Rockford Systems Page 2

For more information, call Western Safety Products at 206-264-0808 or email sales@westernsafety.com.

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Slide Operated Lockout Valve

SLIDE-OPERATED VALVE
This three-way valve is operated with the manual movement of a slide that opens and closes the valve. This valve shuts off air at the press and then bleeds off downstream air. It can be locked only in the off position.

Slide operated lockout valve
Part No. Port Size In-Out
RCD-113 1/2"
RCD-114 3/4"

EEZ-ON Lockout Valve

EEZ-ON VALVE
This valve shuts off air supply to the machine and bleeds downstream air when the valve is closed. When the valve is open, it gradually allows air into the air system to prevent damage to air components. It can be locked only in the off position. This valve is furnished with a muffler.

EEZ-ON Lockout Valve
Part No Port Size In-Out Port Size Exhaust
RCD-121 1/2" 3/4"
RCD-122 3/4" 3/4"

Single Phase Disconnect Switch with Magnetic Motor Starter & Self Latching Emergency Stop Button

This single-phase unit is designed for motors that have built-in overloads. Typical applications for these combinations include smaller crimping machines, grinders, drill presses, and all types of saws.
Part No. CSS-055 (115 V, 1/2 HP max.)
The 115-V, 15-A disconnect switch and nonreversing magnetic motor starter are housed in a NEMA 12 enclosure. Enclosure size is 8" x 6" x 3-1/2". It includes a self­latching red emergency-stop palm button and a green motor control start push button. It can be used on machines with 115-V power and is rated up to 1/2 HP maximum.
The disconnect switch has a rotary operating handle which is lockable in the off position only. This meets OSHA regulations and ANSI standards.
For machines with 230-V AC single-phase motors, a transformer is required to reduce the control circuit voltage to 115-V AC in order to comply with NFPA 79. See the RSD series disconnect switches, motor starters, and combinations in tables below

Single Phase Disconnect Switch

Single Phase Starter with Self Latching Emergency Stop Button

CSF-082 (115 V, 1/2 HP max.)
The 115-V, 15-A nonreversing magnetic motor starter, self-latching red emergency­stop palm button, and green motor control start push button are housed in a NEMA 4 polycarbonate enclosure. Enclosure size is 4-1/4" x 4-1/4" x 3-1/2". It can be used for machines with 115-V power and is rated up to 1/2 HP maximum.
For machines with 230-V AC single-phase motors, a transformer is required to reduce the control circuit voltage to 115-V AC in order to comply with NFPA 79. See the RSD series disconnect switches, motor starters, and combinations in tables below

CSF-082, 115V, 1/2 HP Max

Part No. CSF-301 (115 V, 2 HP max.)
The 115-V, 30-A nonreversing magnetic motor starter, self-latching red emergency-stop palm button, and green motor control start push button are housed in a NEMA 12 enclosure. Enclosure size is 8" x 6" x 6". It can be used for machines with 115-V power and is rated up to 2 HP maximum.
For machines with 230-V AC single-phase motors, a transformer is required to reduce the control circuit voltage to 115-V AC in order to comply with NFPA 79. See the RSD series disconnect switches, motor starters, and combinations in tables below

CSF-301 115V, 2 HP Max

Enclosed Transformers

These transformers comply with OSHA regulations and ANSI standards and are available for use when the motor start/stop station is remotely located from the starter enclosure, and voltage to these buttons must be 115 V or less. These transformers mount directly to the frame of the machine. If the existing motor starter operating coils are a higher voltage (208, 230, 460, 575 V), they must be replaced with a 115-V coil when furnishing these transformers. A replaceable fuse is accessible from the outside of the transformer housing.

Enclosed Transformer

Part No.

Description

RSF-021

100-VA, 230/460-V primary and 115-V fused secondary with a 1 A, 230-V fuse

RSF-030

150-VA, 230/460-V primary and 115-V fused secondary with a 1.5 A, 230-V fuse

IEC Fused Disconnect Switches, Magnetic Motor Starters, and Combinations

These three-phase disconnect/starters are housed in a NEMA 12 metal enclosure. The enclosure size will vary depending on the motor starter required. These units can be used on machines with 208, 230, 460, or 575 V. They are furnished with an overload relay and have operating coils of 115 V, 60 Hz. The disconnect operating handle is lockable in the off position only. These combination units meet OSHA regulations, ANSI standards, and NFPA 79.
To obtain the part number of the motor starter required, please refer to the part numbering chart on the table below.
A remote station is required when using any plain-door starter. To obtain the part number of the remote opera­tor station required, please refer to the part numbering chart on the table below.

