ess3 user manual
Contents
1. The slack rope method of operation requires that the pull cord have very little slack without any tension This is achieved by pulling any slack around one of the eyelets at either end of the pull cord and securing it using a U bolt clamp 6 MONITORED LANYARD OPERATION Monitored lanyard installation is only intended when the pullkey type ESS3 is fully integrated into industrial machinery or conveyor control systems using control signals of less than 32 volts ac or 48 volts dc This type of installation is not to be carried out without prior additional guidance from Austdac Inc to ensure that the installation is in accordance with UL NFPA and NEC requirements The monitored lanyard method of operation can distinguish between intentional operation and system faults The monitored lanyard method of actuation can also detect a broken actuating cord Photograph 5 ESS3 Pullkey with monitored lanyard setup Photograph 5 above shows an example of the monitored lanyard method of actuation No tensioning of the pull cord is required for this method of actuation 7 TENSIONED OPERATION The tensioned variant of the ESS3 employs tensioned plastic coated stainless steel cable as the means of actuation All electrical cabling between pullkeys is in conduit or cable ducting This method of operation is prone to coefficient of expansion issues and movement within conveyor structure This method requires correct tensioning of the actuation cable2. A ac Title PULLKEY SWITCH TYPE ESS3 USER S MANUAL Document Number 92 300 12 06 REVISION CONTROL if 04 Change 50 C to 60 C 2011 07 14 PB PB MC 03 Change 40 C to 50 C 2011 06 16 PB PB MC 06 Add UL number 2014 09 09 SCa SCa RG 05 Add mounting instructions 2011 09 14 PB PB NK Issue Details Date Written Designed Approved Austdac Pty Ltd Unit 1 4 Packard Avenue Castle Hill NSW 2154 Australia PO Box 6486 Baulkham Hills Business Centre NSW 2153 Australia Phone 61 2 8851 5000 Fax 61 2 9899 2490 Website www austdac com au Austdac Inc 455 Lowries Run Rd Pittsburgh PA 15237 USA Phone 1 888 254 9155 Fax 1 412 635 0179 Copyright 2011 01 06 This document remains the property of Austdac Pty Ltd It is subject to its recall and must not be reproduced in part or whole or its contents divulged to third parties without prior written approval from Austdac Pty Ltd PULLKEY SWITCH 2 OF 16 ESS3 USER S MANUAL 52 300 12 x austda TABLE OF CONTENTS REVISION CONT ROL as secackvaatceccgaseceantece skinenn eresia arataa nE Cates cats cancsvemeaacadseaduendessiveceas nacida 2 TABLE OF CONTENTS 0 reer eee er ee eee en ee ee ee ee re 3 PR ROTOGRAP HS atera 3 TABLES mire a ee a ee ee ee eee ee re ee 3 FIGURE Stress 3 1 GENERAL DESCRIPTION s n later iron 4 2 FRONT PANEL LAYOUT asta t 5 ODES euca
3. 06 ron x i i 2 FRONT PANEL LAYOUT The front panel has a centrally located red switch actuator and indicator knob This knob can be used to operate the switch or be used as an indicator of the status of the switch The knob rotates between the two switch status positions the RESET or ON position and the LOCKOUT or OFF position The knob is surrounded by a raised area of the front cover with a channel through this raised area either side of the knob If the switch is in the RESET state the knob points to the RESET indicator text on the raised portion of the front cover The raised area hides the knob cat s eyes from general view providing long distance indication that the switch is in the RESET or ON state If the switch is in the LOCKOUT or OFF state the knob is rotated to align with the channels on both sides This allows the cats eyes to be seen at a distance indicating that the switch is in the LOCKOUT or OFF state Photograph 2 The switch in the reset or on state Photograph 2 shows the pullkey in the RESET or ON state the knob slopes at 60 Photograph 3 The switch in the lockout or off state Photograph 3 shows the pullkey in the LOCKOUT or OFF state the knob is now horizontal exposing the cats eyes through the channels of the cover PULLKEY SWITCH 5 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 3 MODELS
