Issue 5 PK 80155 Installation Instructions for the Cable Pull Safety Switch (2CPS Series) Instrucciones de instalacin para el interruptor de seguridad de traccin de cable (Serie 2CPS) Einbauanweisungen fr Sicherheitsseilzugschalter (Serie 2CPS) Instructions dinstallation de linterrupteur de scurit cble (srie 2CPS) Istruzioni di installazione per linterruttore di sicurezza con cavo di azionamento (serie 2CPS) Instrues de instalao para a chave de segurana acionada por trao de cabo (srie 2CPS) The direct acting switch contacts are held closed when the WARNING actuating cable is under proper tension and the reset knob IF USED IN APPLICATIONS CONCERNING HUMAN is set to RUN. When the actuating cable is pulled, SAFETY slackened or broken, a cam positively opens the NC Only use NC direct opening (positive opening/positive (Normally Closed) switch contacts. The snap action, trip break) contacts, identified by the symbol . operation causes the switch contacts to change state and Do NOT use flexible/adjustable actuators. Only use mechanically latch almost simultaneously when the cable actuators designed for safety applications. is pulled, slackened or broken. The NC switch contacts Do NOT defeat, tamper, remove, or bypass this switch. remain open until the 2CPS is reset by properly tensioning Hazardous voltage, disconnect power before servicing. the cable and manually rotating the reset knob. Strictly adhere to all installation and maintenance When the direct acting switch contacts open, the auxiliary instructions. contacts also actuate (open contacts close and closed Consult with local safety agencies and their requirements contacts open). The auxiliary contacts are electrically when designing a machine-control link, interface and all isolated from the direct acting switch contacts. These NO control elements that affect safety. (Normally Open) contacts may be used for monitoring or Failure to comply with these instructions could result signaling. in death or serious injury. A removable contact block version is available for robust and easy termination. Hardware packets are available separately (see Table 1 WARNING on page 13). IMPROPER USE STEP 1: MOUNT, WIRE AND SEAL SWITCH Use the 2CPS Cable Pull Safety Switch in emergency stop applications only. Do not use in general production WARNING stop applications. IMPROPER OPERATION Failure to comply with these instructions could result Locate the 2CPS such that the installed cable is visible in death or serious injury. from the 2CPS reset OR inspect the length of the cable whenever a stop is signaled. WARNING Ensure no barriers or physical obstructions prevent the operator from actuating the 2CPS Cable Pull Safety IMPROPER SYSTEM PERFORMANCE Switch. The 2CPS Cable Pull Safety Switch provides only the Failure to comply with these instructions could result front end switching/sensing function. The machine, its in death or serious injury. external machine interfaces, and the safety monitoring of A. Refer to pages 14-19 for: the machine and its interfaces, are the responsibility of Specifications (Table 2). the machine safety control system. Mounting dimensions (Figure 1). The user is SOLELY RESPONSIBLE for determining the Wiring configurations and travel distances Figure 2). appropriate level of risk. Installation drawings (Figures 3, 4, 5). The 2CPS Cable Pull Safety Switch must be installed in B. Mount switch using four M6, 1/4-28 UNF or 1/4-20 UNC a fashion that complies with all codes and standards that screws or bolts. Torque: are applicable to the particular application of the device. M6 to 6,1 N m7,5 N m 54 in lb66 in lb . EN 1050 and ANSI TR3 Risk Assessment and Risk 1/4-28 UNF to 8,6 N m10,4 N m 76 in lb92 in lb . Reduction provide assistance on how to perform risk 1/4-20 UNC to 7,3 N m9,0 N m 65 in lb79 in lb . assessment. C. Refer to the circuit diagram on the switch cover. The Failure to comply with these instructions could result diagram depicts the switch contacts when the cable(s) is in death or serious injury. (are) at proper tension and the reset knob is in the RUN position. GENERAL INFORMATION D. Remove the cover plate. The 2CPS is available in either single actuator or dual actuator versions. The maximum cable length in a single direction is 76 m 250 ft for a combined length of 152 m 500 ft in dual directions. Sensing and Control 2CPS Series ISSUE 5 PK 80155 E. Wire the switch (use 90 C wire when the ambient A. Ensure you have the following: temperature is over 75 C): Cable supports to fit the cable. Standard wiring version: Connect 0,75 mm21,5 mm2 B. Install a cable support as close to the end of the actuator (18 AWG16 