Disconnect Switches, Magnetic Motor Starters and Combinations

Please furnish the exact motor horsepower, voltage, and full-load amps when ordering any of the disconnects or starters from the table below. This information is usually on the motor nameplate. Voltage can be 208, 230, 460, or 575 V. If other sizes are required, please consult the factory.

Disconnect Switches, Motor Starters & Accessories

SELECTING A DISCONNECT, STARTER, OR COMBINATION DlSCONNECT/STARTER(S)
To determine the 9-digit configured part number for a disconnect, starter, or combination disconnect/starter(s) required, follow directions 1-7 below and use the information in the PART NUMBERING SYSTEM CHART below.

  1. The first 3 digits for all disconnects, starters, or combination disconnect/starter(s) are RSD.
  2. The 4th digit determines the size of the disconnect switch, if required. Zero (0) indicates no disconnect switch provided.
  3. The 5th digit determines the type of the main motor starter and/or 2nd motor starter. Zero (0) indicates no starters.
  4. The 6th digit determines the size of the main motor starter. Zero (0) indicates no main motor starter.
  5. The 7th digit determines the size of the 2nd motor starter. Zero (0) indicates no 2nd motor starter.
  6. The 8th digit (if required) determines the configuration and location of the operator controls.
  7. The 9th digit determines if a transformer and/or wiring is required.
Part Number Chart

Selecting A Remote Operator Station

DISCONNECT SWITCHES, MOTOR STARTERS, & ACCESSORIES
SELECTING A REMOTE OPERATOR STATION
To determine the 8-digit configured part number for a remote operator station required. follow directions 1-3 below and use the information in the PART NUMBERING SYSTEM CHART below.

  1. The first 3 digits determine the orientation of the remote operator station.
  2. Digits 4 through 7 determine motor operators. Zero (0) indicates no operator(s).
  3. The 8th digit (if required) determines the 2nd motor operators.
Remote Operator Selection Chart

The example shown above. RSD-3521-P-l. indicates that the enclosure containing the combination disconnect/starter(s) has a 60-A disconnect switch. a 17-A reversing main motor starter. and a 12-A non­reversing 2nd motor starter. All motor controls will be in a remote station. This disconnect/starter(s) will be generically numbered and wired to terminals and will include a transformer.

The example shown above. VOS-31 00-1. indicates that it is a vertical-oriented remote operator station which includes main motor start/stop/E­stop buttons. main motor forward/reverse selector switch. and start/stop push buttons for the 2nd motor starter.

Disconnect Switches, Motor Starters & Accessories
HOS-4000 Remote Station HOS-4200 Remote Station

REMOTE STATIONS
Part No. HOS-4000
This 4-1/2" x 3-1/2” x 3" station has a self-latching red emergency-stop palm button in a NEMA 12 metal enclosure. To reset this button. turn it to the right.

Part No. HOS-4200
(For Use With Reversing Motor Starters)
This 3-1/2” x 8-3/4" x 3" station has motor forward and reverse push buttons and a self-latching emergency-stop palm button in
a NEMA 12 metal enclosure.

VOS-2000

Part No. VOS-2000
(For Use With Nonreversing Motor Starters)
This 6-3/4" x 3-1/2” x 3" station has a motor start push button and a self-latching red emergency­stop palm button in a NEMA 12 metal enclosure.

Part No. VOS-1100
(For Use With Reversing Motor Starters)
This 8-3/4" x 3-1/2" x 3" station has motor start and stop push buttons and a motor forward/ reverse selector switch in a NEMA 12 metal enclosure.

HOS-4201 Remote Station with motor jog/run switch VOS-2100

Part No. HOS-4201 (For Use With Reversing Motor Starters)
This 3-1/2" x 10-1/2" x 3" station has a motor jog/run selector switch. forward and reverse push buttons. and a self-latching emergency-stop palm button in a NEMA 12 metal enclosure.

Part No. VOS-2100
(For Use With Reversing Motor Starters)
This 8-3/4" x 3-1/2" x 3" station has a motor forward/reverse selector switch. a motor start push button. and a self-latching red emergency-stop palm button in a NEMA 12 metal enclosure.

