Banner RP-LS42 Rope Pull Switches User Manual

Rope Pull Emergency Stop Switches

RP-LS42F-75L.. Series 42 mm Latching Switches with Rope Actuators

Features

•   

Positive-opening safety contacts (IEC 60947-5-1), not dependent

upon springs

•  Contacts latch open when rope is pulled; requires manual reset

•   Heavy-duty thermoplastic housing, rated IP67 and NEMA 4, suitable      
for demanding industrial environments

•   Innovative design provides quick, easy rope fixing and tensioning on models 

RP-LS42F-75LE and RP-LS42F-75LF

•  Rope spans up to 75 m (245')

•   Both safety contacts are closed with normal rope tension, and open when rope is 
pulled or if rope breaks (or if tension is reduced from normal amount)

•  Extra contacts for monitoring or to provide dual-channel input to a safety module

•  Indicator mark on switch shows when rope has proper tension for operation

•  Long life, switch rated at 1 million mechanical operations, minimum

•  Three available models: one with E-stop button, all with latching outputs

Insulated device (IEC 60947-5-1) on all models with plastic housings

• 

Printed in USA 07/06 P/N 67709 rev. A

Rope Pull Emergency Stop Switches –

RP-LS42F-75L.. Series

Important Information

Regarding the Use of Rope Pull Emergency Stop Switches

In the United States, the functions that Banner rope pull emergency stop switches are intended to perform are regulated by the Occupational 
Safety and Health Administration (OSHA). Whether or not any particular rope pull switch installation meets all applicable OSHA requirements 
depends upon factors that are beyond the control of Banner Engineering Corp. These factors include the details of how the switches are applied, 
installed, wired, operated, and maintained.

Banner Engineering Corp. has attempted to provide complete application, installation, operation, and maintenance instructions. This information is 
found in the instruction manual packaged with each rope pull switch. Direct any questions regarding the use or installation of rope pull switches to 
the factory applications department at the telephone numbers or address shown below.

Banner Engineering Corp. recommends that rope pull emergency stop switches be applied according to the guidelines set forth in standards listed 
below. In addition, the user of Banner rope pull switches has the responsibility to ensure that all local, state, and national laws, rules, codes, 
and regulations relating to the use of Banner rope pull switches in any particular application are satisfied. Extreme care is urged that all legal 
requirements have been met and that all installations and maintenance instructions are followed.

Application Assistance

Toll Free:  1-888-3-SENSOR (1-888-373-6767)
Email:  [e-mail]
Address:  9714 Tenth Avenue North

  Minneapolis, MN 55441

U. S. Standards Applicable to Use of Emergency Stop Safety Modules

ANSI B11     Standards for Machine Tools  “Safety Requirements for the Construction, Care and Use”
          Available from:  Safety Director
              AMT—The Association for Manufacturing Technology
              7901 Westpark Drive
              McLean, VA 22102
              Tel.: [phone]

NFPA79     “Electrical Standard for Industrial Machinery (1997)”
          Available from:  National Fire Protection Association
              1 Batterymarch Park, P.O. Box 9101
              Quincy, MA 02269-9101
              Tel.: [phone]

ANSI/RIA R15.06    “Safety Requirements for Industrial Robots and Robot Systems”
          Available from:  Robotic Industries Association
              900 Victors Way, P.O. Box 3724
              Ann Arbor, MI 48106
              Tel.: [phone]

European Standards Applicable to Use of Emergency Stop Safety Modules

ISO/TR12100-1&-2  “Safety of Machinery—Basic Concepts, General Principles for Design
  (EN 292-1 & -2)    Part 1: Basic Terminology, Methodology”; Part 2: Technical Principles and Specifications

  ISO13849-1 (EN 954-1)  “Safety of Machines—Safety Related Parts of Control Systems”

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

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

  ISO13850 (EN 418)  “Safety of Machinery—Emergency Stop Equipment Functional Aspects, Principles for Design”

IEC 60947-5-5    “Electrical Emergency Stop Devices with Mechanical Latching Function”
          Available from:  Global Engineering Documents
              15 Inverness Way East
              Englewood, CO 80112-5704
              Tel.: [phone]