4. and constant checking for conveyor structure movement and re tensioning to avoid nuisance trips or stops The monitoring of the actuation cable is carried out by the tensioned actuation cable The tensioned method can not distinguish between an intentional operation or system problem or fault This method of actuation can detect a broken actuating cord Photograph 6 ESS3 Pullkey with Tension Setup PULLKEY SWITCH 8 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 roo x ih The actuating cord or steel cable needs to be tensioned correctly before the pullkey front panel knob can be placed in the reset position To achieve the correct tension the pull cord needs to be connected to the pullkey via fully extended turnbuckle as shown in photograph 5 above The other end of the pull cord should be secured to another pullkey in a similar fashion or to a tension spring as shown in photograph 6 below Photograph 7 Tension Spring Secured to Structure The pull cord should then be made taut by pulling any slack around one of the eyelets at either end of the pull cord and securing it using a U bolt clamp The turnbuckle should then be wound to tension the pull cord continue tensioning the pull cord until the tension gauge indicates the correct tension position as shown in photograph 7 below Lock off the turnbuckle using the two back nuts fitted to the turnbuckle Place the pullkey in the reset position The tension gauge
5. are operated differently by the cam they are both less likely to fail from a common cause failure 2 TB2D O 10 1 SWla D 3 TB2E lr 11 SERIES STOP CIRCUIT OUT SHOWN IN RESET TB2F 12 L CAM PUSHES SWITCH LEVER GOING INTO LOCKOUT E 2 TB3D 2 16 1 SW3a 23 TB3E_ 2 17 SHOWN IN RESET CAM PUSHES SWITCH LEVER GOING INTO LOCKOUT SERIES STOP CIRCUIT IN Figure 3 Switch Wiring without Diversity Figure 2 above shows switch SW1 wired in series with SW3 and because both switches are operated by the same method they are both likely to fail from a common cause failure PULLKEY SWITCH 10 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 i 9 TERMINATIONS AND CONNECTIONS All connections to the type ESS3 pullkey are via cage clamp terminals located within the main body of the pullkey Access to these terminals is gained by loosening the four front panel retaining screws and removing the front cover These terminals can accommodate up to 2 5mm or 14awg conductors All contact references NO NC are for the pullkey in the reset position if DESCRIPTION NORMALLY OPEN CONTACT 11 NC NORMALLY CLOSED CONTACT 12 COM COMMON CHANGEOVER CONTACT Table 3 Switch SW1a Termination Details 3 TB2D 10 NO SWla _9 1 ea A 2 TB2E zH NC SHOWN IN RESET TB2F z2 COM CAM PUSHES SWITCH LEVER GOING INTO LOCKOUT Figure 4 Switch SW1a Schematic The pullkey cam activates the lever of switch SW1a w
