0
C (open +/- 5
0
C, reset (close) 30
0
C 70
0
C (Open +/-5
0
C, reset (close) 50
0
C
Alarm 2 70
0
C (open +/- 5
0
C, reset (close) 50
0
C 90
0
C (Open +/-5
0
C, reset (close) 60
0
C
Maximum temperature: 160
0
C (long term exposure limit).
Mounting:
Horizontal or vertical via M8 or M10 bolt through centre of Thermo tilt or via
M10 trough external tag mount or clamped to shaft.
42
Important Safety Notice
The FT-1000 consists of a heavy duty polypropylene oat double
moulded onto a high quality three core cable. The oat contains a
single pole double throw switch, which can be used to give adjust-
able control over the level of liquid in tanks, pits and dams. By careful
tethering of the cable the switch can be set to give an on or off action
at any desired position. The heavy duty switch can directly control small pump
motors, and is also ideal for instrument or PLC signalling
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Product Information
Heavy Duty Float Switch
FT-1000 Range
FT-1000 Range brochure - Rev A
The FT-1000 switches have been designed and built
to be as tough as possible, and can withstand harsh
environments. Great care should be taken to ensure
that the switch is only installed in positions where it will
not be subjected to entanglement, severe agitation
and abrasion against tank walls or moving equip-
ment.
If the application requires control of mains voltage,
local electrical codes my require the switch to be
isolated at a low voltage supply. This may be re-
quired, regardless of the high voltage rating of the
oat switch. Please check with your local Electrical
authority before connection the FT-1000 to a mains
voltage supply.
NSW DEPARTMENT OF MINERALS AND ENERGY
APPROVAL NUMBER CS4937N
The switch is made of high grade polypropylene.
Our high tech manufacturing process produces a
sealed, seamless and glandless oat that is totally
tamperproof and extremely tough.
The heavy duty cable tted to the FT-1000 switch is
constructed from Hypalon rubber, which is speci-
cally designed for permanent immersion in water.
The switch and cable are also resistant to oil, grease,
fat, sewerage and a variety of chemicals.
Extra strong polypropylene oat
S.P.D.T three wire switch
No mercury or lead components
High quality rubber cable
No corrodible metal parts
Sealed tamperproof design
Highly chemical resistant
Wide range of cable lengths available
APPLICATIONS
High and low level control in tanks, pits and dams
Loss of prime protection for pumps
Automatic control of sump pumps
Control of tank lling and draining valves
Control of levels in efuent and separation pits
Level control in bulk liquid tanks
Control of level warning equipment
Features Applications
Cable Data
ump
e
um
180mm
180mm
56mm
10mm dia. Cable
Plan View
Side View
FT-1000 H.Duty Float Switch
43
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
FT-1000 Range
CABLE SPECIFICATIONS
Cable type
Heavy duty EPR/CSP
Flexible Hypalon Rubber
Outer sheathing
CSP Hypalon, Oil Resistant & Flame Re-
tarded to VDE 0472
Inner sheathing R-EP-90 Special Elastomer Insulation
Cores 3 Cores, each 1.2mm diameter
Cable diameter 10mm Nominal
Core colours
Blue (Common) Black (Normally Closed)
Brown (Normally Open)
Cable voltage rating Uo/U 600V/1kV
AC test voltage 2.5kV
Cable current carrying capacity
18 Amps Continuous at a Temperature of
30.5C
Cable maximum tensile strength 15 N/mm
2
Minimum bending radii 50mm
Maximum ambient
Operating temperature
80C
Minimum permissible
ambient temperature
-40C
Minimum permissible ambient tem-
perature for fully exible operation
-25C
Cable maximum permissible
short circuit temperature
250C
Standards of cable construction
Meets or exceeds AS1125, AS3191, AS3116
and DIN/VDE0282
Cable lengths available
1, 3, 4, 6, 10, 15, 20, 30, 50 Metres standard.
Against special order switches to 1000
Metres can be supplied
SWITCH SPECIFICATIONS
Switch type Single pole double throw
Contact gap 1mm
Contact material Silver alloy
Contact resistance 15 milli Ohms (max)
Rated voltage AC 0 to 240V AC
Rated voltage DC 0 to 250V DC
Current rating AC resistive 21 A at 250V
Motor load current rating AC 4 A at 250V
Current rating DC resistive 0.3 Amps at 250V
Maximum lamp load AC 3 Amps at 250V
Maximum lamp load DC 0.05 Amps at 250V
Maximum operating frequency,
electrical
60 operations per minute
Insulation resistance 100M Ohms minimum at 500 V DC
Dielectric strength between
contacts
1000 V AC at 50 to 60Hz for 1 minute
Life expectancy mechanical 50,000,000 operations minimum
Life expectancy electrical 100,000 operations minimum
Approved standards
UL508 E41515, CSA C22.2 No.55 (File No
LR21642)
ENVIRONMENTAL LIMITATIONS
Maximum submergence 30meters, 300kPa static pressure
Maximum liquid temperature 60C
Minimum liquid temperature -20C
Liquid specifc gravity >0.82
Liquid Ph 1 to 14
Smallest diameter well that the switch
can operate in
600mm
Liquid level change for switch to
operate
350mm (approx.)
Smallest opening through which the
switch will ft
108mm diameter
Minimum distance between oat and
closest tethering point or cable weight
150mm
Suitability for use in diesel fuel
Can be used, but some swelling
and softening of the cable and
boot may occur
Suitability for use in sodium hypochlorite Fully compatible
Suitability for sea water use Fully compatible
Suitability for use in octane (petrol) Not suitable
Suitability for use in potable water Fully compatible
TYPICAL INSTALLATION
Normally Closed (Black Wire)
Common (Blue Wire)
Normally Open (Brown Wire)
PART NUMBER CREATION
Below is an example of how to cre-
ate a part number for the FT-1000
oat switch, using the stocked cable
length of 15m
FT-1000-15
Model Serial
Number
Cable Length
(in metres)
350mm
Maximum
3 WIRE SINGLE POLE
DOUBLE THROW SWITCH
Normally Closed (Black Wire)
Common (Blue Wire)
Normally Open (Brown Wire) Switching range adjustable up to
a maximum of 350mm depending
on tethering point.
44
Hazardous Applications Construction
Important Safety Notice
The FT-2000 is a compact three-wire oat switch for highly accurate
and repeatable single point level sensing and control applications.
It is ideal for use in water, sea water and most acids and alkali solu-
tions. It will provide a stable switching action with a very high degree
of reliability. The teardrop shape of the oat makes it ideal for efuent
and sewage usage, as the oat cell has no shoulders or edges for solids to build on.
ate
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Product Information
Float Switch
FT-2000 Range
FT-2000 Range brochure - Rev A
The FT-2000 level regulators are rated for mains volt-
age operation. However, in the interest of safety we
recommend that they are only ever operated at low
voltage, preferably at 24 to 48V AC. Where mains
voltage operation is unavoidable an earth leakage
circuit breaker should always be installed in the con-
trol circuit. The application and wiring of this oat
switch should always be carried out by a qualied
electrical personnel and must always conform to lo-
cal wiring rules.
This level regulator is classed as a simple device and
does not require separate certication to be used in
hazardous applications. In any such installation the
level regulator should be isolated by an intrinsically
safe barrier, a zener barrier.
The FT-2000 houses a heavy ball that is balanced on
the actuating arm of a high precision switch. When
rising liquid causes the oat to lift and tilt, the centre
of gravity of the ball moves away from the actuat-
ing axis of the switch and allows it to de-actuate. A
falling liquid level allows that oat to straighten up
and the centre of gravity of the ball shifts back onto
the switch causing it to again actuate. This simple
reliable action only requires the oat to tilt by 45 de-
grees in any direction for the switch to operate.
The oat chamber is a double moulded hermetically
sealed cell with a double moulded barrier of solid
polypropylene sealing the cable entry. The switch
housed within the oat cell is a precision single pole
double throw device rated at 0 to 240V AC at up to
15 Amps resistive load.
Low differential switching
All direction tilt action
S.P.D.T 3 wire single point switch
Polypropylene & hypalon construction
Wide range of cable lengths available
Stable repeatable switching action
No mercury or lead components
Compact size (75mm diameter)
Optional cable weight available
APPLICATIONS
Basic liquid level control
Multi point level control
Sewerage level control
Chemical level controls
High & low level alarms
Self powered signalling
Pump protection
Potable water systems
Features Applications
Operating Principle
BLACK BROWN
BLUE
75mm
109mm
150mm min.
FT-2000 H.Duty Float Switch
45
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
FT-2000 Range
CABLE SPECIFICATIONS
Cable type
Heavy duty EPR/CSP
Flexible Hypalon Rubber
Outer sheathing
CSP Hypalon, Oil Resistant & Flame Re-
tarded to VDE 0472
Inner sheathing R-EP-90 Special Elastomer Insulation
Cores 3 Cores, each 0.75mm Sq. tinned copper
Cable diameter 7.5mm Nominal
Core colours
Blue (Common) Black (Normally Closed)
Brown (Normally Open)
Cable voltage rating Uo/U 600V/1kV
AC test voltage 2.5kV
Cable current carrying capacity
18 Amps Continuous at a Temperature of
30.5C
Cable maximum tensile strength 30 N
Minimum bending radii 40mm
Maximum ambient
Operating temperature
80C
Minimum permissible
ambient temperature
-40C
Minimum permissible ambient tem-
perature for fully exible operation
-25C
Cable maximum permissible
short circuit temperature
250C
Standards of cable construction
Meets or exceeds AS1125, AS3191, AS3116
and DIN/VDE0282
Cable lengths available
1, 3, 4, 6, 10, 15, 20, 30, 50 Metres standard.
