Banner RP-QM90 Rope Pull Switch User Manual

23 24

11 12

11 12

23 24

23 24

11 12

11 12

23 24

23 24

11 12

11 12

23 24

11 - 12

23 - 24

40°

40°

30°

30°

0

Lock

70N

70N

Lock

Lever

11 - 12

23 - 24

RightLeft

RP-QM90 Series Rope Pull Switches

62086

Datasheet

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

upon springs

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

• Heavy-duty die cast metal housing, rated IP65, suitable for demanding

industrial environments

• Rope spans up to 100 m (330 ft), with the switch mounted in the center

of the span

• 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

• Switch actuator position clearly indicates when rope has proper tension

for operation

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

•
Protective Earth Terminal (IEC 60947-1)

Model

Max. Overall

Run Position Cable Pulled

Rope Length

RP-QM90F-100L 100 m (330 ft)

Contacts: Open Closed

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.

Important... Read This First

(either side)

Cable Break
(either side)

Switching Diagram

Regarding the Use of Rope Pull Switches. In the United States, the functions that Banner rope pull 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 in this document. Direct any questions regarding the use or installation of rope pull switches to the factory
applications department.

P/N 62086 Rev. D 4 February 2014

RP-QM90 Series Rope Pull Switches

Banner Engineering Corp. recommends that rope pull switches be applied according to the guidelines set forth in the
standards listed below. In addition, the user is responsible for ensuring all local, state, and national laws, rules, codes, and
regulations relating to the use of Banner rope pull switches in each application are satisfied. Extreme care is urged that all
legal requirements are met and that all installation and maintenance instructions are followed.

Applicable U.S. Standards

OSHA Code of Federal Regulations: Title 29, Parts 1900 to 1910
Available from: Superintendent of Documents, Government Printing Office, P.O. Box 371954, Pittsburgh, PA 15250-7954,

Tel: [phone]
ANSI B11 Standards for Machine Tools Safety
Contact: Safety Director, AMT – The Association for Manufacturing Technology, 7901 Westpark Drive, McLean, VA 22102,

Tel.: [phone]

Applicable European and International Standards

ISO/TR 12100-1 (EN 292-1 & -2) Safety of Machinery – Basic Concepts, General Principles for Design
ISO 13852 (EN 294) Safety of Machinery—Safety Distances to Prevent Danger Zones Being Reached by the Upper Limbs
ISO 13853 (EN 811) Safety of Machinery—Safety Distances to Prevent Danger Zones Being Reached by the Lower Limbs
ISO 13849-1 (EN 954-1) Safety-Related Parts of Control Systems
ISO 13855 (EN 999) The Positioning of Protective Equipment in Respect to Approach Speeds of Parts of the Human Body
ISO 14119 (EN 1088) Interlocking Devices Associated with Guards – Principles for Design and Selection
IEC 60204-1 Electrical Equipment of Machines Part 1: General Requirements
IEC 60947-5-1 Low Voltage Switchgear – Electromechanical Control Circuit Devices
Contact: Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5704, Tel.: [phone]

Overview

The model RP-QM90F-100L is a two-sided rope pull switch in a heavy-duty metal housing. When used with steel wire rope,
it can provide stop actuation along conveyors and similar machinery. This model is designed to be mounted in the center
of a long, straight run of cable (up to 100 meters/330 ft total); this model switch does not accommodate corners along the
cable’s length. Red PVC-covered 4 mm diameter wire rope is recommended.

The switch features redundant terminal pairs. Both pairs of terminals 11–12 will act concurrently and identically to latch
open when the rope is pulled, regardless of which side of the switch the rope is pulled. Both pairs of terminals 23–24 are
normally open monitoring contacts; they will act concurrently and identically to close when the rope is pulled. If the rope
should break or become slack for any reason, the switch actuator will pull to the taut side, so contact behavior for a rope
break condition is the same as that for a rope pull. The contact pairs (the two 11–12 and the two 23–24) should be wired
together, in series.