AWG) stranded wire or 0,75 mm2 shaft as possible without interfering with the switch 2,5 mm2 (18 AWG14 AWG) solid wire to the terminals. operation. Torque: C. Install the cable supports at intervals of no greater than Switch terminal screws to 0,8 N m1,0 N m 2,4 m 8 ft along the cable span. 7 in lb9 in lb . D. Thread the cable through the cable supports. Ground screw to 1,0 N m1,8 N m 9 in lb 16 in lb . STEP 4: INSTALL CABLE TERMINATION Heavy duty wiring removable contact block version: NOTICE Connect 3,5 mm2 (12 AWG) or smaller stranded or solid With an endspring installed, the switch will operate wire to the terminals. Torque: satisfactorily over a temperature change of Switch terminal screws and ground screw to 17 C 30 F up to a typical length of 76 m 250 ft . 1,0 N m1,8 N m 9 in lb16 in lb . Without an endspring installed, the temperature change F. OPTIONAL: Wire the LED indicator. Wrap the wire allowed is 8 C 15 F . clockwise around the terminal screws. Ensure all wire In order to comply with standards, install a cable pull strands are secured under the screw heads. Torque the switch at each end of the cable or an endspring at the terminal screws to 0,8 N m1,0 N m 7 in lb9 in lb . For dc opposite end of the cable from the switch. indicators, ensure the positive lead wire is attached to the A. RECOMMENDED: Install an endspring: terminal with the + sign. (There is no polarity requirement Ensure you have the following: for ac indicators.) Thimbles to fit all terminations. G. Seal the conduit opening according to the instructions in Cable clamps to fit all terminations. PK 80112 (included). Endspring to fit all terminations. H. Reassemble the cover plate. Torque the cover screws to Install an endspring at the end of the cable opposite the 1,5 N m (13 in lb). switch in the same manner as Steps 2.C and 2.D. Attach the endspring to a fixed support. STEP 2: INSTALL J-HOOK TURNBUCKLE AND B. Secure the cable end to a fixed support: ACTUATING CABLE Ensure you have the following: A. Ensure you have the following: Thimbles to fit all terminations. Red plastic-coated aircraft cable 3,18 mm 1/8 in Cable clamps to fit all terminations. diameter to 4,76 mm 3/16 in diameter in desired length, Fixed support to fit all terminations. not to exceed 76 m 250 ft per each actuator. Attach the cable end to a fixed support in the same J-hook turnbuckle with locknuts. manner as Steps 2.C and 2.D. Thimbles to fit all terminations. Cable clamps to fit all terminations. STEP 5: ADJUST CABLE TENSION B. Attach the hook end of the J-hook turnbuckle to the A. Tighten the turnbuckle until the tension indicator is in the actuator. middle of the indicator window. C. Attach the eye end of the J-hook turnbuckle to the cable B. Tighten the turnbuckle locknuts. using one thimble and one cable clamp by fitting the cable C. Periodically check and adjust the cable tension. in the thimble groove and placing the cable clamp as close to the thimble as possible. STEP 6: VERIFY INSTALLATION BY PERFORMING D. Tighten the cable clamp according to the manufacturers FUNCTIONAL TESTS instructions. (The torque for the cable clamp in the accessory packet is 7,3 N m9,0 N m 65 in lb79 in lb .) CAUTION SWITCH DAMAGE NOTICE Do not attempt to rotate the reset knob from OFF to RUN If improved cable visibility is needed, install labels, unless the switch is under proper tension. markers or flags to the cable or adjacent to the cable. Failure to comply with these instructions may result in product damage. STEP 3: INSTALL CABLE SUPPORTS (EYEBOLTS) A. Ensure the cable actuates freely. Ensure the installation elements are not subject to mechanical damage due to WARNING positioning or location. B. Turn the reset knob to RUN. IMPROPER OPERATION C. PULLED CABLE STATE: Pull the cable. Ensure the reset Do not allow excessive side loads to occur that could knob rotates to OFF. bend the switch actuator shaft. D. Turn the reset knob to RUN. Failure to comply with these instructions could result E. SLACKENED CABLE STATE: Unhook the J-hook in death or serious injury. turnbuckle. Ensure the reset knob rotates to OFF. F. Reattach the J-hook turnbuckle and turn the reset knob to NOTICE RUN. The first cable support should be in line with, and no farther than, 0,46 m 18 in from the end of the actuator NOTICE shaft. After actuation and before resetting the 2CPS, the When changing the actuating cable direction, i.e., around machinery should be inspected along the entire length of a corner, ensure the cable runs freely through a pulley or the actuating cable in order to determine the reason for cable supports. actuation. 2 Honeywell Sensing and Control