6. L R 3MS cccccccceeeeeeseeeneeeeeeeeeeeeseeensaaees 0 5A DC Electrical life at rated DC lo adheicicccssccccstsscnccessinreecasacneetnesedieeatdecsithenesateetannse 6 000 operations Me hanical life seacoast ie cases easier eee eee ean ee ee 2 x 10 operations Switch status WIC ATOM rabia passive reflective Cable ENTES iaa Up to 4 x down facing Auxiliary EMOS nido Pere 1 x up facing M20 nipple or cable entry PULLKEY SWITCH 15 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 A austdac a Actuator pull force straight out cita idas 1 to 10N Actuator pull force pull down over pigtails at 3m spacing coooooooooccccn nnnnnncocancccnnnnnnnnns 1 to 10N Actuator pull distance non tensiONed oooooooccccn nncononcononcncnnnonnnnnnnnnnn non nonnn nn nana nn rrcnnnninns 40mm Actuator pull distance tensioned eco 20mm Actuator release distance tensioned oocccconnnononccocnonononnnnnnnccnnnnnnnn nana 20mm nl 5N Knob angular TONG sirensis niian tii 1 to 10N Knob angular displacement sun s 60 degrees Internal volume ae en ee o ee net ee cere eee ee ee 1 195L PULLKEY SWITCH 16 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06
7. The Pullkey type ESS3 is available in various models depending on the actuation method and the type of switch module fitted Refer to table 1 below for a list of models and features if PULLKEY TYPE ESS3 MODEL NUMBERS F OPERATION FITTED TYPE RATIN pO Et METHOD SWITCHES FITTED j SLACK sal 5A PKEY001 ROPE SW2a b DC1 125Vac SW3a b SWia b 5A PKEYO51 TENSIONED SW2a b DC1 125Vac SW3a b SWia b SLACK 0 1A PKEY002 ROPE SW2a b DC3 125Vac SW3a b SWia b 01A PKEY052 TENSIONED SW2a b DC3 l 125Vac SW3a b SWia b DC3 0 1A 125Vac SLACK PKEY003 SW2a b DC1 5A 125Vac ROPE NOT FITTED SWia b DC3 0 1A 125Vac PKEY053 TENSIONED SW2a b DC1 5A 125Vac NOT FITTED NOTE 1 This table does not apply to monitored lanyard installations see section 5 Always contact Austdac Inc for additional guidance and information for these types of installations Table 1 Pullkey type ESS3 model numbers Models fitted with DC1 type switches with a rating of 5 amps at 125 volts a c are designed to be used in systems that simply place pullkey switches in series along a conveyor and control a contactor that in turn controls the conveyor motor These types of installations employ low voltage circuits that can cause electric shock and should only be maintained by persons with appropriate qualifications or licenses Models fitted with DC3 type switches with a rating of 0 1 amps at
8. should be used periodically to check for the correct tension and the turnbuckle adjusted accordingly LOCKOUT BEFORE REMOVING COVER Photograph 8 Use of tension gauge in tensioned installations Photograph 8 above shows correct use of tension gauge in setting up the correct tension of the type ESS3 tensioned pullkey PULLKEY SWITCH 9 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 8 IEC 61508 DIVERSITY Some installations may require two switches in series to help meet redundancy requirements of IEC61508 simply placing two switches in series may not achieve the required failure rate required by the installation The pullkey type ESS3 has internal switches that are actuated and not actuated depending on the position of the front panel control knob X austda RESET Not actuated Actuated Not actuated LOCKOUT Actuated Not actuated Actuated Table 2 ESS3 switch actuation details By wiring the correct switches in series the reliability of the breaking of the series circuit can be significantly improved o2 TB2D D 10 1 SWla a3 TB2E gt 11 SERIES STOP CIRCUIT OUT SHOWN IN RESET 12 2 CAM PUSHES SWITCH LEVER GOING INTO LOCKOUT i e a 2 TBID 2 4 2 3 TBIE A 5 SHOWN IN RESET TBIF 5 6 CAM RELEASES SWITCH LEVER GOING INTO LOCKOUT SERIES STOP CIRCUIT IN Figure 2 Switch Wiring with Diversity Figure 1 above shows switch SW1 wired in series with SW2 and because the two switches