Against special order switches to 1000
Metres can be supplied
SWITCH SPECIFICATIONS
Switch type Single pole double throw
Contact gap 0.5mm
Contact material Silver alloy
Contact resistance 15 milli Ohms (initial value)
Rated voltage AC 0 to 240V AC
Rated voltage DC 0 to 250V DC
Current rating AC resistive 15 A at 250V AC, 15A at 125V DC
Motor load current rating AC
1.5 A at 250V AC, 2.5A at 125V AC (1/4
HP)
Current rating DC resistive 15 Amps at 14V DC, 6 Amps at 30V DC
Maximum lamp load AC 1.25 Amps at 250V AC
Maximum lamp load DC 1.5 Amps at 30V DC
Minimum operating load 100mA at 12V, or 60mA at 24V
Maximum operating frequency,
electrical
24 operations per minute
Insulation resistance 100M Ohms minimum at 500 V DC
Dielectric strength between
contacts
1000 V AC at 50 to 60Hz for 1 minute
Life expectancy mechanical 20,000,000 operations minimum
Life expectancy electrical 500,000 operations minimum
Approved standards
UL508 E41515, CSA C22.2 No.55 (File No
LR21642)
ENVIRONMENTAL LIMITATIONS
Maximum submergence 30meters, 300kPa static pressure
Maximum liquid temperature 60C
Minimum liquid temperature -20C
Liquid specifc gravity >0.82
Liquid Ph 1 to 14
Smallest diameter well that the switch
can operate in
Within a 160mm inside diameter
vertically mounted pipe
Liquid level change for switch to oper-
ate
35mm
Closest switching point to tank oor 50mm
Smallest opening through which the
switch will ft
75mm diameter
Minimum distance between oat and
closest tethering point or cable weight
150mm
Suitability for use in diesel fuel
Can be used, but some swelling
and softening of the cable and
boot may occur
Suitability for use in sodium hypochlorite Fully compatible
Suitability for sea water use Fully compatible
Suitability for use in octane (petrol) Not suitable
Suitability for use in potable water Fully compatible
TYPICAL INSTALLATION PART NUMBER CREATION
OPERATION
High Water Level
Pumping Range
with 2 oat
switches
Low Water Level
Pump
High Level
Float Switch
Low Level
Float Switch
Float Vertical
Blue
Black
Brown
Black
Brown
Float Tilted
Blue
35mm
Below is an example of how to cre-
ate a part number for the FT-2000
oat switch, using the stocked cable
length of 15m
FT-2000-15
Model Serial
Number
Cable Length
(in metres)
OPTIONAL CABLE WEIGHT
Below is the part number of the
stocked optional cable weight
KCW
Optional Cable
weight
46
Product Information
Cable
Diameter
(mm)
Weight (kg)
Length
(mm)
Pennant
Colour*
Choker
Capacity
(kg)
Cable Bun
Order Code
Sling Order
Code
49-54 3.97 540 Green 2041 CB-101 CRS-101
55-64 4.42 540 Orange 2041 CB-102 CRS-102
65-69 4.76 540 Blue 2041 CB-103 CRS-103
70-79 5.1 540 Pink 2041 CB-104 CRS-104
80-89 5.44 540 Red 2041 CB-105 CRS-105
90-99 5.78 540 Yellow 2041 CB-106 CRS-106
100-109 6.8 540 - 3447 CB-107 CRS-107
110-120 7.26 540 Green/Yellow 3447 CB-108 CRS-108
Rope Brake Features
Self-braking for maximum safety
Design meets industry requirements
Maintenance free and never wears out
Ropebrake Order
Code
Dimensions
Weight (kg)
Length (mm) Width (mm) Height (mm)
11W-030 584 279 381 16
Cable Bun Features
Provides high voltage power cable suspension
Lightweight, easy to handle & highly visible
Made from strong & exible polyurethane
Partnered with a two ply latex treated web sling
Engineered for maximum protection when hoisting cables!
Cable Accessories
Rope Brake Order Code:
Cable Accessories - Rev A
* Cable buns are supplied with colour coded pennants
sewn into the sling for easy visual identication.
Cable Bun Order Codes:
Both the Rope Brake and Cable Bun are readily available and when used in
conjunction provide maximum safety for your suspension needs.
Rope Brake
Cable Bun
Cable Accessories
47
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4962 1522
Regional QLD P: +61 7 4952 3833 F: + 61 2 4014 9099
Cable Accessories
Patton & Cooke cable riser brackets attach in-
sulated cable, conduit or piping to walls, roofs,
and poles. The brackets keep the cable rigidly
held in place.
Available in a variety of combinations and sizes;
low and high prole mounting brackets for one
or three cables.
Introducing the new Patton and Cooke Cable
Handling Tool.
With an electrostatically applied powder coating
and a PVC shaft with berglass back bone this
tool is a handsome addition to any cable han-
dlers arsenal. Highly resilient polyester powder
coating ensures longer life in extreme mining en-
vironments.
Benefts:
Helps protect berglass core from bruises and
abrasions
High strength, light weight Good electrical
isolation with proper care and maintenance
Optimal length to reduce operator back strain
Corrosion resistant
Fork curvature allows for easy cable pick up
and retention Heat shrink cover
Solid Fiberglass core
28 inch tool length
Powder coated steel twist fork
The split strain relief entrance tting
is ideally suited for installations where
trailing cable couplers are not being
used, but where cables may be in-
stalled and removed frequently. The
split design means that the entrance
tting can be installed or removed
without disturbing the stress cones,
sleeves or taping which makes up
the cable termination.
Cables can be installed and re-
moved quickly. The strain relief en-
trance tting is tightened to provide
a positive clamp on the cable. No
tools are required. Available in sizes
which cover cable outside diam-
eters from 2.76 to 3.50 ( 70 to 89
mm).
The strain relief entrance tting combines a
watertight seal with a positive clamping action
around the cable. It is ideal for permanent en-
try of a cable into a mine power center, switch
gear, disconnect switch or standard terminat-
ing box. These ttings are available in sizes from
0.82 to 3.5 (21 - 89 mm) outside diameter.
Note:
Clamp and seal kit specic to the cable outside
diameter must be ordered separately.
The strain relief clamp is designed to prevent cable jacket damage and to
withstand the tough use typical in mining, construction and utility applica-
tions.
Eliminates strain on the cable connections at the coupler/enclosure
interface on electric shovels, drills, LHDs, jumbos, junction boxes or cable
supports.
Supports a cable in vertical shaft and pole suspension applications.
Corrosion resistant with galvanized hardware and wire rope
The strain relief clamp covers a cable diameter range of 0.625-3.625
(16-92 mm). Larger sizes are available on request.
Strain Relief Entrance ftting Strain Relief Clamp System
STRAIN RELIEF CLAMP STRAIN RELIEF CLAMP SHOWN
INSTALLED ON TRAILING CABLE
Cable Riser Brackets
J-Hook Cable Handling Tool Split Strain Relief
Entrance Fitting
Patton & Cooke
Catalog Number
73 - 76 2.88 - 3.00 11W-040-D-V
77 - 79 3.01 - 3.12 11W-040-D-W
80 - 82 3.13 - 3.25 11W-040-D-X
83 - 85 3.26 - 3.37 11W-040-D-Y
86 - 89 3.38 - 3.50 11W-040-D-Z
70 - 72 2.76 - 2.87 11W-040-D-U
Outside Cable Diameter
(mm) (in)
48
Engineered roof suspension hook...!
Product Information
Viking Nut
Viking Nut Brochure - Rev B
M24
110kg Hook SWL*
170kg Centre Hole SWL*
The safe working loads have been determined by ex-
tensive design and independent testing, including -
nite element analysis and independent testing and
certication.
Ongoing production testing is conducted for every
production run to ensure all units meet the minimum
Safe Working Load (SWL) requirements.
* SWL have been determined by loading of hooks or
centre hole (i.e. not a combination of hook and centre
hole)
Manufacturing and Testing Quality
Straps available as an optional extra include:
450mm Strap: RSH-00000350100
800mm Strap: RSH-00000350200
1200mm Strap: RSH-00000350300
Have you considered
strapping your nuts?
Ease of Installation & Recovery Testing & Certifcation
The roof suspension hook incorporates a moulded
hexagon prole to allow the unit to be installed
and recovered from ground level using a stan-
dard M24 roof bolt. The hook is simply placed
onto the head of the bolt and screwed onto a
roof bolt, allowing rows of hooks to be preinstalled
without the use of diesel vehicles. The hooks can
also be recovered using a roof bolt in a similar
fashion.
The roof suspension hook further lends itself to
being recovered by being manufactured from
bright yellow material (for improved visibility) and
from a high strength material that will not rust or
seize onto the roof bolt thread.
Features
Certied safe working load limits that use a
minimum 8:1 factor of safety
The hook combines 2 traditional products into 1
Exceptional manufacturing & testing quality
Low purchase price
Detailed product design
Ease of installation & recovery
Will not rust or seize onto roof bolt thread
The roof suspension hooks are manufactured using
premium grade Nylon 6 which has a high tensile
strength.
Strap Order Codes
Viking Nut
49
Product Information
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
Sounders & Strobes...
Yodalarm
DC & AC types standard supply voltages covered by 3 varieties
3 wired polarised or 2 wire bi-polar DC second stage control on all types.
3-wire AC second stage control on YO5, YL5 and YO3 types
Complies with BS 5839-1 : 1980 Clause 9.5
Flame Resistant ABS Plastic Enclosure
Choice of lens colour (except YO3)
32 sound signals
2 Stage Alarm
YO3 YO5 YL5
YO8/YO8
SUPER
YL8/YL8
SUPER
A 118mm 169mm 169mm 269mm 269mm
B 102mm 153mm 153mm 250mm 250mm
C 89mm 134mm 134mm 216mm 216mm
D 85mm 128mm 128mm 153mm 153mm
E 8mm 9.5mm 9.5mm 11mm 11mm
F 6mm 8mm 8mm 8mm 8mm
G - - 57.5mm - 57.5mm
H - - 88mm - 88mm
Dimensions (mm)
Yodalarm brochure - 070611
YO3 YO5 YL5 Y08 Y08 SUPER YL8 YL8 SUPER
Supply Voltages
12, 24, 48V DC +/-10%
110, 120, 240V AC +/-10%
Ambient Temp
Operating -25 to +55
0
C
Storage -40 to 70
0
C
Relative Humidity 90% @ 40
0
C
Sound Output @ 1metre 100dB* 110dB* 110dB* 116dB 120dB 116dB 120dB
Mounting
The alarms may be simply installed in any place by xing to
any suitable surface via the case lugs
Ratings
The alarms are electrically continuously rated. The standard versions are weather pro-
tected to IP54. IP65 protection is available to order.
Line Integrity
For 3-wire 2 stage alarm systems, line integrity may be monitored via reverse polarity.
For 2-wire 2 stage alarm systems, by threshold monitoring, applied voltage <IV
Maintenance
No regular maintenance is required.
Operation of the alarm should be checked via the site system test routine.
Lens Colour option Red, Amber, green, blue, opal, clear
*12Vdc versions will produce approx 6dB less output
Sounders & Strobes
50
Calculating the maximum length of Pull Wire for a Lanyard Switch
Assuming a straight and level installation using a 3mm ID wire rope, the maximum length of Pull Wire
that can reliably be connected to each side of a Lanyard Switch, is determined by three criteria:
1. The annual temperature range.
2. The Pull Wire Switch deadband zone.
3. The rate of thermal expansion for the Pull Wire
Once these three things are known, a simple formula reveals the maximum length of 3mm wire rope
that can be used, so as to not vary in length by more than the Lanyard Switch can compensate for.
If this maximum length is exceeded, nuisance tripping is likely to occur, especially during extreme tem-
peratures or sudden temperature changes. This can mean that switches need seasonal re-adjustment
in Summer and Winter - a time consuming and costly exercise!
Minimum Winter Temperature (C)
Maximum Summer Temperature (C)
Annual Temperature variation (C)
Total Lanyard Deadband (mm)
Maximum possible cable length (m)
= a
= b
= c (b - a)
= d
= e (d *80) / C
NOTE: The formula at e works because it incorporates the thermal coefcient of expansion for steel pull wire
rope: 0.0000125 per degree Celsius. Calculations assume the use of a preferred 3mm plastic
coated pull wire.
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Gloucester P: +61 2 6558 2986 F: + 61 2 4962 1522
Regional QLD P: +61 7 4952 3833 F: + 61 7 4014 9099
Manufactured in
Australia by
Product Information
Example 1:
A site with a 45C annual temperature variation, using a Lanyard Switch with a 20mm deadband,
could not reliably use a Pull Wire length of more than 35m per side of the Lanyard Switch.
Example 2:
The same site using a Pull Wire Switch (installed as per the Instal-
lation instructions) which has a total deadband of 60mm, could reliably use up to 106m under the
same conditions.