2 P/N 67709 rev. A

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

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

21 22

13 14

41 42

33 34

21 22

13 14

41 42

33 34

21 22

13 14

41 42

33 34

13-14

21-22

Break (180N)

Tension

Set Point

240N

Latch

Pull (300N)

-5 (0.20)

+5 (0.20)

-3.8 (0.15)

-3 (0.12)

+3 (0.12)

mm (in)

+3.8 (0.15)

33-34

41-42

Latch

Models

RP-LS42F-75L.. Series

†

Model

RP-LS42F-75L No No

RP-LS42F-75LE Yes Yes

RP-LS42F-75LF No Ye s

NOTE:     This symbol for a positive-opening safety contact (IEC 60947-5-1) is used in the switching diagram to identify the point in actuator travel where 

the normally-closed safety contact is fully open.

E-Stop

Built-in

Turnbuckle

WARNING ...

Run

Position

Cable Pulled/

Cable Break

Contacts: 

Overview

Switching

Diagram

 Open        Closed        Transition

Not a Safeguarding
Device

An Emergency Stop Device, including,
but not limited to buttons, rope pulls and
cable pulls, is not generally considered
a safeguard; and does not alone fulfill
U.S. or International requirements for
safeguarding hazards associated with
machinery.

The definition of safeguarding is the 
"protective measure using safeguards [guards 
or protective devices] to protect persons from 
the hazards which cannot reasonably be 
eliminated..." (ISO12100-1, 3.29 and 3.30).

A safeguard limits or eliminates an individual's 
exposure to a hazard (examples include 
interlocking devices, safety mats, safety light 
screens). An emergency stop is considered 
to be a complementary protective measure, 
which is neither an inherently safe design 
measure, nor safeguarding, but may 
be required as part of the safety related 
control system and risk reduction strategy 
(ISO12100-2, 4.5.1 and 4.5.2).

The user must refer to the relevant
standard(s) to determine the safeguarding
requirements for their particular situation.

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

P/N 67709 rev. A 3

www.bannerengineering.com  •  Tel: [phone]

Models RP-LS42F-75L.. are rope pull emergency stop switches in compact, limit switch­style housings made of high-impact thermoplast. When used with steel wire rope, they 
can provide emergency stop actuation along conveyors and similar machinery. Red
PVC-covered 3 mm diameter wire rope is recommended (see page 10).

The switches have redundant contacts; terminals 21/22 and 41/42 are positive opening 
when there is a cable-pull or cable-brake situation. When used separately, these contacts 
provide inputs to a dual-channel safety module (see Figure 6). Terminals 21/22 and 
41/42 can also be used individually to provide single-channel switching or as a single­channel input to a safety module. Terminals 13/14 and 33/34 are for monitoring purposes 
only (closed in a cable-brake/-pull situation).

When the rope is properly tensioned (240N), the red arrows are centered on the hash 
mark on the tension indicator window, the contacts at terminals 21/22 and 41/42 are 
closed, and the contacts at terminals 13/14 and 33/34 are opened (see Figures 1, 2

and 4).

These rope pull emergency stop switches are not generally considered safeguarding 
devices, in that they do not prevent or reduce exposure of individuals to a hazard. They 
provide the same function as other types of emergency stop switches.

All models feature “latching” operation. When the rope is pulled, the switch contacts 
21/22 and 41/42 open and remain open until the built-in reset button is manually reset

(see Figure 1).

Rope Pull Emergency Stop Switches –

Run Position: Proper Rope Tension

Rope Pulled: Contacts S21/22 and 41/42 Open

Rope Break or Slack: Contacts S21/22 and 41/42 Open

RP-LS42F-75L.. Series

Figure 1. Run, rope pulled, and rope break switch positions

Mechanical Installation

Installation Guidelines

•   The wire rope should be easily accessible and visible along its entire length. Markers 
or flags may be fixed on the rope to increase its visibility.

•  Mounting points, including support points, must be rigid.

•  The rope should be free of friction at all supports. Pulleys are recommended.  

•   Use only pulleys (not eye bolts) when routing the rope around a corner, or whenever 
direction is changed, even slightly.

•  Never run rope through conduit or other tubing.  

•  Never attach weights to the rope.