VOS-1000 Parts

Part No. VOS-1000
(For Use With Nonreversing Motor Starters)
This 6-3/4" x 3-1/2" x 3" station has motor start and stop push buttons in a NEMA 12 metal enclosure.

Part No. PB5R00-01-
Self- Latching Emergency-Stop Mushroom-Head Push Button
Part No. CTM-506- Yellow Emergency-Stop Nameplate (22.5 mm hole)
Part No. CTC-550­ Push/Pull to Release Emergency-Stop Push Button
Part No. CTM-548- Yellow Emergency-Stop Nameplate (30 mm hole)

CTL-507 Palm Buttons CTC-737 Chrome Palm Button

Part No. CTL-507-This palm button assembly consists of two black palm buttons (with ring guards) and one latching red emergency-stop but­ton. All buttons have 1 NO and 1 NC contact arrangement.

CHROME PALM BUTTON
Part No. CTC-737-This heavy­duty, light-push single plunger run palm button provides 1 NO and 1 NC contact arrangement. This 2-1/4" palm but­ton is constructed from zinc die cast and has a flat plunger. The palm button cover plate has a solid neoprene gasket which provides an oil-tight seal upon installation. This palm button can replace the black palm button described previously. The force required to operate this button is 2.5 lb.

CTK-006 Palm Button Ring Guard CTL-555 Touchdown Palm Button

UNIVERSAL PALM BUTTON RING GUARD
Part No. CTK-006 This palm button ring guard is used to protect new and existing run palm buttons from accidental operation. This high-impact PVC plastic ring guard can be used with most palm button brands. Four 1-1/4" screws are fur­nished with each ring guard.

TOUCHDOWN!™ PALM BUTTON Part No. CTL-555-Standard Voltage
(115 V AC, 45-60 Hz, 40 mA) Part No. CTL-553-Low Voltage (24 V DC, 100 mA) This ergonomic run/inch palm button can replace the black or chrome palm buttons described previously. The palm button has a solid neoprene gasket which provides an oil-tight seal upon installation. The contact arrangement is 1 NO and 1 NC.

CTC-726 Black Palm Button CTC-736 Emergency-Stop Palm Button with lockout

BLACK PALM BUTTON
Part No. CTC-726- This standard heavy-duty, single plunger run palm button provides 1 NO and 1 NC contact arrangement. This 2-1/4" button is mushroom-shaped. The palm button cover plate has a solid neoprene gasket which provides an oil-tight seal upon installation. When applying two-hand control as a safeguard to any machine, fixture, device, etc., the palm buttons must be installed at the proper safety distance. The force required to operate this button is 4.3 lb.

EMERGENCY-STOP PALM BUTTON W/LOCKOUT Part No. CTC-736-This heavy- duty, single plunger red emergency-stop palm button with yellow cover plate provides 1 NO and 1 NC contact arrangement. This 2-1/4" button has a mushroom­shaped plunger with a spring latch that keeps the button latched down when pushed. A side release plunger is incorporated. The palm button cover plate has a solid neoprene gasket which provides an oil-tight seal upon installation.

MOUNTING BOXES FOR TOUCHDOWN!™ PALM BUTTONS ONLY
Part No. CTK-038 Deep single-hub mounting box Part No. CTK-039 Deep double-hub mounting box

CTK-004 Single hub mounting box CTK-003 Double hub mounting box

Part No. CTK-004
A Single-hub mounting box is supplied with all palm button assemblies. It is used when wire terminates at this box. It can also be used when remote mounting electrical cut-off systems or duplex power outlets.

Part No. CTK-003
A double-hub mounting box is supplied with all palm button assemblies. It is used when wires are required to go through the box and on to another mounting box.