Conclusion:
The use of a Lanyard Switch offers not only greater immunity from thermal expan-
sion and contraction trips, when set to the Mean Point of the temperature range of the site; but can
lower the cost and increase reliability of the Emergency Stop system, as less Switches are needed
to cover long distances.
WIRE LANYARD PULL ROPES:
How far can you go?
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Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
Lanyard Rope (Calculating lengths)
51
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Regional QLD P: +61 7 4952 3833 F: + 61 7 4014 9099
Manufactured in
Australia by:
Wire Sizes:
3mm ID x 5mm OD 6 x 7 Construction Blue PVC coated Wire Rope @ 0.049Kg per M
Electric Control Products (Part No STL-10-SS) 3mm ID x 5mm OD
6 x 19 Construction Red UV Stable Polyurethane coated 304 Stainless Steel Wire Rope
@0.052Kg per M
3.5mm ID x 5.5mm OD 6 x 7 Construction Blue PVC coated Wire Rope @ 0.060 Kg per M
4mm ID x 6mm OD 6 x 7 Construction Blue PVC coated Wire Rope @ 0.083Kg per M
QUESTION: Our Lanyard run is 80m, how does the wire size affect the workings and
parameters of the Lanyard Switch?
Over an 80m Lanyard run 3mm ID x 5mm OD 6 x 7 Construction Blue PVC coated Wire Rope @ 0.049Kg per M
over 80m is 3.92Kg in weight.
Over an 80m Lanyard run Electric Control Products (Part No STL-10-SS) 3mm ID x 5mm
OD 6 x 19 Construction Red UV Stable Polyurethane coated 304 Stainless Steel Wire Rope @ 0.052Kg per M is
4.16Kg in weight.
Over an 80m Lanyard run 3.5mm ID x 5.5mm OD 6 x 7 Construction Blue PVC coated Wire Rope @ 0.060 Kg
per M is 4.8Kg in weight.
Over an 80m Lanyard run 4mm ID x 6mm OD 6 x 7 Construction Blue PVC coated Wire Rope @ 0.083Kg per M
is 6.64Kg in weight.
When a lanyard is pulled in either the slack wire operation or the 90 degree to the run operation, you need to pull
the weight of the wire and the tension of the springs at the remote end of the run and inside the switch to activate
a trip. If you use a 4mm ID x 6mm OD 6 x 7 Construction Blue PVC coated Wire Rope you are adding an extra
2.48Kg in wire weight to the recommended Electric Control Products wire size. So when you try to test the Switch
and Installation to the AS 1755 Standard in any direction you are needing to pull an extra 2.48Kg of weight plus
the extra friction caused by the extra weight if you are at either end of the switch or 1.24Kg of weight plus the extra
friction caused by the extra weight if you pull in the centre of the run. The extra weight and friction may cause
the Switch and Installation NOT to perform to the AS1755 Standards. Electric Control Products has tested their
Switch the using the recommended Electric Control Products 3mm ID x
5mm OD 6 x 19 Construction Red UV Stable Polyurethane coated 304 Stainless Steel Wire Rope and found it to
comply with the AS1755 Standards over a 100m lanyard run, when set up to Electric Control Products Installation
Instructions.
Now we have the right wire size the next thing is friction reduction.
Using Galvanised or Zinc plated Pig Tails or Eye Bolts cause extra friction plus premature wire wear, using a purpose
made rope guide like the R&D Technology Lanyard Wire Support(LWS) which is designed to reduce friction and wire wear
will increase the effectiveness of the workings of the switch thus improving the Kg pull to activate the switch.
At the end is the ongoing maintenance of the lanyard installation with a testing procedure being done every 3 4
months depending on the environment it is installed in.
WIRE LANYARD PULL ROPES:
How do they
Compare and
Work?
Newcastle P: +61 2 4014 9000 F: + 61 2 4014 9099
Brisbane P: +61 7 3846 2644 F: + 61 7 3846 2346
Wollongong P: +61 2 4285 9978 F: + 61 2 4285 9989
Gloucester P: +61 2 6558 2986 F: + 61 2 4014 9099
Mackay P: +61 7 4952 3833 F: + 61 2 4014 9099
Safe-T-Lanyard (How do they work)
52
Safe-T-Pull (Installation) - new series
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4 x Tamper Proof Screw Covers.
NOTE: All warranties void if
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NOTE:
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SW 1 and SW 2 fitted in
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Fail Safe Micro Switch SW
1, SW 2, SW 3 and SW 4
fitted in STP-M-C-4 /
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/ STP-M-B-4
P/N STP M LIMIT SWITCH WIRING DIAGRAM
P/N STP M

LIMIT SWITCH WIRING DIAGRAM for STROBE LIGHT Option
A.C.N. 060 617 987
2
Changeover contacts.
High reliability snap
action contacts.
Silver alloy self cleaning
contacts, or Gold Flash
available.
Positive opening NC
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WIRING NOTE:
All wires to be kept away
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Clear info on the Cover.
General Characteristics
Comply with IEC / EN61058, UL 1054
Rated impulse withstand voltage Uimp V 1500
Rated operating current le: ac 8A - 250V resistive load, 3A -250V inductive load
Pollution class 2
Life cycles Mechanical 10
6
, electrical 5x10
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PUB No. DEL 024 10 - 07
55
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PUB No. DEL 024B 10 - 07
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Safe-T-Pull (Installation) - old series
56
SAFE T PULL
P/N: STP SSB NONSTD INSTALLATION & SETTING INSTRUCTIONS
EMERGENCY STOP
ACN: 060 617 987
Conformity
S T R O P P U S R E H T O T R O P P U S T S R I F
600mm
MINIMUM
3000mm
NOTE: - FIRST SUPPORT
MUST BE ON CENTRE LINE
OF SWITCH PULL ROD
WIRE SUPPORT
P/N STG- 200
AKLS
Cable Clamp
MAX. DISTANCE:
BOTH SIDES OF THE SWITCH
100 METRES - STRAIGHT CONVEYOR
80 METRES - INCLINE CONVEYOR
(OVER 5)
SHACKLE
P/N STP-70SS
ENSURE CLEARANCE FOR PULL
WIRE FIXINGS TO FIRST WIRE
SUPPORT WHEN PULL WIRE IS
FULLY ACTIVATED.
SHACKLE
P/N STP-70SS
YELLOW INDICATION
FLAG P/N: STP-F
The Indication Flag
should be ftted when
there is more than one
switch used on the
conveyor as noted
in AS1755-2000
Clause 2.7.9.1 (e)
P
U
B
N
o
.
D
E
L
0
2
4
C
1
0
-
0
7
AKLS
Cable Clamp
Use gland to suit cable
with 20mm thread
Electric
Communication
Cable.
NOTE: Max. diametre 13.5mm
at 250 gms per metre.
NOTE: To ensure the
Communication Cable
lines up with the next
switch, adjust the height
of the Wire Supports on
a gradual incline to suit.
CAT No. STP-M
175.5
MADE IN AUSTRALIA
RESET
TRIP
SET
EMERGENCY STOP
130.5
Internal Dimension
26.5
272.5
224
Internal Dimension
120
9.0 Mounting
Holes x 4
26.5
100
SET POSITION
200 175
175
56
Internal Dimension
98.5
S
W
I
T
C
H

P
L
A
T
E
25 25
SWITCH CANNOT BE RESET UNTIL BOTH PULL WIRES ARE CORRECTLY TENSIONED TO THE SET POSITION
ie. 100mm from pull rod end to switch body.
For further requirments refer to AS 4024-1-1996
Safeguarding of Machinery Part 1: General principals
and AS 1755-2000 Conveyors Design, Construction,
Installation and Operation, Safety requirements,
respectively for coveyors used in Australia.
NOTE: TO COMPLY WITH AS 1755-2000 Clause 2.7.9
A matched compensation spring must be ftted to the remote
end of the Pull Wire to allow tripping in both directions.
AS 1755-2000 is the Australian Standards for Conveyor
Safety Requirements.
SAFE T PULL
P/N STP SSB INSTALLATION & SETTING INSTRUCTIONS
EMERGENCY STOP
CAT No. STP-M
175.5
MADE IN AUSTRALIA
RESET
TRIP
SET
EMERGENCY STOP
130.5
Internal Dimension
26.5
272.5
224
Internal Dimension
120
9.0 Mounting
Holes x 4
26.5
100
SET POSITION
200 175
175
56
Internal Dimension
98.5
S
W
I
T
C
H

P
L
A
T
E
25 25
ACN: 060 617 987
Conformity
FIRST SUPPORT OTHER SUPPORTS
600mm
MINIMUM
3000mm
NOTE: - FIRST SUPPORT
MUST BE ON CENTRE LINE
OF SWITCH PULL ROD
For further requirments refer to AS 4024-1-1996
Safeguarding of Machinery Part 1: General principals
and AS 1755-2000 Conveyors Design, Construction,
Installation and Operation, Safety requirements,
respectively for coveyors used in Australia.
NOTE: TO COMPLY WITH AS 1755-2000 Clause 2.7.9
A matched compensation spring must be fitted to the remote
end of the Pull Wire to allow tripping in both directions.
AS 1755-2000 is the Australian Standards for Conveyor
Safety Requirements.
SWITCH CANNOT BE RESET UNTIL BOTH PULL WIRES ARE CORRECTLY TENSIONED TO THE SET POSITION
ie. 100mm from pull rod end to switch body.
PULL WIRE 7 x 7 PVC COATED
3mm ID 5mm OD FLEXIBLE
WIRE ROPE P/N STP-10
WIRE SUPPORT
P/N STG- 200
TURNBUCKLE
P/N STP-20
(Can be mounted
at remote end of
Pull Wire)
MAX. DISTANCE:
BOTH SIDES OF THE SWITCH
100 METRES - STRAIGHT CONVEYOR
80 METRES - INCLINE CONVEYOR
(OVER 5)
SHACKLE
P/N STP-70SS
ROPE GRIP
P/N STP-51
Alternative fitment:
HORSE SHOE
ROPE GRIP
INSTALLATION
P/N STP-50
ROPE THIMBLE
P/N STP-40
MATCHED SS
COMPENSATION SPRING
P/N STP-H60
(see note below)
PULL WIRE SHOULD BE STRAIGHT AND
CLEAR OF OBSTRUCTIONS
ENSURE CLEARANCE FOR PULL
WIRE FIXINGS TO FIRST WIRE
SUPPORT WHEN PULL WIRE IS
FULLY ACTIVATED.
SHACKLE
P/N STP-75SS
PIG TAIL
P/N STP-90 ROPE GRIP
P/N STP-51
YELLOW INDICATION FLAG:
P/N STP-F
The Indication Flag should
be fitted when there is more
than one switch used on the
conveyor as noted in AS1755-
2000 Clause 2.7.9.1 (e)
Alternative fitment:
HORSE SHOE
ROPE GRIP
INSTALLATION
P/N STP-50
ROPE THIMBLE
P/N STP-40
P
U
B

N
o
.
D
E
L

0
2
4
A

1
0
-
0
7
Safe-T-Pull (Stainless Steel)
57
20mm
Top View
Conveyor
Belt Direction
13mm
minimum
between
Roller
and Belt
7mm minimum from the belt edge
to the under side of the Switch
End View
Limit switch trip position to be set anywhere before
the Conveyor Belt rides over the top of the roller.
The roller arm has the ability to
rotate 90 from its set resting
position in both directions,
so that you can get maximum
belt drift travel and maintain
switch & roller reliabilty. The
arm returns to its set resting
position when the belt returns
to its normal running position.