9. 125 volts a c are designed to be used in signal line systems that use microprocessor based transmitters that send codes to a control system rather than switch a simple series circuit These types of installations employ extra low voltage circuits typically less that 24 volts d c making them safer and capable of meeting various touch potential laws These systems tend to be lanyard actuated PULLKEY SWITCH 6 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 x i 4 MOUNTING INSTRUCTIONS The PULLKEY ESS3 should be mounted with 2 x M8 or M10 bolts not supplied directly to the mounting fixture Fixing centres are 230mm apart SPRING WASHER WASHER WASHER Ns FIXTURE BOLT Figure 1 Pullkey Typical Mounting 5 SLACK ROPE OPERATION The slack rope variant of the ESS3 employs a non tensioned plastic coated stainless steel cable as the means of actuation All electrical cabling between pullkeys is in conduit or cable ducting This method of operation is particularly suitable to installations prone to wide temperature changes and conveyor structure that may move as it does not produce nuisance trips or stops associated with coefficient of expansion characteristics of actuation cables and movement in conveyor structure This method of actuation can not detect a broken actuating cord Photograph 4 ESS3 Pullkey with Slack rope setup PULLKEY SWITCH 70F 16 52 300 12 ESS3 USER S MANUAL Issue 06 austdac staac
10. 17 NC SHOWN IN RESET TB3F gt 18 COM CAM PUSHES SWITCH LEVER GOING INTO LOCKOUT Figure 8 Switch SW3a Schematic The pullkey cam activates the lever of switch SW3a when the pullkey is placed in the lockout position and deactivates the switch lever when the pullkey is placed in the reset position RI ESIGNAT DESCRIPTION 13 NO NORMALLY OPEN CONTACT 14 NC NORMALLY CLOSED CONTACT 15 COM COMMON CHANGEOVER CONTACT Table 8 Switch SW3b Termination Details 3 TB3A 13 NO SW3b_9 m 1 a g2 TB3B 2 14 NC SHOWN IN RESET TB3C J 15 COM CAM PUSHES SWITCH LEVER GOING INTO LOCKOUT Figure 9 Switch SW3b Schematic The pullkey cam activates the lever of switch SW1a when the pullkey is placed in the lockout position and deactivates the switch lever when the pullkey is placed in the reset position PULLKEY SWITCH 13 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 x i 10 CABLE ENTRY The Pullkey type ESS3 is available with conduit or cable gland type entries depending on the type of installation Photograph 9 Pullkey with conduit hubs fitted Photograph 11 Earth continuity detail PULLKEY SWITCH 14 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 aa M 11 SPECIFICATIONS Name sssseeeeessesrrrrrrnretrrrrrrnnnnsessrrnrnnnneeeeeeee Lanyard operated pull key or cable pull limit switch Yp ens aA A N AEE AAE a NEA AEE NARKA A Oak ESS3 MOJO sao ti See table 1 A o An 270mm W
11. ch caer Rashereesncalinaedaneedwauieds 14 TABLES Table 1 Pullkey type Esos model RUIDOS ai A AA 6 Table 2 ESS3 switch actuation details us 10 Table 3 Switch SW1a Termination DetallS oononnncncnnnnoccconocancccnnnnancnnnnnnnoncnnnnnnnncnnnnnnnn cnn naar cnn cnn 11 Table 4 Switch SW1b Termination DetallS oooonnnccccnniccconncancccnnonancncnnnnnnncnnnnnnnncnnnnnnnn cnn nann ana nnnnns 11 Table 5 Switch SW2a Termination DetallS oonoccccnnnnicccnnnnoccccnnnnonccnnnnnnnncnnnnnnnnn cnn nnnnnnnnnnnnnnnnnnnnes 12 Table 6 Switch SW2b Termination DetallS oooooccnnnncccconnnocccccnononncccnnnnnnononnnnnno non nnnnn cnn nnnnncncnnnnos 12 Table 7 Switch SW3a Termination Details ire cea 13 Table 8 Switch SW3b Termination DetallS ccoo sbaevstnied euncdnenedevaoeennennes 13 FIGURES Figure 1 Pullkey Typical Mounting ii os 7 Figure 2 Switch Wiring with Diversity cion ir i 10 Figure 3 Switch Wiring without Diversity oooooccconnnncccconnncccccnonaccncnnnonannnnncnnnnnnnnnnnnn rn nana nn cnn nnancnnnnnns 10 Figure 4 Switch SW1a SOME AUG seran dde 11 Figure 5 Switch SW1b SOMA spin 11 Figure 6 Switch SW2a SAM us a 12 Figure 7 Switch SW2b SCHEV AUG usina 12 Figure 8 Switch SW3a SChSMA escusa iia caia in 13 Figure 9 Switch WSR SEMEN AUG ss ad acian sence eiveduumetenmarsuusinenanseiettasaneatencs 13 PULLKEY SWITCH 3 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 il 1 GENERAL DESCRIPTION The Austdac pull key or cable pu