These rope pull switches are not safeguarding devices, in that they do not protect personnel from injury. They provide the
same function as other types of stop switches.

This rope pull switch features “latching” operation. When the rope is pulled, the switch contacts 11–12 open and remain
open until the built-in reset actuator (the ring) is manually pulled to reset.

WARNING: Not a Safeguarding Device
An Emergency Stop Device is not considered a safeguarding device because it requires an

overt action by an individual to stop machine motion or hazards.

A safeguarding device limits or eliminates an individual's exposure to a hazard without action by the
individual or others. Because an individual must actuate the device for it to function, these devices do

not fit the definition of a safeguarding device and cannot be substituted for required safeguarding. Refer
to the relevant standards to determine those requirements.

2 www.bannerengineering.com - tel: [phone] P/N 62086 Rev. D

11

23

11 12

23 24

Pull ring
to reset

L2 L2

L6

Spring breakage

protector cable

400 mm (16") max.

for Actuation of Switch

50 m (165')

max.

50 m (165')

max.

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

RP-QM90 Series Rope Pull Switches

Figure 1. Run Position: Proper Rope Tension

Figure 2. Rope Pulled: Contact Pairs 11-12 Open

Figure 3. Rope Break or Slack: Contact Pairs 11-12 Open

Mechanical Installation

Installation Guidelines

• The 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 and allow sufficient space around the rope to allow easy
access

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

• The rope may not be routed around a corner, for this model.

• Never run rope through conduit or other tubing

• Never attach weights to the rope

• Temperature affects rope tension. The wire 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 specified total rope length. Banner offers models for other spans; contact Banner
Engineering or visit www.bannerengineering.com for model selection

Springs Used

Tensioning Spring #1 1 m to 2 m (3 ft to 6.5 ft) 380 mm to 410 mm (15.0 inches to 16.1 inches)
Tensioning Spring #2 2 m to 2.5 m (6.5 ft to 8 ft) 310 mm to 320 mm (12.2 inches to 12.6 inches)

P/N 62086 Rev. D www.bannerengineering.com - tel: [phone]

Figure 4. Assembly of Rope and Hardware

Max. Span Between Pulleys (L2) Spring Breakage Protector Cable Length (L6)

Rope Pull

or Break Position –

Not Ready for Operation

Proper Tension for

Operation

11 12

23 24

11 12

23 24

Jumper

To Single-Channel

Safety Device

11 12

23 24

11 12

23 24

Ch 1 Ch 2

To Dual-Channel

Safety Device

RP-QM90 Series Rope Pull Switches

All hardware is supplied by the user. The switch mounting holes are on a standard limit switch mounting pattern of 30 x 60
millimeters, and accept M5 (#10) hardware. Wire rope and associated hardware may be ordered separately; see
Accessories.

Installation Procedure

1. Mount the switch securely on a solid, stationary surface,
approximately in the center of the rope span.

2. Fasten an eye bolt at the far ends of the rope span, up to 50 m
(165 ft) from the switch. The anchor for the eye bolts also must be
solid and stationary, to withstand the constant tension of the rope.

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

4. Use pulleys (recommended) or eye bolts at each support point. If
tensioning spring #1 is used, the span between pulleys may not
exceed 2 m (6.5 ft). If tensioning spring #2 is used, the span
between pulleys may not exceed 2.5 m (8 ft).

Figure 5. Correct Rope Tension Indicator

5. Apply tension to the rope using the turnbuckles on both sides of
the switch actuator. Apply tension until both springs are stretched
equally and the switch actuator is perpendicular to the switch
housing. (Contacts 11–12 will close and contacts 23–24 will remain
open.)

6. Pull hard on the rope and reset the latch several times. If contacts
11–12 remain open following the reset, further tighten the
turnbuckle, until the contacts close.

7. Repeat step 6 until contacts 11–12 remain closed for the Run
condition

Electrical Installation

Access to the Wiring Chamber. The wiring chamber is accessed via a cover plate (remove four screws). A conduit

adapter is supplied to convert the 20 millimeter threaded entrance to 1/2" NPT. An accessory cable gland which fits the
metric thread is also available.