Safety Interlock Switches
Interlock Switches

The safety switches, monitoring systems, and safety relay described in this section are designed to interlock safeguarding systems such as barrier guards, gates, covers, and shields. They can be used on exposed machinery, conveyors and handling equipment, as well as textile, packaging, and processing machines, robots and other types of machinery. They are designed to be used in various types of industrial environments.
Some of the safety switches have tamper-resistant enclosures, actuators and fasteners. They are not easily defeated because two independent components are required to actuate the switch. This minimizes accidental or deliberate operation of the switch by anything other than the correct actuator. These switches are designed for simple installation and maintenance by authorized personnel only. This increases the integrity of the system and helps provide a safer work environment for all employees.
Proper installation of these safety interlock switches is as important as the accurate design and manufacturing of the switches. It is critical that a safety interlock switch, monitoring system, or safety relay is installed as part of a suitable safety control circuit. All devices are shipped with complete installation instructions. The instructions are simple, but all installation work should be performed by qualified personnel.
The purpose of interlock switches is two-fold. First, when the interlock is open, the machine should not be able to start any hazardous motion. Second, if the interlock is opened during a machine cycle, the hazardous motion must stop quickly. The type of stop command, either emergency stop or top stop (machine stops in open or end-of-cycle position), can be critical, depending on the guard's location or the machine's ability to stop quickly.
Using the new ANSI, UL, NFPA 79, and Harmonized European standards for reference, interlocks must be designed, installed, and maintained in a control­reliable configuration. The interface between the switch and the machine control system is very important to maintain reliability. If there is a high degree of risk associated with the machine, the interlock must have control reliability which means it uses redundant contacts and cross-checking (monitoring). The safety relays and monitoring systems found on following tables can be used to accomplish this.
When deciding what type of interlock switch is required on a machine, determine where the interlock will be most effective in the control circuit of the machine. To do this, a risk assessment/hazard analysis should be done first. This assessment should include the following:

  1. frequency of exposure to the hazard: seldom, occasional, or frequent
  2. probability of injury: unlikely, possible, probable, or certain
  3. severity of injury: minor, serious, major, or fatal

Each of these must be considered separately. Each of these categories must also be considered for all stages of machine operation including installation, normal operation, maintenance, inspection, and removal from service. Remember, when interlock­ing guards, there are many factors that must be considered, including safety, reliability, convenience, production, and maintenance.
Note: This section of the catalog uses NO for normally open contacts and NC for normally closed contacts in the specifications and descriptions. All safety contacts are specified as normally open when the actuator is not inserted in the switch.

Safety Interlock Switches

Either tamper-resistant safety switch can be used to interlock hinged, sliding, or lift-off guards. Closure of the guard or latch causes the actuator to enter the switch and release the dual antitamper locking cams. The actuator allows the main center cam to rotate and make the switch contacts. When opening the guard or latch, the actuator positively forces the contacts open due to the cam action built into the switch.
These versatile switches have multiple actuation entry positions. Actuators and conduit adapter are sold separately.

6025067 Safety Switch 6025073 Safety Switch

TECHNICAL SPECIFICATIONS
Safety Contacts: 2 NO
Auxiliary Contact: 1 NC
Actuator Entry Positions: 3
Switching Ability: 2 A @ 250 V AC, 2 A @ 24 V DC
Operating Temperature: -4° to 176°F (-20° to 80°C)
Switch Dimensions: 3.7" H x 2" W x 1.2" D (95 H x 52 W x 32 D mm)
Part No. 6025067 Standard Safety Switch (Actuator and Conduit Adapter Sold Separately)

TECHNICAL SPECIFICATIONS
Safety Contacts: 3 NO
Auxiliary Contact: 1 NC
Actuator Entry Positions: 5
Switching Ability: 3 A @ 240 V AC, 3 A @ 24 V DC
Operating Temperature: -4° to 176°F (-20° to 80°C)
Switch Dimensions: 4.5" H x 1.5" W x 1.6" D (116.5 H x 40 W x 43 D mm)
Part No. 6025073 Standard Safety Switch With Die-Cast Zinc Housing (Actuator and Conduit Adapter Sold Separately)

6025059 Compact Safety Switch

COMPACT SAFETY SWITCH
This compact switch is designed for tight spaces. The switch body is 1.2" (31 mm) wide. It works on the same principles as the standard switches described above.
The head of this switch can rotate every 90° which allows the actuator to enter the switch from five (5) different positions. It provides both side and end actuator entry.
Actuators and conduit adapter are sold separately.