12. hen the pullkey is placed in the lockout position and deactivates the switch lever when the pullkey is placed in the reset position DESCRIPTION 7 NORMALLY OPEN CONTACT 8 NC NORMALLY CLOSED CONTACT 9 COM COMMON CHANGEOVER CONTACT Table 4 Switch SW1b Termination Details 1 3 TB2A 7 NO SWlb 94 Pie 02 TB2B gt 8 NC SHOWN IN RESET TB2C gt 9 COM CAM PUSHES SWITCH LEVER GOING INTO LOCKOUT Figure 5 Switch SW1b Schematic The pullkey cam activates the lever of switch SW1b when the pullkey is placed in the lockout position and deactivates the switch lever when the pullkey is placed in the reset position PULLKEY SWITCH 11 OF 16 52 300 12 ESS3 USER S MANUAL Issue 06 if Il LE SWITCH SW2a TERMINATIONS TERMINAL DESIGNATION DESCRIPTION 4 NO NORMALLY OPEN CONTACT 5 NC NORMALLY CLOSED CONTACT 6 COM COMMON CHANGEOVER CONTACT PULLKEY SWITCH ESS3 USER S MANUAL Table 5 Switch SW2a Termination Details i SW2a o 3 TBID gt 4 NO 8 m 2 TBIE D 5 NC SHOWN IN RESET TB1F 2 6 COM CAM RELEASES SWITCH LEVER GOING INTO LOCKOUT Figure 6 Switch SW2a Schematic The pullkey cam deactivates the lever of switch SW2a when the pullkey is placed in the lockout position and activates the switch lever when the pullkey is placed in the reset position This is the opposite of switches SW1 and SW3 This provides some degree of diversity to the operation of the
13. lipto rea 6 4 MOUNTING INSTRUCTIONS dotarse rial paa 7 5 SLACK ROPE OPERATO Nasca 7 6 MONITORED LANYARD OPERATION susccinirarae 8 7 TENSIONED OPERATION osituai nataa idad idad 8 8 EC 61508 DIVERSITY cotistr an as 10 9 TERMINATIONS AND CONNECTIONS conavsuasitasiiodiacasia adi 11 10 CABLE ENTRY aeren a a aao e eee eee 14 11 SPECIFICA HONS ecnin ne eee re ee ee ee 15 PHOTOGRAPHS Photograph 1 General view of ESS3 Pullkey conosca 4 Photograph 2 The switch in the reset or ON state oooonoonnnncccccnonccnnnnnonccccnononnnnnn nn narra 5 Photograph 3 The switch in the lockout or off State ooccooonnnnccccnnnnnnnsncnnanncncrnn nana 5 Photograph 4 ESS3 Pullkey with Slack rope Setup cooooocccccnoccccnnccccccnnnonancccnnnannnononnnann cnn nnnnnnnnnnnns 7 Photograph 5 ESS3 Pullkey with monitored lanyard SetUp cooooccccncnocccnnonccncccnonanccononananccncnanancnnnnnns 8 Photograph 6 ESS3 Pullkey with Tension Setup isso coxis dc canetne ena 8 Photograph 7 Tension Spring Secured to Structure ccccoooccccnonacccocononnncnnonanccnnnnnnnnnnnnnnnnnnnncnannnnncnnns 9 Photograph 8 Use of tension gauge in tensioned installations oooocccnononicooaccccnnnnonononnnan nono 9 Photograph 9 Pullkey with conduit hubs fitted ooomonncccccnnnnnnncccccconcrccnnnnnannnnnnnrrernnnnnnnnnnnanos 14 Photograph 10 Earth continuity of conduit hubs cu sncaa aida ida 14 Photograph 11 Earth continuity detail ui eeconxececetenaean
14. ll limit switch type ESS3 finds many applications in controlling distributed plant such as conveyors or belts used in the mining or materials handling industries The pull key is used to provide controlled stop functions for distributed plant or conveyors The pull key can be operated using the front centrally located knob or each of the two side located flexible cable pull actuators The side cable pull actuators can be used in tensioned and non tensioned systems it Photograph 1 General view of ESS3 Pullkey Each of the cable pull actuators is fitted with an eyelet to allow easy attachment of the lanyard or pull wire