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]