•   Temperature affects rope tension. The rope expands (lengthens) when temperature 
increases, and contracts (shrinks) when temperature decreases. Significant 
temperature variations require frequent checks of the tension adjustment.

•   Do not exceed the maximum total rope length, as specified in Figure 3. Banner offers 
models for greater spans; contact the factory or visit www.bannerengineering.com for 
model selection.

Installation Procedure

1. Mount the switch securely on a solid, stationary surface.

2.  Fasten an eye bolt at the opposite end of the rope span, up to 75 m (245') from the 

switch. The anchor for the eye bolt also must be solid and stationary, to withstand the 
constant tension and possible pull of the rope.

3.  Assemble the rope, as shown in Figure 3. Keep the rope’s PVC cover intact along its 

complete length.

4.  Use pulleys (recommended) or eye bolts at each support point. A pulley must be used 

when routing the rope around a corner, regardless of the angle.

4 P/N 67709 rev. A

Figure 2. Tightening the rope into the internal

turnbuckle (models RP-LS42F-75LE
and RP-LS42F-75LF)

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

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

340 mm

L3

Spring breakage

protector cable

L1

L1

L3

L4 L2

L4L4

400 mm (16") max.

for actuation of switch

Note:
Force to actuate must
not exceed 200 N (45lbf)

L2

RP-LS42F-75L.. Series

NOTE:
All hardware is supplied by the user. The
switch mounting holes are on a mounting
pattern of 30 x 124 millimeters, and
accept M5 (#10) hardware.

Max. Total

Length

L1

75 m (245') 3-5 m (10'-15') 150 mm (6") 150 mm (6")

*Closer, if possible
**Distance must allow necessary clearance to all mounting hardware

Max. Distance

Between Pulleys

L2

Figure 3. Assembly of rope and hardware (rope span components are listed on page 10)

Tension
indicator

Tension
indicator

Installing Model RP-LS42F-75LE or RP-LS42F-75LF

These models have their own internal turnbuckle and clamp to tension the rope and 
to hold it in place. This innovative design provides for quick and easy rope fixing and 
tensioning, and means no external turnbuckle is required, nor is any additional clamp 
required at the switch end of the rope.

To install the rope at the switch end, strip away several inches of the cable covering, as 

Too Little
Tension
Shown

8 mm wrench

Proper
Tension
Shown

shown in Figure 2. Loosen the set screw on the switch fitting, using a 4 mm hex wrench. 
Insert the cable into the center hole, and pull the cut end out from the side hole. When 
the tension is correct, tighten the set screw to hold the rope firmly in place.

Tensioning the Rope

After the rope span components are installed, apply tension to the rope until the arrows 
in the tensioning indicator are centered on the line in the indicator window (see Figure 4). 
This indicates sufficient rope tension. (Contacts 21/22 and 41/42 will close.)

Max. Distance To

Spring/Turnbuckle

L3*

Min. Distance

Fitting to Pulley

L4**

Model RP-LS42F-75L: Turn the turnbuckle until the arrows are centered. 
Models RP-LS42F-75LE
and RP-LS42F-75LF:    Turn the shaft of the switch using an 8 mm wrench as shown in

Figure 4, until the arrows are centered.

Figure 4. Applying tension to the rope

(models RP-LS42F-75LE and
RP-LS42F-75LF)

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

P/N 67709 rev. A 5

www.bannerengineering.com  •  Tel: [phone]

indicator window do not return to the correct position (centered on the line in the 
window), further tighten or loosen the rope tension as needed until proper tension is 
shown after such a reset.

Pull hard on the rope and reset the latch several times. If the arrows in the tensioning 

Rope Pull Emergency Stop Switches –

41 42 33 34

13 14 21 22

RP-LS42F-75L.. Series

Electrical Installation

Access to Wiring Chamber

The wiring chamber is accessed via the hinged door. Simply insert a flat-blade 
screwdriver, as shown in Figure 5, and pry gently down to open. Select the best wiring 
entrance and thread in the ½" x 14 NPSM conduit adapter (supplied), or the optional
M20 x 1.5 cable gland (page 11). The switch knockout will break loose with the final turn 
of the conduit adapter or cable gland.

To open wiring chamber:

1.  Insert the screwdriver blade 
into slot in cover to pry cover

open.