Wiring. Because the model RP-QM90F-100L has redundant pairs of safety contacts, this switch may be wired for either
single-channel or dual-channel output to a safety device. Monitor contacts, in either case, may be wired as desired to an
external alarm device. Wire the two switch contacts in series.

Single-Channel Output. Jumper the two pairs of safety contacts 11–12 and wire together to the input of a safety device
Dual-Channel Output. No jumpering is required between the two pairs of safety contacts 11–12. Wire them

independently to two safety device inputs.

Figure 6. Single-Channel Safety Device

4 www.bannerengineering.com - tel: [phone] P/N 62086 Rev. D

Figure 7. Dual-Channel Safety Device

RP-QM90 Series Rope Pull Switches

Maintenance/Checkout

At switch installation or replacement and at machine set up, a Designated Person

1

must test each switch for proper
machine shutdown response and check the switch(es) and installation for proper operation, physical damage, mounting
(looseness), and excessive environmental contamination. This must also take place on a periodic schedule determined by
the user, based on the severity of the operating environment and the frequency of switch actuations. Adjust, repair, or
replace components as needed. If inspection reveals contamination on the switch, thoroughly clean the switch and
eliminate the cause of the contamination. Replace the switch and/or appropriate components when any parts or
assemblies are damaged, broken, deformed, or badly worn; or if the electrical/mechanical specifications (for the
environment and operating conditions) have been exceeded. Always test the control system for proper functioning under
machine control conditions after performing maintenance, replacing the switch, or replacing any component of the switch.

Additional items that should be included in the checkout and/or regularly scheduled maintenance of a rope pull system:

• Check for proper rope tension and adjust as needed

• Verify free operation (no binding) of the rope and proper tripping when the rope is pulled

• Periodically lubricate the pulleys and other moving parts associated with the rope

• Repair any loose or damaged hardware, worn/frayed rope (cable), missing red rope sheathing or flags/markers (if
used)

• Remove or clean off any contamination and eliminate its cause

Repairs

Contact Banner Engineering for troubleshooting of this device. Do not attempt any repairs to this Banner device; it
contains no field-replaceable components. If the device or a device component is determined to be defective by a

Banner Applications Engineer, they will advise you of Banner's RMA (Return Merchandise Authorization) procedure.

Important: If instructed to return the device, pack it with care. Damage that occurs in return shipping
is not covered by warranty.

Specifications

Contact Rating

10 A at 24 V ac
10 A at 110 V ac
6 A at 230 V ac
6 A at 24 V dc

2.5 kV max. transient tolerance
NEMA A300 P300

European Rating

Utilization categories: AC15 and DC13
Ui = 500 V ac; Ith = 10 A

40-60 Hz

Ue (V) Ie/AC-15 (A) Ie/DC-13 (A)

24 10 6
110 10 1
230 6 0.4

Contact Material

Silver-nickel allow

Maximum Switching Speed

50 operations per minute

Recommended Rope Size

4 mm diameter steel rope

Maximum Rope Pull Length

100 m (330 ft); equal lengths up to 50 m (165 ft) on either side of
switch

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 mm2) to 16 AWG (1.5 mm2) for
one wire
Stranded: 20 AWG (0.5 mm2) to 18 AWG (1.0 mm2) for two wires

Cable Entry

M20 x 1.5 threaded entrance. Adapter supplied to convert M20 x

1.5 to ½"-14 NPST threaded entrance

Construction

Aluminum alloy die-cast

Environmental Rating

IEC IP65

Operating Conditions

Temperature: –30 °C to 80 °C (–22 °F to 176 °F)

Weight

3.8 Kg (8.4 lbs)

Certifications

1

A Designated Person is identified in writing by the employer as being appropriately trained to perform a specified checkout procedure.