Using the Part No. STD-P-LATCH
the arm can be preset to a
position where the belt drifts
and trips the switch, and the
arm rotates over to the 90
position and only returns when
it is physically pushed back to
position and then the conveyor
may be restarted.
Eg. Use the roller arm as a Belt
Drift Switch visual flag indicator.
Conveyor Belt when drifting
must push on the Roller
20mm (min) above the Rollers base.
In this position the
Switches activiated
are Nos 1 (Alarm)
and 2 (Trip)
STD-VA
ARM,
SHOWN
STD-VASR
ARM,
SHOWN
FACTORY SET LIMIT SWITCH ALARM POSITION
(ALARM LIMIT SWITCH ON)
(Factory Setting may be changed after Switch Installation to required position.
See Micro Switch Installation Instructions for adjustment)
FACTORY SET LIMIT SWITCH TRIP POSITION
(TRIP LIMIT SWITCH ON)
(Factory Setting may be changed after Switch Installation to required position.
See Micro Switch Installation Instructions for adjustment)
In this position the Switches
activiated are Nos 1 (Alarm)
and 2 (Trip)
5
5
Telephone: (08) 9249 1044
MATERIAL ZONE
Made in Australia P
u
b
N
o
. D
E
L
0
2
8
: 0
7
/
0
5
VERTICAL ARM
Part Nos: STD-VA; STD-VASR; STD-VA50
Installation Instructions
Recommended Belt Drifts to use with STD - VA / VASR / VA50
Part Nos: STD- P / -? STD- P- K / -?
Part No.
STD - VA
STD Roller
Total length of
vertical arm 270mm
M10 Fixed nut
STD - VA Clamp
150
30
20
70
50
Part No.
STD - VA50
STD Roller
Total length of
vertical arm 320mm
M10 Fixed nut
STD - 50 extension
STD - VA Clamp
Turn nut with 17mm
spanner to tighten
Roller onto extension
and VA Clamp.
50
150
70
50
30
20
Part No.
STD - VASR
STD Roller
Total length of
vertical arm 350mm
M10 Fixed nut
Roller Spring
STD - VA Clamp
Turn nut with 17mm
spanner to tighten
Roller onto Spring
and VA Clamp.
50
150
70
80
30
20
Recommended Belt Drifts to use with STD - HA / HASR
Part Nos: STD- P- D / -? STD- P- D- K / -?
HORIZONTAL ARM
Part Nos: STD-HA; STD-HASR;
HA Rollers are used for large items on conveyor
Pub No. DEL 027: 07/ 05
Made in Australia
Telephone:
(08) 9249 1044
In this position the
Switches activiated are
Nos 3 (Alarm) and 4 (Trip)
In this position
the Switches
activiated are
Nos 1 (Alarm)
and 2 (Trip)
Top View
Conveyor
Belt Direction
6mm minimum
between Roller and Belt
160mm minimum from the belt
edge to the under side of the Switch
FACTORY SET
LIMIT SWITCH
TRIP POSITION
(TRIP LIMIT SWITCH ON)
(Factory Setting may
be changed after Switch
Installation to required position.
See Micro Switch
for adjustment)
FACTORY SET LIMIT
SWITCH ALARM POSITION
(ALARM LIMIT SWITCH ON)
(Factory Setting may
be changed after Switch
Installation to required position.
See Micro Switch Installation
Instructions for adjustment)
60
Roller arm
Set Point
5
5
Roller arm full travel

90
End View
STD-HA
ARM,
SHOWN
STD-HASR
ARM,
SHOWN
5
MATERIAL ZONE
Limit switch
trip position
to be set
anywhere
before the
Conveyor
Belt rides
over the top
of the roller.
5
Conveyor Belt when drifting
must push on the Roller
20mm (min) above the Rollers base.
20mm
Spring Washer
M10 Set Screw
Turn Set Screw
with 17mm
spanner to
tighten Roller
onto Spring.
Part No.
STD - HASR
STD Roller
Total length of
horizontal arm 350mm
M10 Fixed nut
Roller
Spring
STD - HA
Roller Arm
150
70
80
75
50
165
Turn nut
with 17mm
spanner to
tighten Roller
onto Spring.
50
Part No.
STD - HA
STD Roller
Total length of
horizontal arm 320mm
M10 Fixed nut
STD - HA
Roller Arm
Turn nut with
17mm spanner
to tighten Roller
onto Nyloch Nut.
M10 Nyloch Nut
150
70
75
165
Safe-T-Drift (Horizontal) Safe-T-Drift (Vertical)
58
Micro Switch Installation Sheet
Mi cro Swi tch Cam
Rest Posi ti on
See Vertical or Horizontal Arm
Installation Instructions for Micro
Switch activation sequence.
SW 1 Mi cro Swi tch
Is the ALARM SWITCH
Factory Preset to
switch on when the
roller arm moves 5
SW 2 Mi cro Swi tch
Is the TRIP SWITCH
Factory Preset to
switch on when the
roller arm moves 10
The ALARM & TRIP
SWITCHES may be
adjusted by losening
the Micro Switch Cam
Screws and moving
the Cams backwards
or forwards to the
desired Limit Switch
Set Point, and then
retighten the Micro
Switch Cam Screws
for operational use.
SW 3 Mi cro Swi tch
Is the ALARM SWITCH
Factory Preset to
switch on when the
roller arm moves 5
SW 4 Mi cro Swi tch
Is the TRIP SWITCH
Factory Preset to
switch on when the
roller arm moves 10
A.C.N. 060 617 987
Telephone: (08) 9249 1044
TERMINAL Nos
Wiring diagram for Part No: STD-P/HB-D
(TUNNEL TYPE TERMINALS)
sw
1
Mi cro Swi tch Cam
Adj ustment Screw
Mi cro Swi tch Cam
Adj ustment Screw
Earth Screw
See Termination drawings below,
for Wiring Instructions.
sw
3
sw
4
sw
2
SW 1 (ALARM) SW 2 (TRIP)
TERMINAL Nos
Wiring diagram for Part No: STD-P/HB-D-K
(RAIL MOUNT TYPE TERMINALS)
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
W
ir
e
.7
5
m
m
NO COM NC NO COM NC NO COM NC NO COM NC
1 12 2 3 4 5 6 7 8 9 10 11
W
ir
e
.7
5
m
m
TERMINAL Nos
Wiring diagram for Part No: STD-P/HB
(TUNNEL TYPE TERMINALS IN STD- P/ HB or RAIL MOUNT TYPE IN STD- P/ HB/ - K)
1 2 3 4 5 6
NO COM NC NO COM NC
W
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e

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7
5
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7
5
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.
7
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1 2 3 4 5 6
NO COM NC NO COM NC
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7
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SW 3 & SW 4
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NOTE:
Switches 3 & 4 and Switch 3 & 4
Cam only fitted in Part Nos.
STD-P/HB-D or STD- P/HB-D-K
Safe-T-Drift (Micro Switch Install)
59
Safe-T-Rip (wiring diagram)
60
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Safe-T-Rip (Installation)
61
Safe-T-Rip (wiring diagram)
62
Pull-Safe (Installation)
63
Safe-T-Pull (Standards)
Standards
The complies with the relevant parts of these Standards:
IEC 60947-5-1:2003 Control circuit devices & switching elements
AS 60947-5-1:2004 Control circuit devices & switching elements
IEC 609475.5:1997 Control circuit devices & switching elements-Electrical emergency stop devices with
mechanical latching function.
AS 3947.5.5:2000 Control circuit devices & switching elements-Electrical emergency stop devices with
mechanical latching function.
AS 4024.1-2006 Safety of Machinery.
AS 1755-2000 Conveyors-Safety requirements.
Ce Conformity to:
98/37/EEC Machinery Directive
73/23/EEC Low Voltage Directive
Harmonised Standards:
EN ISO 12100 Parts 1 & 2 Safety of machinery
EN 60204-1:1997 Safety of Machinery-Electrical equipment of machines
EN 418:1992 Safety of machinery-Emergency stop equipment
Workshop Tested
All switches are tested by trained personnel before leaving ELECTRIC CONTROL PRODUCTS and have a date & name label
of manufacture so that all relevant Standards are complied with and the product is in a full working order.
Modifications of Switch
Any modifications are ONLY to be made by ELECTRIC CONTROL PRODUCTS or one of their registered repairers. Any
unauthorised modifications may not comply with the relevant standards and may diminish the integrity and workings of the switch
and the warranty will become void.
ELECTRIC CONTROL PRODUCTS and their registered repairers or distributors will not be responsible for any damage
caused to the altered switch or any item in, on, related or near the switch, nor any injury incurred, nor actions resulting from the
unauthorised alterations.
Returns Policy/ Re Stocking
Please return any defective switch to place of purchase for assessment. If they are deemed to be warranty repairs or not. Return
warranty switches as per warranty clause. Restocking returns will only be accepted if received by ELECTRIC CONTROL
PRODUCTS in their original condition and within thirty (30) days of delivery date stated on delivery documentation. A restocking
fee applies (contact place of purchase for costs).
Warranty
Warranty period is twelve (12) months from date of purchase or longer as indicated by Electric Control Products. Electric
Control Products warrants that if any product is defective, it will, at its option, replace or repair the product. This warranty
shall not apply to any defect which arises from improper use, failure to follow the products instructions, or any repair or
modification made with out the consent of ELECTRIC CONTROL PRODUCTS.
The customer must return or dispose of the product, in accordance with Electric Control Products instructions which are made
available through one of its registered repairers or distributors. If returned they must be suitably packaged and, where relevant,
returned in accordance with any particular instructions which Electric Control Products or one of its registered repairers or
distributors may have notified to the customer at the time of supply and then returned to that relevant supplier. Returned products
must be accompanied by an advice note stating the nature of any defect being claimed. Any products or parts which are
replaced by Electric Control Products or one of its registered repairers shall be come the property of Electric Control Products.
Title to replacement products shall pass to the customer on delivery, and the period of the warranty shall be calculated
from the date of the defective product.
All warranty returns to Electric Control Products or its registered repairers or distributors will be sent by the customers freight
Product Life Expectancy
Electric Control Products estimate the product life expectance to 10-15 years.
A shorter or longer product life maybe experienced due to environmental situations.
Electric Control Products cant give a written life expectance on any of its products due to the different situations the products
are used.
P/N STPM
A.C.N. 060 617 987
3
64
4
Technical Support
Technical advice will be given at any time by Electric Control Products or Distributor on any of the Electric Control Product range.
Contact Electric Control Products or your local Distributor for this service.
Obsolete Products
Notification will be given to Distributors only for the products becoming obsolete and a time frame of when this will occur. Please
contact Distributors for this information.
The Obsolete product range will have spare parts for 12 months after becoming obsolete or until they run out, complete products
will be available for a short time after it has become obsolete.
Maintenance Procedure
All switches require minimal maintenance but as in AS 4024.1:1996 & AS 1755:2000 maintenance procedure
should be carried out.
Maintenance at 3 Month recommended intervals, or as per Applied Risk Assessment
1. Check that the switches are installed as per installation instructions.
2. Visual inspection of enclosure to ensure IP67 rating and correctly operating device. i.e. Damaged enclosure, bent pull rod,
damaged dust boot etc.