Figure 5. Access to wiring chamber – use a small flat-blade screwdriver

To connect wires to terminals:

1.  Insert the screwdriver blade into the slot below the 
desired wiring terminal.

2.  Twist the screwdriver blade in the slot to open the 
terminal jaws; insert wire.

3. Hold wire in place and remove screwdriver.

Wiring

These switch models have redundant pairs of safety contacts, so they may be wired for 
either single-channel or dual-channel output to a safety module or E-stop circuit. Monitor 
contacts, in either case, may be wired as desired to an external alarm device.

Single-Channel Output: Wire contacts 21/22 or 41/42 together to the input of a safety 
module or E-stop circuit.

Dual-Channel Output: Wire contacts 21/22 and 41/42  independently to the two safety 
module inputs (see Figure 6).

Dual-Channel Safety Device

CH 1CH 2

Figure 6. Wire the two switch contacts in

series

6 P/N 67709 rev. A

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

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

RP-LS42F-75L.. Series

Model RP-LS42F-75L
and RP-LS42F-75LF

Pull

Model RP-LS42F-75LE

Turn clockwise
to reset

NOTE: Proper rope tension must

be displayed before latch
can be reset

Figure 7. Resetting the latch

E-Stop Reset

E-Stop and Latch Reset

Following the pulling of the rope or the pressing of the E-stop button (model RP-LS42F­75LE), the latch must be reset. The procedure differs slightly between the two models. 

See Figure 6.

Models RP-LS42F-75L and RP-LS42F-75LF: Pull the blue reset button; the arrows 
should then be centered in the tensioning indicator window.

Model RP-LS42F-75LE: The E-stop can be reset only when proper tension is indicated. 
Turn the yellow knob clockwise until the blue arrow is in the “I” position (indicating that 
the latch has been reset). The latch should make an audible click when reset.

Maintenance

Each rope pull emergency stop installation should be tested for proper machine 
shutdown response at each shift change or machine setup by a Designated Person*.
In addition, a Qualified Person* should check for proper rope tension, and adjust as 
needed, on a periodic schedule determined by the user, based upon severity of the 
operating environment and the frequency of switch actuations.

The pulleys and other moving parts associated with the rope should be periodically 
lubricated. If inspection reveals dirt on the rope pull switch or rope assembly, the dirt 
must be cleaned off and its cause must be eliminated. Replace the rope pull switch 
and/or rope assembly when any parts (including contacts) or assemblies are found to be 
damaged, broken, deformed, or badly worn.

The rope pull switch and rope assembly should be replaced at specified intervals based 
upon the environment and operating conditions. Replacement of the rope pull switch and 
rope assembly should be considered after no more than 500,000 operations. Always 
test the control system for proper functioning under machine control conditions after 
maintenance or replacement of the rope pull switch.

* A Designated Person is identified in writing by the employer as being appropriately trained to perform 

a specified checkout procedure. A Qualified Person possesses a recognized degree or certificate 
or has extensive knowledge, training, and experience to be able to solve problems relating to the 
emergency stop rope pull switch installation.

Repairs

Banner rope pull emergency stop switches have no field-replaceable components.  
Contact the Banner Factory Application Engineering Group at the address or the 
numbers listed at the bottom of the back page. They will issue an RMA (Return 
Merchandise Authorization) number for your paperwork, and give you the proper shipping

address.

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

P/N 67709 rev. A 7

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

Specifications

Contact Rating 10A @ 24V ac, 10A @ 110V ac, 6A @ 230V ac

6A @ 24V dc

2.5 kV max. transient tolerance
NEMA A300 P300

European Rating Utilization categories: AC15 and DC13

Ui  = 500V ac
Ith = 10A

Contact Material Silver-nickel alloy

Maximum Switching Speed 50 operations per minute

Recommended Rope Size 3 mm diameter steel rope (See Accessories, p. 10)

RP-LS42F-75L.. Series

40-60 Hz

U

V

24 10 6

110 10 1

230 6 0.4

Ie/AC-15

e

A

I

/DC-13

e

A

Maximum Rope Pull Length 75 m (245')

Short Circuit Protection 10 amp Slow Blow, 15 amp Fast Blow. Recommended external fusing or overload protection.