P/N 62086 Rev. D www.bannerengineering.com - tel: [phone]

11 12

23 24

11 12

23 24

206 mm

(8.10")

10.0 mm
(0.39")

58 mm
(2.33")

24.5 mm
(0.97")

125 mm

(4.90")

137 mm

(5.40")

186.0 mm
(7.33")

103 mm

(4.1")

60.0 mm
(2.36")

90 mm
(3.50")

100 mm

(3.90")

4x ø10.0 mm

(0.39")

M20 x 1.5

M20 x 1.5
(one on each end)

16.5 mm
(0.65")

ø30 mm

(1.20")

95 mm
(3.70")

63 mm
(2.50")

25.0 mm
(1.0") square

M20 x 1.5

24.0 mm
(0.94")

35.5 mm
(1.40")

23.0 mm
(0.91")

M20 x 1.5

24.0 mm
(0.94")

1/2"-14 NPT

Internal Thread

O-ring

RP-QM90 Series Rope Pull Switches

Dimensions

Accessories

Cable Glands

Model

SI-QM-CGM20 M20 × 1.5 Metal

Conduit Adapters

Model

SI-QM-M20

6 www.bannerengineering.com - tel: [phone] P/N 62086 Rev. D

For Cable

Size

Diameter

Dimensions Used With

SI-LM40 Safety Interlock

5.0 to 12.0 mm
(0.20 to 0.47 inches)

Switches
SI-QM100 Safety Interlock
Switches
RP-RM83 Rope Pull Switches
RP-LM40 Rope Pull Switches
RP-QM72/QMT72 Rope Pull
Switches
RP-QM90 Rope Pull Switches

Size Thread Conversion Dimensions Used With

SI-LM40 Safety Interlock
Switches
SI-QM100 Safety Interlock

½ in-14 NPT
Metal

M20 × 1.5 to ½
in-14 NPT

Switches
RP-RM83 Rope Pull Switches
RP-LM40 Rope Pull Switches
RP-QM72/QMT72 Rope Pull
Switches
RP-QM90 Rope Pull Switches

11

23

11 12

23 24

Pull ring
to reset

Thimble Clamp

PulleyTensioning Spring

Turnbuckle Eye Bolt

Spring breakage

protector cable

RP-QM90 Series Rope Pull Switches

One conduit adapter is supplied with each switch.

Components for the Wire Rope Assembly

Figure 8. Wire Rope Assembly Components

Model
RPA-C3-10 10 m (33 ft)
RPA-C3-100 100 m (330 ft)

Length Description Wire Rope

4 mm steel wire rope with 0.5 mm red PVC jacket
(unterminated)

Model Quantity Description Thimble

RPA-T3-4 4 Thimble for 4 mm wire rope

Model Quantity Description Clamp
RPA-CC3-4 4 Clamp for 4 mm wire rope

Model Quantity Description Turnbuckle
RPA-TA2-1 4 #5 Turnbuckle

Model Quantity Description Eye Bolt

RPA-EB1-1 1 ¼"-20 Eye bolt (3" bolt shaft)

Model Quantity Description Pulley
RPA-P1-1 1 Hanging pulley for in-line use

P/N 62086 Rev. D www.bannerengineering.com - tel: [phone]

Model Quantity Description Tensioning Spring
RPA-S1-1 1 Tensioning spring #1

Model Quantity Description Tensioning Spring
RPA-S2-1 1 Tensioning spring #2

RP-QM90 Series Rope Pull Switches

Banner Engineering Corp Limited Warranty

Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following
the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture
which, at the time it is returned to the factory, is found to have been defective during the warranty period. This warranty
does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.

THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR
IMPLIED (INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE, COURSE OF DEALING OR
TRADE USAGE.

This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO
EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR
ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSEQUENTIAL OR
SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE
PRODUCT, WHETHER ARISING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY,
NEGLIGENCE, OR OTHERWISE.

Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any
obligations or liabilities relating to any product previously manufactured by Banner Engineering Corp.

www.bannerengineering.com - tel: [phone]