3. Inspect compensation springs (Overall relaxed size is 213mm +/- 10mm)
4. Inspect all attachments are tight, free from obstructions and not worn and replace if necessary.
5. Inspect pull wire supports for wear, deteration and build up of material, replace if necessary.
6. Inspect pull wire for wear or deteration and replace if necessary.
7. Check that the pull rods are tensioned to the set position as per installation instructions.
8. Test that the Lanyard works as per Australian Standards AS1755-2000
Attach the or other weight measurement device to the pull wire via the rope or other
means (See Figure1). The test needs to be conducted along the axis of the pull wire in both directions. Pull the wire along the
axis until the switch trips then check the amount of force used to activate a trip. The reading must be less than 230N (23Kg).
This must be done at intervals at the centre of pull wires length, 3m-4m from the switch and 3m-4m from the compensation
spring in both directions (See Figure 1). After each trip the switch will need to be reset before the next axis trip test is to be
conducted. If the reading is higher than 230N then recheck steps 1-7, then retest the axis pull test. If the problem is still present
contact the supplier of the product for advice.
P/N STPM
A.C.N. 060 617 987
TEST PULL ROPE
ATTACHMENT METHOD
NOTE: Comes with
Up to 100 metres
PULL WI RE
STEP 1 STEP 2 STEP 3
Pull tight
Loop end of
Test Rope and
attach to Scales.
Maximum of 3 metres from
Switch in the middle of 2 guides
Pull direction Pull direction
Reading should be no
higher than 230N (23kg)
to Trip the Switch
Pull direction
Pull direction
to Trip the Switch
PULL WI RE
Centre of Pull Wire
Maximum 3 metres from
Compensation Spring in
the middle of 2 guides
Remote
Compensation
Spring
Lanyard Switch
FIGURE 1
Axis Pull Wire Test
Pull direction Pull direction
to Trip the Switch
7.0 kg 7.0 kg 7.0 kg 7.0 kg 7.0 kg 7.0 kg
213mm
+/-10mm
65
Reset the and attach the or other weight measurement device to the pull wire (See
Figure 2), 90 degrees to the pull wire axis. A length measurement needs to be taken as well. The test needs to be conducted 90
degrees to the pull wires axis at the same positions as test 1 and at the centre, between supports (See Figure 2). Pull the wire to
the 90 degree axis and using the or some other weight measurement device, measure the amount of force
it takes to trip the switch. Once the switch trips check to see how far the pull wire needs to be pulled to activate a trip using
a tape measure or ruler. The force used to activate a trip must not exceed 70N (7Kg) and the amount of pull must not exceed
300mm. If the readings are higher than 70N-300mm then recheck steps 1-7, retest the 90 degree axis pull test. If the problem
is still present contact the supplier of the product for advice.
P/N STPM
Up to 100 metres
Maximum of 3 metres from
Switch in the middle of 2 guides
PULL WI RE
Centre of Pull Wire
Maximum 3 metres from
Compensation Spring in
the middle of 2 guides
Remote
Compensation
Spring
Lanyard Switch
FIGURE 2
90 Degree Pull Wire Test
Reading should be
no higher than
70N (7kg) to Trip
the Switch at 300mm.
7 . 0 k g
Pull direction
Reading should
be no higher than
70N (7kg) to Trip
the Switch at
300mm.
7 . 0 k g
Pull direction
to Trip the Switch at
300mm.
7 . 0 k g
Pull direction
7 . 0 k g
M
E
A
R
S
U
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E
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E
N
T
A.C.N. 060 617 987
9. After activation test, check that the set position of the pull rods are as per installation instructions, if not readjust turnbuckle so
the pull rods are at the set position and redo step 8-9.
10. If the switch is not working return to authorised distributor for assessment if under warranty or replace.
Every 12 Month Period
Remove cover & check for corrosion or water ingress. Replace if necessary.
Check electrical connections for security and corrosion.
Clean lid seal and replace cover & torque down lid screws as per limit switch wiring diagram.
5
66
LANYARD SYSTEM RISK ASSESSMENT Diagram to gain a CAT/PL Rating
MOUNTINGS
Mounting Feet should be designed to
fit the purpose they are intended for
and also be external to the enclosure.
Mountings that are on the inside of
an enclosure are hard to mount and
expose the enclosure to water ingress.
LID MOUNTINGS
Types are metal thread screws or single turn screws.
Mounting points are either inside or outside the enclosure.
Mounting points inside the enclosure are prone to IP failure.
SAFE-T-PULL is designed with all lid mountings on the outer
perimeter of the lid seal ensuring the enclosures IP rating.
Single turn screws will not produce enough pressure to keep
an IP rating and are susceptible to expansion and contraction.
SAFE-T-PULL uses a unique lid screw which is designed to
be captive so the screws are not lost in the installation of
the Switch.
PULL RODS & PULL ROD ENTRY POINTS
Steel Wire Pull Ropes cannot be sealed and
have a capillary action when wet. The Switch
may be come wet inside causing the Switch to
fail on Demand.
Stainless Steel Pull Rods can be sealed with
double lip oil seals as in SAFE-T-PULL. Using
rod bushings that are made of Aluminium, Brass,
Stainless Steel or Mild Steel will corrode if not
greased on a regular basis. This will cause the
Switch to fail on Demand. The use of high grade
quality plastic bushings will ensure the Switch
will work on Demand.
DUST BOOTS
Rubber Type Dust Boots are designed to stop the build-up
of material on the Pull Rods. If they are not spring loaded,
they will not cover the Pull Rods in the set position. This
will allow materials to adhere to the surface, causing them
to bind inside the Switch bushings and fail on Demand.
Certain rubbers will degrade over time causing the Switch
to fail. SAFE-T-PULL uses a Synthetic type of rubber that
will not degrade over time, ensuring the Switch will work
on Demand at all times. Dust Boots must be secured in
such away they remain fixed to the bushings. Pull Rods
must be of a certain length so that when they retract, the
exposed part of any Pull Rod is not fed back into the outer
seal or bushing.
CONDUIT ENTRIES
Conduit Entry preferred locations are
at the bottom of an enclosure. Entries
on the sides of enclosures have the
possibility to allow ingress of water. Dirt
and water ingress may cause the Switch
to fail on Demand. Entries on the top of
an enclosure may allow the ingress of
water due to expansion and contraction
capillary effect and also if the cables or
glands are not sealed correctly.
LID SEALING
Foam or Rubber Seals have advantages and
disadvantages. Foam is soft so it moulds to the
surface very well but has a memory therefore
remains flat when removed. Be aware of the type of
foam used, as some foams are not Closed Cell type
which may allow water to penetrate them.
Foam seals are not easy to clean once the lid has
been removed and may need to be replaced. They are
quite large in width, making them more susceptible to
pick up of dirt. SAFE-T-PULL uses a synthetic rubber
seal that is thin and easy to clean. The lid seal is an
integral part of the Switch as it keeps the IP rating
after the installation is complete.
SWITCH MECHANISM SUMMARY
The SAFE-T-PULL Switch has 3 Fail Safe systems working together and also able
to work independently. The Sliders are connected to the Pull Rods by positive
means. Theses have the Micro Switch Mounting Plate fitted above them which
has 2 over centring springs driving the Actuator. The over centring springs
balance the force between then placing no force on the Actuator. They will drive
the Actuator to either a Set or Trip point via a positive mode without the chance
of the Actuator balancing between the two points. The Sliders drive the Actuator
to the trip point by a positive means. Lid drives the Actuator down to the trip
point via a positive means. If the Lid is removed and left off, the switch will still
work under Demand. The Micro Switches are positive break type. They are driven
in the positive mode when tripped as per the standards for CAT/SIL ratings. The
Micro Switches are screwed in place and a tamper proof cover stops the screws
from vibrating loose.
The tamper proof cover is held in place by 4 screws which are sandwiched
between the top and bottom switch plates. These plates are held together by 7
screws and then the plates are held in the enclosure
by another 4 screws. These screws have tamper
proof glued covers. Electricians can only access
the terminals that are needed and therefore making
the switch completely tamper proof and retaining
the CAT rating without possibility of tampering or
any moving parts being snagged by cables.
BASIC GUIDE FOR CAT, PLS and SIL SYSTEMS
CAT, PL and SILs are just measuring sticks for Functional Safety. They all measure in different measurements but all end up at the same level. Functional Safety is broken
down into two parts. Safety, this is freedom from unacceptable risk of physical injury or of damage to the health of people, either directly or indirectly as a result of damage
to property or to the environment. Functional Safety, is part of the overall safety that depends on a system or equipment operating correctly in response to its inputs. For
example, a SAFE-T-PULL mounted on the side of a conveyor system that has guarding. The SAFE-T-PULL system is used to stop the conveyor in an emergency situation via
the mechanical components and electrical/electronic components. This is an instance of Functional Safety. Attaching mesh guarding to a conveyor is not Functional Safety but
is classed as Safety or External Risk Reduction.
The measuring stick is broken into four main sections, Concept & Scope, Analysis, Realisation and Operation. These sections are then broken down into smaller sections.
Concept & Scope; Concept, understand the equipment and its environment. Scope, determined the boundary of the equipment under control plus its control system and also
scoped the hazard and risk analysis. Analyse; Hazard Risk Analysis (demonstrate all hazards are identified). Overall Safety Requirements and Safety Requirements Allocation
(demonstrate adequate and correct methods of hazard protection). Realisation; Overall Planning (Operation, Maintenance, Validation, Installation and Commissioning planning),
Safety Related Systems, Other Technology Safety Related Systems, External Risk Reduction, Overall Installation and Commissioning and Overall Safety Validation). Operation;
Overall Operation and Maintenance, Overall Modification and Retrofit and Decommissioning. To achieve any Functional Safety three standards must be used as all four main
sections are not detailed in only one of the standards. The three standards are AS61508: Functional Safety of Electrical / Electronic / Programmable Electronic Safety-related
Systems. This has all sixteen whole-of- life safety life cycle phases but these are not in detail. AS62061: Safety of Machinery Functional Safety of safety-related Electrical,
Electronic and Programmable Electronic Control Systems, only covers the Realisation section of the sixteen steps but in detail. AS4024 Safety of Machinery, this covers Analysis
and Realisation it also provides general requirements for designing and validating Other Technology (i.e. mechanical, hydraulic, pneumatic) but does not cover the design
of Programmable electronic safety-related systems.
CAT (Category) is the Functional Safety Level found in AS4024 that is related to any Technology or Energy used (Electrical, Hydraulic, Pneumatic, Mechanical, etc.).
SIL (Safety Integrity Level) is found in AS62061, this is detailed information. It is also found in AS61508 overall information.
PL (Performance Level) is found in AS13849, this is the ability of safety-related parts to perform a safety function expressed in performance levels.
When looking at the Functional Safety of a Lanyard system, you need to apply it to the whole system (looking at the overall performance level) e.g. compensation springs,
wire, guides, switch, safety control circuit etc. Because Lanyards have both electrical/electronic and mechanical parts SIL and CAT must be applied to the relevant parts. A
manufacturer of a Lanyard switch will not be able to reliably produce a SIL or CAT level as the whole safety system is not complete. This can only be achieved by the designer
of the complete conveyor safety system, a manufacturer should be able to produce a PL (Performance Level) in which the designer may apply to the overall Functional Safety.