Mechanical Life 1 million operations

Wire Connections Screw terminals with pressure plates accept the following wire sizes –

Stranded and solid: 20 AWG (0.5 mm
Stranded: 20 AWG (0.5 mm

Cable Entry M20 x 1.5 threaded entrance

Adapter supplied to convert M20 x 1.5 to ½" - 14 NPT threaded entrance

Construction High-impact thermoplastic housing; zinc die-cast actuator

Environmental Rating NEMA 4, IEC IP67

Operating Conditions Temperature:

Weight RP-LS42F-75L: 0.48 Kg (1.05 lbs.)

RP-LS42F-75LE: 0.65 Kg (1.43 lbs.)
RP-LS42F-75LF: 0.65 Kg (1.43 lbs.)

Certifications

-25° to +70° C (-22° to +176° F)

2

) to 18 AWG (1.0 mm2) for two wires

2

) to 16 AWG (1.5 mm2) for one wire

8 P/N 67709 rev. A

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

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

88.0 mm
(3.46")

294.0 mm
(11.57")

256.0 mm
(10.08")

42.0 mm
(1.65")

45.0 mm
(1.77")

78.3 mm
(3.08")

5.0 mm
(0.20")

124.0 mm
(4.88")

224.0 mm
(8.82")

30.0 mm
(1.18")

78.3 mm
(3.08")

Dimensions

RP-LS42F-75L

RP-LS42F-75L.. Series

RP-LS42F-75LE

RP-LS42F-75LF

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

P/N 67709 rev. A 9

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

Spring breakage

protector cable

Spring breakage

protector cable

Thimble

Thimble

Clamp

Clamp

Turnbuckle Spring

Spring

Eye Bolt

Eye Bolt

Pulley

Pulley

Accessories

Components for Wire Rope Assembly

Model

RPA-C2-10 10 m (33')

RPA-C2-20 20 m (66')

RPA-C2-80 80 m (264')

RPA-T2-4 4 pcs Thimble for 3 mm wire rope

RPA-CC2-4 4 pcs Clamp for 3 mm wire rope

RPA-TA1-1 1 pc #4 Turnbuckle

Package
Quantity

Description

3 mm steel wire rope with

0.25 mm red PVC jacket
(unterminated)

RP-LS42F-75L.. Series

RPA-EB1-1 1 pc

1/4"-20 Eye bolt
(3" bolt shaft)

RPA-P1-1 1 pc Pulley

RPA-S3-1 1 pc Tensioning spring

Tensioning spring with

RPA-S4-1 1 pc

built-in eye bolt, cable thimble,
clamping, tensioning, and
overload protection

NOTE: If model RPA-S4-1 tensioning spring is used, eliminate eye bolt, spring,

protector cable, clamp and thimble from versions shown here.

Figure 7. Wire rope assembly components

10 P/N 67709 rev. A

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

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

23.0 mm
(0.91")

M20 x 1.5

24.0 mm
(0.94")

1/2"-14 NPT

Internal Thread

O-ring

M20 x 1.5

25.0 mm
(0.98")

37.0 mm
(1.46")

Size Model

Used with

Switch Models

Accessories, continued

Cable Glands

For Cable

Diameters

RP-LS42F-75L.. Series

Dimensions

M20 x 1.5

Plastic

Size Model*

½"-14

NPT Plastic

*NOTE: One conduit adapter is supplied with each switch.

SI-QS-CGM20 All

Used with

Switch Models

SI-QS-M20 All

6.0 to 12.0 mm

(0.24" to 0.47")

Conduit Adaptors

Thread

Conversion

M20 x 1.5 to

½" -14 NPT

Dimensions

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

P/N 67709 rev. A 11

www.bannerengineering.com  •  Tel: [phone]

Rope Pull Emergency Stop Switches –

RP-LS42F-75L.. Series

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

free of charge, any product of its manufacture found to be defective at the time it is returned to the factory during the warranty period. This warranty 
does not cover damage or liability for the improper application of Banner products. This warranty is in lieu of any other warranty either expressed or 
implied.

P/N 67709 rev. A

Banner Engineering Corp., 9714 Tenth Ave. No., Minneapolis, MN USA 55441 • Phone: [phone] • www.bannerengineering.com • Email: [e-mail]