using some of the accessories described in section 7 of this manual The ESS3 provides six independent uncommitted voltage free changeover or SPDT contacts for use in controlling the conveyor The contacts can be configured to handle low voltage mains circuits up to five amps or extra low voltage circuits with currents as low as 100uA The pull cord operated pull key measures 270mm W x 100mm H x 115mm D including its convenient mounting feet that allow the ESS3 to be mounted on a gear tray or conveyor structure with two M10 3 8 bolts The large centrally located knob provides indication of the switch status through its position and through two reflective cats eyes that can only be seen from a long distance when the switch is in the stop or lockout position PULLKEY SWITCH 40F 16 52 300 12 ESS3 USER S MANUAL Issue
15. switch if a contact of SW2 is placed in series with a contact of SW1 or SW3 which in turn eliminates a dangerous failure mode Note that the schematic and termination details are shown correctly and the user does not have to swap the No and NC connections around SWITCH SW2b TERMINATIONS TERMINAL DESIGNATION DESCRIPTION 1 NO NORMALLY OPEN CONTACT 2 NC NORMALLY CLOSED CONTACT 3 COM COMMON CHANGEOVER CONTACT Table 6 Switch SW2b Termination Details i SWD o 3 TBIA D 1 NO p2 TBIB gt 2 NC SHOWN IN RESET TBIC 2 3 COM CAM RELEASES SWITCH LEVER GOING INTO LOCKOUT Figure 7 Switch SW2b Schematic The pullkey cam activates the lever of switch SW2b when the pullkey is placed in the lockout position and deactivates the switch lever when the pullkey is placed in the reset position This is the opposite of switches SW1 and SW3 This provides some degree of diversity to the operation of the switch if a contact of SW2 is placed in series with a contact of SW1 or SW3 which in turn eliminates a dangerous failure mode Note that the schematic and termination details are shown correctly and the user does not have to swap the NO and NC connections around 12 OF 16 52 300 12 Issue 06 N SIGN IN DESCRIPTION 16 NO NORMALLY OPEN CONTACT 17 NC NORMALLY CLOSED CONTACT 18 COM COMMON CHANGEOVER CONTACT Table 7 Switch SW3a Termination Details 3 TB3D gt 16 NO SW3a 1 go 3 TB3E 2
16. x 98mm H x 115mm D MaS chs Be cen te cach etc es cece ds ci cet ae ace ges det een ee tee eee 1 55kg PUN sacs veigiat ence A eee 2 x M8 or M10 bolts o yg e 230mm SA A eee mem eceeeeeacs 20mm x 11mm Ingress PIO uds IP66 NEMA 4X Enclosure material uste Polycarbonate UL 94 V 0 A PA Yellow a AP Polycarbonate UL 94 V 0 MOD Coll escusa adri Red Operating temperature TanQe ooooccconcccnnnonocccnnnnonccnnnnnnnncnnnnnnnnn conca cnn nn nnnnnnna nana 50 C to 60 C Storage temperature TanQl oooococccnnncccnnnnononccnnnnnnncnnnnnnnnccncnnnnnn cnn nan rca narran na nannnnnss 50 C to 80 C Operating relative humidity range ooooocconnncccnnnococccnnananaccninnancnn 10 to 90 Non condensing A A o Pe i UL NKCR E335081 Terminations cinc a Cage clamp 2 5mm 14awg maximum Contact Configuration ooooooccccnnncccccnnoccccccnnnnnss 6 x independently operated SPDT changeover Diversity esinscincisarani s 4 contacts not operated and 2 contacts operated in reset position Maximum switching voltage UL1054 oooocccccnnnonccoccnoncconanananancnnncnnnnnnnnnn nn cc nnnnnnnnnnnnnnnnos 125AC Rated switching current UL1054 cssrcrsientra siii 5A AC Electrical life at rated AC load UL1054 oooooonccccc nnccccccnononcccnnnnnnncnnnnnnnncnnnnanos 6 000 operations Maximum switching VON Oui Ta 24V DC Rated switching current non inductive load cocccnnnnnccncconcncnncnnnnnnnnnnrnncnnnnnnnannnnnnnnnno 1A DC Rated switching current inductive load
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