SWITCH DIAL
Materials made of high grade plastics with UV stability
are preferred, as they will not corrode and seize. Dials
made from plastics should be designed so if broken, the
switch will contiune to work on Demand. If dials are made
from metal they should not be a crucial part in tripping the
Switch, because they are prone to corrosion and seizing.
Shrouds should not encompass the whole Switch Dial as
dirt and grime will collect between the Shroud and Switch
Dial and seize it in place. If the Switch Dial is a crucial part
of the tripping then the Switch will fail on Demand.
Sealing of Switch Dials is crucial as they are exposed to
the elements and ingress of water. The SAFE-T-PULL uses
Double Lip Oil Seals in all entry points of shafts.
HARDWARE FITTINGS
Galvanised fittings are acceptable,
but Stainless Steel fittings are the
preferred option. Stainless Steel
Turnbuckles should be fitted with a
lock nut or clamped shut as they tend
to unwind over time. All these will work
in a tension system as the Switch will
trip if one of them fails. This is not the
case in a Slack Wire System, if one of
the components fail, then the Switch
will not activate on Demand.
PULL WIRES
PVC Coated Wires (Stainless Steel or Galvanised Steel) become brittle in the sun over time because they are
not designed to be used as Pull Wires. The outer coating will break and crumble causing the Pull Wire to stick
inside the Rope Guides. Strands of wire can break becoming sharp objects along the Pull Wire.
If Communication Cable Pull Wires are run through Eyebolts or Pigtails; they can bind over time due to their
heavy weight. The cables are not as flexible as standard Pull Wires making the activation of the Switch difficult.
SAFE-T-LANYARD Wires are designed for Lanyard Pull Wire systems. These wires are UV stable so the outer
coating will not crack or crumble. UV attacks colours from the whole colour spectrum. The first colours to fade
are Purples as they are the closest to UV in colour, next in line is Reds, Oranges, Yellows, Greens, Blues etc. too
black the last in the list. The Red Pull Wire will fade in colour due to this effect but the material will retain its
properties of flexibility and softness.
Stainless Steel or Galvanised Pull Wires will expand and contract due to heat and cold. An annual system reset
may be needed to maintain the parameters found in AS1755.
Non Metallic Wire will reduce ongoing seasonal maintenance as they dont expand or contract like Steel wires
do and dont have a final stretch point when first installed. Steel wires will stretch and take time to settle whereas
Non Metallic wires dont. Materials like Kevlar have a very high temperature rating but are prone to breakage due
to their abrasive nature. Materials like Spectra are very low temperature ropes with a nonabrasive nature and are
non-stretching, but adsorb moisture and become mouldy; therefore they need the ends sealed. Non Metallic Pull
Wires like SAFE-T-LANYARD VECTRAN are a non-stretching material which is nonabrasive and will not adsorb
moisture. The ends of the STL Pull Wire dont need to be sealed because of this reason. They are extremely light
weight so offering less wear to the Rope Guides and Pull Wire itself. This reduces maintenance and maintains
the parameters found in AS1755.
ROPE GUIDES
Over time the Pull Wire can seize within Eyebolts and not allow the
Switch to activate on Demand. This is due to vibration, expansion
and contraction of the Pull Wire causing wear in the Eyebolt and Pull
Wire. This is the case with which ever size diameter Eyebolt is used
(8mm, 10mm, 12mm etc.) or whichever material used (Stainless Steel,
Galvanised Steel etc.) the same result can occur over time.
Over time the Pull Wire can seize within Pigtails and not allow the
and contraction of the Pull Wire causing wear in the Pigtails and Pull
Wire. This is the case with which ever size diameter Pigtail is used
SAFE-T-GUIDE Rope Guides are made of hard plastics with a wide
surface for the Pull Wire to travel, thus reducing the wear found with
Eyebolts and Pigtails. Using a Pull Wire through STG Rope Guides
reduces the wear ensuring the Switch works on Demand. This will
reduce maintenance of the Pull Wire and Rope Guides.
Polyurethane Type Rope Guides may have a wide surface for the
Pull Wire to travel, but due to Polyurethanes softness it creates high
friction and binds to the Pull Wire over time causing the Switch to fail
on Demand.
COMPENSATION SPRING TYPES
Draw Bar Springs can seize due to foreign material
lodging within the spring, thereby causing a Switch
activation failure. The Nm of force on the Pull Wire
may increase because the spring may bind over time
due to environmental conditions.
Extension Springs without a tether wire attached
can become stretched. If they break this may cause
injury to personnel because spring is under tension.
Extension Spring coils will open when the Pull Wire is
pulled towards the Switch and not be inhibited by any
foreign material, making the Switch trip on Demand
and keeping the Nm of force on the Pull Wire to the
recommended parameters.
Covers on Springs are not recommended as they may
cause spring failure due to the build-up of foreign
material gathered under the cover. The cover will
also trap moisture inside, increasing the speed of
corrosion.
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Risk parameters:
S Severity of injury.
S1 Slight (normally reversible injury).
S2 Serious (normally irreversible injury or death).
F Frequency and/or exposure to hazard.
F1 Seldom-to-less-often and/or exposure time is short.
F2 Frequent-to-continuous and/or exposure time is long.
P Possibility of avoiding hazard or limiting harm.
P1 Possibile under specic conditions.
P2 Extremely possible.
Risk Graph for determining required PL for safety function
S1
S2
F1
F2
F1
F2
P1
P2
P1
P2
P1
P2
P1
P2
a
b
c
d
e
This is the start-
ing point for the
evaluation of the
safety functions
contribution to
risk reduction.
1
L = Low contribution
to Risk Reduction.
H = High contribution
to Risk Reduction.
PL
r
= Required Performance Level
Conformity Conformity
LWS
Safe-T-Pull (Lanyard Risk Assessment)
67
LANYARD SYSTEM RISK ASSESSMENT Diagram to gain a CAT/PL Rating
MOUNTINGS
Mounting Feet should be designed to
fit the purpose they are intended for
and also be external to the enclosure.
Mountings that are on the inside of
an enclosure are hard to mount and
expose the enclosure to water ingress.
LID MOUNTINGS
Types are metal thread screws or single turn screws.
Mounting points are either inside or outside the enclosure.
Mounting points inside the enclosure are prone to IP failure.
SAFE-T-PULL is designed with all lid mountings on the outer
perimeter of the lid seal ensuring the enclosures IP rating.
Single turn screws will not produce enough pressure to keep
an IP rating and are susceptible to expansion and contraction.
SAFE-T-PULL uses a unique lid screw which is designed to
be captive so the screws are not lost in the installation of
the Switch.
PULL RODS & PULL ROD ENTRY POINTS
Steel Wire Pull Ropes cannot be sealed and
have a capillary action when wet. The Switch
may be come wet inside causing the Switch to
fail on Demand.
Stainless Steel Pull Rods can be sealed with
double lip oil seals as in SAFE-T-PULL. Using
rod bushings that are made of Aluminium, Brass,
Stainless Steel or Mild Steel will corrode if not
greased on a regular basis. This will cause the
Switch to fail on Demand. The use of high grade
quality plastic bushings will ensure the Switch
will work on Demand.
DUST BOOTS
Rubber Type Dust Boots are designed to stop the build-up
of material on the Pull Rods. If they are not spring loaded,
they will not cover the Pull Rods in the set position. This
will allow materials to adhere to the surface, causing them
to bind inside the Switch bushings and fail on Demand.
Certain rubbers will degrade over time causing the Switch
to fail. SAFE-T-PULL uses a Synthetic type of rubber that
will not degrade over time, ensuring the Switch will work
on Demand at all times. Dust Boots must be secured in
such away they remain fixed to the bushings. Pull Rods
must be of a certain length so that when they retract, the
exposed part of any Pull Rod is not fed back into the outer
seal or bushing.
CONDUIT ENTRIES
Conduit Entry preferred locations are
at the bottom of an enclosure. Entries
on the sides of enclosures have the
possibility to allow ingress of water. Dirt
and water ingress may cause the Switch
to fail on Demand. Entries on the top of
an enclosure may allow the ingress of
water due to expansion and contraction
capillary effect and also if the cables or
glands are not sealed correctly.
LID SEALING
Foam or Rubber Seals have advantages and
disadvantages. Foam is soft so it moulds to the
surface very well but has a memory therefore
remains flat when removed. Be aware of the type of
foam used, as some foams are not Closed Cell type
which may allow water to penetrate them.
Foam seals are not easy to clean once the lid has
been removed and may need to be replaced. They are
quite large in width, making them more susceptible to
pick up of dirt. SAFE-T-PULL uses a synthetic rubber
seal that is thin and easy to clean. The lid seal is an
integral part of the Switch as it keeps the IP rating
after the installation is complete.
SWITCH MECHANISM SUMMARY
The SAFE-T-PULL Switch has 3 Fail Safe systems working together and also able
to work independently. The Sliders are connected to the Pull Rods by positive
means. Theses have the Micro Switch Mounting Plate fitted above them which
has 2 over centring springs driving the Actuator. The over centring springs
balance the force between then placing no force on the Actuator. They will drive
the Actuator to either a Set or Trip point via a positive mode without the chance
of the Actuator balancing between the two points. The Sliders drive the Actuator
to the trip point by a positive means. Lid drives the Actuator down to the trip
point via a positive means. If the Lid is removed and left off, the switch will still
work under Demand. The Micro Switches are positive break type. They are driven
in the positive mode when tripped as per the standards for CAT/SIL ratings. The
Micro Switches are screwed in place and a tamper proof cover stops the screws
from vibrating loose.
The tamper proof cover is held in place by 4 screws which are sandwiched
between the top and bottom switch plates. These plates are held together by 7
screws and then the plates are held in the enclosure
by another 4 screws. These screws have tamper
proof glued covers. Electricians can only access
the terminals that are needed and therefore making
the switch completely tamper proof and retaining
the CAT rating without possibility of tampering or
any moving parts being snagged by cables.
BASIC GUIDE FOR CAT, PLS and SIL SYSTEMS
CAT, PL and SILs are just measuring sticks for Functional Safety. They all measure in different measurements but all end up at the same level. Functional Safety is broken
down into two parts. Safety, this is freedom from unacceptable risk of physical injury or of damage to the health of people, either directly or indirectly as a result of damage
to property or to the environment. Functional Safety, is part of the overall safety that depends on a system or equipment operating correctly in response to its inputs. For
example, a SAFE-T-PULL mounted on the side of a conveyor system that has guarding. The SAFE-T-PULL system is used to stop the conveyor in an emergency situation via
the mechanical components and electrical/electronic components. This is an instance of Functional Safety. Attaching mesh guarding to a conveyor is not Functional Safety but
is classed as Safety or External Risk Reduction.
The measuring stick is broken into four main sections, Concept & Scope, Analysis, Realisation and Operation. These sections are then broken down into smaller sections.
Concept & Scope; Concept, understand the equipment and its environment. Scope, determined the boundary of the equipment under control plus its control system and also
scoped the hazard and risk analysis. Analyse; Hazard Risk Analysis (demonstrate all hazards are identified). Overall Safety Requirements and Safety Requirements Allocation
(demonstrate adequate and correct methods of hazard protection). Realisation; Overall Planning (Operation, Maintenance, Validation, Installation and Commissioning planning),
Safety Related Systems, Other Technology Safety Related Systems, External Risk Reduction, Overall Installation and Commissioning and Overall Safety Validation). Operation;
Overall Operation and Maintenance, Overall Modification and Retrofit and Decommissioning. To achieve any Functional Safety three standards must be used as all four main
sections are not detailed in only one of the standards. The three standards are AS61508: Functional Safety of Electrical / Electronic / Programmable Electronic Safety-related
Systems. This has all sixteen whole-of- life safety life cycle phases but these are not in detail. AS62061: Safety of Machinery Functional Safety of safety-related Electrical,
Electronic and Programmable Electronic Control Systems, only covers the Realisation section of the sixteen steps but in detail. AS4024 Safety of Machinery, this covers Analysis
and Realisation it also provides general requirements for designing and validating Other Technology (i.e. mechanical, hydraulic, pneumatic) but does not cover the design
of Programmable electronic safety-related systems.
CAT (Category) is the Functional Safety Level found in AS4024 that is related to any Technology or Energy used (Electrical, Hydraulic, Pneumatic, Mechanical, etc.).
SIL (Safety Integrity Level) is found in AS62061, this is detailed information. It is also found in AS61508 overall information.
PL (Performance Level) is found in AS13849, this is the ability of safety-related parts to perform a safety function expressed in performance levels.
When looking at the Functional Safety of a Lanyard system, you need to apply it to the whole system (looking at the overall performance level) e.g. compensation springs,
wire, guides, switch, safety control circuit etc. Because Lanyards have both electrical/electronic and mechanical parts SIL and CAT must be applied to the relevant parts. A
manufacturer of a Lanyard switch will not be able to reliably produce a SIL or CAT level as the whole safety system is not complete. This can only be achieved by the designer
of the complete conveyor safety system, a manufacturer should be able to produce a PL (Performance Level) in which the designer may apply to the overall Functional Safety.
SWITCH DIAL
Materials made of high grade plastics with UV stability
are preferred, as they will not corrode and seize. Dials
made from plastics should be designed so if broken, the
switch will contiune to work on Demand. If dials are made
from metal they should not be a crucial part in tripping the
Switch, because they are prone to corrosion and seizing.
Shrouds should not encompass the whole Switch Dial as
dirt and grime will collect between the Shroud and Switch
Dial and seize it in place. If the Switch Dial is a crucial part
of the tripping then the Switch will fail on Demand.
Sealing of Switch Dials is crucial as they are exposed to
the elements and ingress of water. The SAFE-T-PULL uses
Double Lip Oil Seals in all entry points of shafts.
HARDWARE FITTINGS
Galvanised fittings are acceptable,
but Stainless Steel fittings are the
preferred option. Stainless Steel
Turnbuckles should be fitted with a
lock nut or clamped shut as they tend
to unwind over time. All these will work
in a tension system as the Switch will
trip if one of them fails. This is not the
case in a Slack Wire System, if one of
the components fail, then the Switch
will not activate on Demand.
PULL WIRES
PVC Coated Wires (Stainless Steel or Galvanised Steel) become brittle in the sun over time because they are
not designed to be used as Pull Wires. The outer coating will break and crumble causing the Pull Wire to stick
inside the Rope Guides. Strands of wire can break becoming sharp objects along the Pull Wire.
If Communication Cable Pull Wires are run through Eyebolts or Pigtails; they can bind over time due to their
heavy weight. The cables are not as flexible as standard Pull Wires making the activation of the Switch difficult.
SAFE-T-LANYARD Wires are designed for Lanyard Pull Wire systems. These wires are UV stable so the outer
coating will not crack or crumble. UV attacks colours from the whole colour spectrum. The first colours to fade
are Purples as they are the closest to UV in colour, next in line is Reds, Oranges, Yellows, Greens, Blues etc. too
black the last in the list. The Red Pull Wire will fade in colour due to this effect but the material will retain its
properties of flexibility and softness.
Stainless Steel or Galvanised Pull Wires will expand and contract due to heat and cold. An annual system reset
may be needed to maintain the parameters found in AS1755.
Non Metallic Wire will reduce ongoing seasonal maintenance as they dont expand or contract like Steel wires
do and dont have a final stretch point when first installed. Steel wires will stretch and take time to settle whereas
Non Metallic wires dont. Materials like Kevlar have a very high temperature rating but are prone to breakage due
to their abrasive nature. Materials like Spectra are very low temperature ropes with a nonabrasive nature and are
non-stretching, but adsorb moisture and become mouldy; therefore they need the ends sealed. Non Metallic Pull
Wires like SAFE-T-LANYARD VECTRAN are a non-stretching material which is nonabrasive and will not adsorb
moisture. The ends of the STL Pull Wire dont need to be sealed because of this reason. They are extremely light
weight so offering less wear to the Rope Guides and Pull Wire itself. This reduces maintenance and maintains
the parameters found in AS1755.
ROPE GUIDES
Over time the Pull Wire can seize within Eyebolts and not allow the
and contraction of the Pull Wire causing wear in the Eyebolt and Pull
Wire. This is the case with which ever size diameter Eyebolt is used
Over time the Pull Wire can seize within Pigtails and not allow the
and contraction of the Pull Wire causing wear in the Pigtails and Pull
Wire. This is the case with which ever size diameter Pigtail is used
SAFE-T-GUIDE Rope Guides are made of hard plastics with a wide
surface for the Pull Wire to travel, thus reducing the wear found with
Eyebolts and Pigtails. Using a Pull Wire through STG Rope Guides
reduces the wear ensuring the Switch works on Demand. This will
reduce maintenance of the Pull Wire and Rope Guides.
Polyurethane Type Rope Guides may have a wide surface for the
Pull Wire to travel, but due to Polyurethanes softness it creates high
friction and binds to the Pull Wire over time causing the Switch to fail
on Demand.
COMPENSATION SPRING TYPES
Draw Bar Springs can seize due to foreign material
lodging within the spring, thereby causing a Switch
activation failure. The Nm of force on the Pull Wire
may increase because the spring may bind over time
due to environmental conditions.
Extension Springs without a tether wire attached
can become stretched. If they break this may cause
injury to personnel because spring is under tension.
Extension Spring coils will open when the Pull Wire is
pulled towards the Switch and not be inhibited by any
foreign material, making the Switch trip on Demand
and keeping the Nm of force on the Pull Wire to the
recommended parameters.
Covers on Springs are not recommended as they may
cause spring failure due to the build-up of foreign
material gathered under the cover. The cover will
also trap moisture inside, increasing the speed of
corrosion.
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ACN: 060 617 987
Risk parameters:
S Severity of injury.
S1 Slight (normally reversible injury).
S2 Serious (normally irreversible injury or death).
F Frequency and/or exposure to hazard.
F1 Seldom-to-less-often and/or exposure time is short.
F2 Frequent-to-continuous and/or exposure time is long.
P Possibility of avoiding hazard or limiting harm.
P1 Possibile under specic conditions.
P2 Extremely possible.
Risk Graph for determining required PL for safety function
S1
S2
F1
F2
F1
F2
P1
P2
P1
P2
P1
P2
P1
P2
a
b
c
d
e
This is the start-
ing point for the
evaluation of the
safety functions
contribution to
risk reduction.
1
L = Low contribution
to Risk Reduction.
H = High contribution
to Risk Reduction.
PL
r
= Required Performance Level
Conformity Conformity
LWS
68
Lanyard System
RISK ASSESSMENT
CAT/PL Rating
SAFE-T-PULL Switch
Actuator Mechanism
SAFE-T-PULLs internal Actuator Mechanism is made up of three
major parts, each working as its own separate Fail Safe mechanical
system.
The rst part of the operation is the Left Hand and Right Hand Pull
Rod Sliders. These are xed to the Pull Rods so when pulled in any
direction they WILL have a positive tripping action on the Micro
Switch Mounting Plate Actuator system.
The second part of the operation is the Micro Switch Mounting Plate.
The plates Actuator is activated by the Sliders that are under the
Slider Base Plate (This plate is screwed into the bottom of the Micro
Switch Mounting Plate). This is done via xed mechanical cams on
both the Sliders and Micro Switch Mounting Plate Actuator giving a
positive tripping action through to the forced open contact type Micro
Switches. The Micro Switches are mounted so when tripping the
Micro Switch Mounting Plate Actuator they are driven in the positive
mode of opening the contacts as per most Safety Standards and Risk
Assessments. The Micro Switch Mounting Plate Actuator has its
own positive tripping action from two over centring springs that are
designed with no sharp bends making sure there are no spring failure
points. The over centring springs are attached to the Actuator via xed
mechanical means. The Micro Switch Mounting Plate Actuator system
WILL operate on either one or two over centring springs making the
system Fail Safe. The Switch Plates Actuator can not oat between the
Set and Tripped positions as the springs are mounted so they operate in
the centre of the Set and Trip point.
The third part of the operation is the lid system. The dial on the
lid is made up of three parts, the rst being the Switch Top which
is used to Set or Trip the SAFE-T-PULL via the dial or the switches
actuator system . The second part is the Fixed Cam that will activate
the SAFE-T-PULL via the dial. The dial maybe turned towards the
trip point while the SAFE-T-PULL is in the set position. This will trip
the switch via a xed mechanical cam. The third part of the system
is the Spring Loaded Cam. Once the system is activated, the system
is held in a tripped position by the dials torsion spring which pushes
the Spring Loaded Cam down on to the Micro Switch Mounting Plate
Actuator. The Micro Switch Mounting Plates over centring springs are
also forcing the Actuator down. This means there are three points of
mechanical force holding the Actuator in a tripped position. The other
function of the Spring Loaded Cam is so that if the switches dial is
turned towards the reset position while the Pull Rods are not tensioned
to the correct set position then the Spring Loaded Cam will rotate
backwards not allowing the switch to be set or the Micro Switches to
activate until such time the Pull Rods are adjusted to the set position.
SAFE-T-PULLs Micro Switches are a positive break type switch
(Positive mode opening in the tripped position). These are held down
by two M3 MTS threaded into brass ttings set into the Micro Switches
Mounting Plate. The M3 screws are held down in position by the Micro
Switch Mounting Plate Cover which also insulates the Micro Switches
terminals and their output connections. This cover is held down by
four plastic cutting type screws which are screwed up from underneath
the Micro Switch Mounting Plate and into the cover. Under the Micro
Switch Mounting Plate is the Slider Base Plate. This plate holds the
Sliders in position. It is xed to the Micro Switch Mounting Plate via
eight 4g x 3/8 CSK MTS. This complete assembly is secured in the
enclosure by four 8g x 1 CSK MTS. The Switch Actuator Mechanism
xing screws are then sealed with the Switch Actuator Mechanism
Fixing Screw Covers. This then makes the switch tamper proof and
only Electric Control Products may repair the switch if necessary as
the Switch Actuator Mechanism Fixing Screw Covers will only be
held at Electric Control Products. Once all the six SAFE-T-PULL
lid screws are installed, then the cam system of the lid will hold the
Switch Actuator Mechanism in place. For any part to fall or vibrate
off this sequence must be put in reverse. Electric Control Products has
designed this mechanism with a risk assessment of this happening to
be rated as extremely low.
At any one time of any activation of the SAFE-T-PULL the positive
breaking Micro Switches will be held in position by no less than three
mechanical forcing devices and are opened in the positive mode. The
Fail Safe systems in place ensure correct and reliable operation of the
switch at all times. With these systems in place failure of a component
WILL not inhibit the actuation of the switch. E.g. SAFE-T-PULL lid
is left off (Risk Medium); customers wiring caught in moving parts
(Risk Medium).
With this design of Emergency Stop switch any Safety Integrity Level
(SIL) rated product up to three can be installed in the SAFE-T-PULL.
Which ever level is the lower then this will be the rating e.g. SAFE-T-
PULL (PL 3) tted with a SIL 2 electronic safety system would be rated
at PL 2; SAFE-T-PULL (PL 3) tted with a 2-wire SIL 3 emergency
stop system would be rated at PL 3.
Risk Assessment Chain of Events
by Electric Control Products
Here is the list of events that must occur before a particular
part of the Safe-T-Pull Switch can dislodge or fall out and fail.
Before any possibility of the Switch Actuator Mechanism failing
due to it falling out; these are the unlikely steps that must occur:
6 x Safe-T-Pull lid screws vibrate loose causing the lid to fall off.
4 x Switch Actuator Mechanism xing screw covers glue
becomes loose causing the covers to fall off.
4 x 8g x 1 CSK MTS holding the Switch Actuator Mechanism
in place vibrate loose and falls out.
Signal supply cables come loose in terminals and fall out.
Signal supply cable glands come loose and fall out.
Switch Actuator Mechanism falls out.
Switch fails on Demand.
Before any possibility of the Micro Switches failing due to it falling
off the Switch Actuator Mechanism; these are the unlikely steps
that must occur:
6 x Safe-t-pull lid screws vibrate loose causing the lid to fall off.
4 x Switch Actuator Mechanism Fixing Screw Covers glue
becomes loose causing the covers to fall off.
4 x 8g x 1 CSK MTS holding the Switch Actuator Mechanism
in place vibrate loose and fall out.
8 x 4g x 3/8 CSK MTS Micro Switch Mounting Plate screws
vibrate loose and fall out.
4 Micro Switch Mounting Plate Cover screws vibrate loose and
fall out.
2 x M3 Micro Switch screws vibrate loose and fall out.
Micro Switches fall out.
Switch fails on Demand.
PUB No. DEL: INS 001D 07- 11
69
Marcus Punch Pty. Ltd.
Risk and Reliability
Page 1 of 2
Marcus Coyle
Managing Director
Electric Control Products
Unit 2/172 Beringarra Ave
Malaga
WA 6090
9
th
August 2011
Re: Safe-T-Pull Conveyor Lanyard Switch
Dear Sir,
You have requested that I provide an independent opinion regarding the approach Electric
Control Products has taken to assuring functional safety and machinery safety compliance of
their Safe-T-Pull conveyor lanyard switch.
You have informed me that Electric Control Products has engaged TV Rheinland to
independently certify the device against a number of international standards for machinery
safety and functional safety, which may include ISO13849, IEC61508 and IEC62061. These
standards have also been adopted in Australia within AS4024.1, AS62061 and AS61508
respectively. In my view this is an appropriate and effective approach for a device designer,
manufacturer or supplier.
TV product functional safety certification provides proof, via independent audit, testing and
analysis that the requirements of the subject standards have been complied with in the design,
manufacture, testing and documentation of the subject device, including its hardware and
software elements.
This process usually results in the issue of a functional safety certificate and test report for the
device by the certifying agency. Furthermore, this certification usually provides a statement of
the capability of the device when used in safety-related systems, which is usually expressed
as a SIL, CAT or PL.
This certification and capability statement only applies to the device, and does not imply the
level of safety integrity that would be achieved by any safety-related system in which the
device is used. It is usually the responsibility of the safety-related system designer to
determine the overall level of safety integrity achieved by each safety function in their safety-
related system, and this includes a consideration of all other devices or sub-systems used, their
configuration, usage or duty, installation environment and proposed testing frequencies. The
designers CAT, PL or SIL claims are then verified by the end user of the safety-related
system, or their representative.
ABN: 27 131 307 723
70 Collinson St, Tenambit NSW 2323, Australia.
Phone: +61 (0)2 49333989
Mobile: +61 (0)432168849
Email: marcus@marcuspunch.com
Web: www.marcuspunch.com
Risk and Reliability
Page 2 of 2
It is not appropriate for me to speculate on the results of the TV product functional safety
certification process and any CAT/PL or SIL capability that may be achieved by your device.
However, I have reviewed the Electric Control Products product data sheet entitled Safe-T-
Pull Lanyard System Risk Assessment CAT/PL Rating (Pub No. DEL INS 001D 07-11) and
find it commendable that a designer has taken the initiative to explain in detail the design
features of their product and how the potential failure modes of each component have been
prevented or mitigated by the design.
Yours sincerely,
Marcus Punch
TV FSExpert (Machinery, ID:154/10), TV FSEng (SIS, ID:735/07), CPEng, NPER, RPEQ
Director
70
Standards
AS 4024.1-2006 Safety of Machinery
Ce Conformity to:
Workshop Tested
All switches are tested by trained personnel before leaving ELECTRIC CONTROL PRODUCTS and have a date &
name label of manufacture so that all relevant Standards are complied with and the product is in a full working order.
Any modifications are ONLY to be made by ELECTRIC CONTROL PRODUCTS or one of their registered
repairers. Any unauthorised modifications may not comply with the relevant standards and may diminish the
integrity and workings of the switch and the warranty will become void.
ELECTRIC CONTROL PRODUCTS and their registered repairers or distributors will not be responsible for any
damage caused to the altered switch or any item in, on, related or near the switch, nor any injury incurred, nor actions
resulting from the unauthorised alterations.
Please return any defective switch to place of purchase for assessment. If they are deemed to be warranty repairs
or not. Return warranty switches as per warranty clause. Restocking returns will only be accepted if received by
ELECTRIC CONTROL PRODUCTS in their original condition and within thirty (30) days of delivery date stated
on delivery documentation. A restocking fee applies (contact place of purchase for costs).
Warranty
Warranty period is twelve (12) months from date of purchase or longer as indicated by Electric Control Products.
Electric Control Products warrants that if any product is defective, it will, at its option, replace or repair the product.
This warranty shall not apply to any defect which arises from improper use, failure to follow the products
instructions, or any repair or modification made with out the consent of ELECTRIC CONTROL
PRODUCTS.
The customer must return or dispose of the product, in accordance with Electric Control Products instructions which
are made available through one of its registered repairers or distributors. If returned they must be suitably packaged
and, where relevant, returned in accordance with any particular instructions which Electric Control Products or one
of its registered repairers or distributors may have notified to the customer at the time of supply and then returned to
that relevant supplier. Returned products must be accompanied by an advice note stating the nature of any
defect being claimed. Any products or parts which are replaced by Electric Control Products or one of its registered
repairers shall be come the property of Electric Control Products. Title to replacement products shall pass to the
customer on delivery, and the period of the warranty shall be calculated from the date of the defective product.
All warranty returns to Electric Control Products or its registered repairers or distributors will be sent by the
customers freight.
A.C.N. 060 617 987
PUB No. DEL 040B 06- 06
P/N STD - P, - SSB
Safe-T-Drift (Standards)
71
All switches require minimal maintenance but as in AS 1755:2000 a maintenance procedure
must be carried out.
Maintenance at 3 Month Intervals
1. Visual inspection of enclosure to ensure IP67 rating and correctly operating device. ie. Damaged enclosure,
bent actuator rod, damaged dust boot, damaged roller etc.
2. Activate the via the roller making use it moves freely are returns to its set position (Note:
STD-LATCH wont return until pushed).
3. Inspect roller for wear or deteration and replace if necessary.
4. After inspection, check the set position of the switch as per installation instructions.
Clean lid seal and replace cover & torque down lid screws as per micro switch installation sheet.
A.C.N. 060 617 987
PUB No. DEL 040B 06- 06
P/N STD - P, - SSB
72
All switches require minimal maintenance but as in AS 4024.1:1996 & AS 1755:2000 a maint-
enance procedure should be carried out.
1. Visual inspection of enclosure to ensure IP67 rating and correctly operating device. ie. Damaged enclosure, etc.
2. Inspect the SAFE-T-RIP GUIDE which is under the belt for damage or ware and replace if necessary.
3. Activate the by pulling the socket off then clean the inside & reattach.
4. Inspect rip wire for wear or deteration and replace if necessary.
5. Check the rip wire is free from obstructions and is held in the wire guides.
Clean lid seal and replace cover & torque down lid screws as per reed switch wiring diagram.
A.C.N. 060 617 987
PUB No. DEL 040E 06- 06
P/N STR - P, - SSB
Standards
AS 4024.1:2006 Safety of Machinery
Ce Conformity to:
Workshop Tested
Warranty
PRODUCTS.
customers freight.
A.C.N. 060 617 987
PUB No. DEL 040E 06- 06
P/N STR - P, - SSB
Safe-T-Rip (Standards)
73
All switches require minimal maintenance but as in AS 4024.1:1996 & AS 1755:2000 a maint-
enance procedure should be carried out.
1. Visual inspection of enclosure to ensure IP67 rating and correctly operating device. ie. Damaged enclosure, etc.
2. Inspect the SAFE-T-RIP GUIDE which is under the belt for damage or ware and replace if necessary.
3. Activate the by pulling the socket off then clean the inside & reattach.
4. Inspect rip wire for wear or deteration and replace if necessary.
5. Check the rip wire is free from obstructions and is held in the wire guides.
Clean lid seal and replace cover & torque down lid screws as per reed switch wiring diagram.
A.C.N. 060 617 987
PUB No. DEL 040E 06- 06
P/N STR - P, - SSB
74
Standards
IEC 609475.5:1997 Control circuit devices & switching elements
- Electrical emergency stop devices with mechanical latching function.
AS 3947.5.5:2000 Control circuit devices & switching elements
- Electrical emergency stop devices with mechanical latching function.
AS 4024.1-1996 Safeguarding of machinery.
Ce Conformity to:
Workshop Tested
Warranty
PRODUCTS.
A.C.N. 060 617 987
PUB No. DEL 040C 06- 06
P/N PS -P
Pull-Safe (Standards)
75
customers freight.
All switches require minimal maintenance but as in AS 4024.1:1996 & AS 1755:2000 a
maintenance procedure should be carried out.
1. Check that the switches are installed as per installation instructions.
2. Visual inspection of enclosure to ensure IP67 rating. I.e. Damaged enclosure, bent pull rod, damaged dust boot
etc.
3. Inspect compensation springs (Overall relaxed size is 138mm +/- 10mm)
4. Inspect all attachments are tight, free from obstructions and not worn and replace if necessary.
5. Inspect pull wire supports for wear, deteration and build up of material, replace if necessary.
6. Inspect pull wire for wear or deteration and replace if necessary.
7. Check that the pull rod is tensioned to the set position as per installation instructions.
8. Activate the via the pull wire, in both directions and check that it still functions as per the pull
requirement loads of AS1755-2000 Clause 2.7.9. Note: Reset the switch after each operation.
9. After activation test, check that the set position of the pull rod is as per installation instructions, if not readjust
turnbuckle so the pull rod is at the set position and redo step 8-9.
10. If the switch is not working return to authorised distributor for assessment if under warranty or replace.
Clean lid seal and replace cover & torque down lid screws as per limit switch wiring diagram.
A.C.N. 060 617 987
PUB No. DEL 040C 06- 06
P/N PS -P

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Revised 14.2.

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