TECHNICAL SPECIFICATIONS
Safety Contacts: 2 NO
Auxiliary Contact: 1 NC
Actuator Entry Positions: 5
Switching Ability: 3 A @ 240 V AC or 3A @ 24 V DC
Operating Temperature: -4 ° to 176°F (-20° to 80°C)
Case: Glass-Fiber Reinforced Thermoplastic
Operating Head: Rotates Every 90°
Switch Dimensions: 3.5" H x 1.2" W x 1.1" D (90.5 H x 31 W x 30 D mm)

LOCKING SAFETY SWITCHES

These switches are designed to prevent accidental or deliberate access while the machine is in motion. The mechanical locking feature is ideal for machines that have to finish a sequence, a program, or coast to a stop before the interlocked guard can be opened. The switches allow the guard to be mounted closer to the hazard than nonlocking switches.
The operating principle of these switches is simple. When the actuator enters the switch, it engages with and operates a tamper-resistant locking mechanism, closing the contacts in a similar way to the standard switches shown above. This locks the actuator in and holds the guard closed. When the contacts are closed and the mechanism is locked in, the machine is allowed to start.
To open the guard, a separate signal is required to energize the solenoid which releases the locking mechanism after the machine has stopped or the cycle has finished. A timer or stopped-motion detec­tor can be used for this signal (see tables below). The timer can be used on machines with a consistent coastdown time. The stopped-motion detector is available for machines that have a variable or inconsistent coastdown time. If power is lost, a supervised override mechanical release, built into the switch, can be used.
Actuators and conduit adapter are sold separately.
Safety contacts are normally open (NO) when the switch is in the position shown. without the actuator inserted.
6022580 Light Duty Locking Safety Switch 6025060 Medium Duty Locking Safety Switch

LIGHT-DUTY LOCKING SAFETY SWITCH TECHNICAL SPECIFICATIONS
Safety Contacts: 2 NO
Auxiliary Contact: 1 NC
Door Monitoring Contact: 1 NO
Actuator Entry Positions: 5
Locking Force: 1200 N
Switching Ability: 4 A @ 230 V AC or 4A @ 24 V DC
Operating Temperature: -4 ° to 131°F (-20° to 55°C)
Case: Glass-Fiber Reinforced Thermoplastic
Operating Head: Rotates Every 90°
Switch Dimensions: 7.5" H x 1.5" W x 1.6" D (192 H x 40 W x 42 D mm)
Part No. 6022580 Light Duty Safety Switch
(Actuator and Conduit Adapter Sold Separately)

MEDIUM-DUTY LOCKING SAFETY SWITCH TECHNICAL SPECIFICATIONS
Safety Contacts: 2 NO
Auxiliary Contact: 1 NC
Actuator Entry Positions: 3
Locking Force: 1200 N
Switching Ability: 2 A @ 250 V AC or 2A @ 24 V DC
Operating Temperature: 14° to 140°F (-1 0° to 60°C)
Case: Glass-Fiber Reinforced Thermoplastic
Switch Dimensions: 4.7" H x 2.2" W x 1.4" D (120 H x 58 W x 37 D mm)
Part No. 6025060 Medium-Duty Safety Switch
(Actuator and Conduit Adapter Sold Separately)

6025115 Heavy Duty Locking Safety Switch

HEAVY-DUTY LOCKING SAFETY SWITCH TECHNICAL SPECIFICATIONS
Safety Contacts: 2 NO
Door Monitoring Safety Contacts: 2 NO
Door Monitoring Auxiliary Contact: 1 NC
Actuator Entry Positions: 3
Locking Force: 1200 N
Switching Ability: 2 A @ 250 V AC or 2A @ 24 V DC
Operating Temperature: -4° to 140°F (-20° to 60°C)
Case: Glass-Fiber Reinforced Polyester
Switch Dimensions: 5.1" H x 3.6" W x 1.4" D (130 H x 93 W x 37 D mm)
Part No. 6025115 Heavy-Duty Safety Switch
(Actuator and Conduit Adapter Sold Separately)

Stopped Motion Detector CMC-080 Timer

STOPPED-MOTION DETECTOR
The stopped-motion detector is designed to be used with locking safety switches (see above) that are applied to machines or robots with an inconsistent or variable coastdown time.
The stopped-motion detector has an on-delay that can be adjusted between 0.1 second and 40 minutes through a series off our time ranges. It also uses two independent proximity sensors and monitors two moving metal parts of the machine or robot. This means it can detect when hazardous motion has stopped. Should either sensor detect motion, the machine guard will remain locked. This capability is essential on machines which do not have a consistent coastdown time.
SENSOR SPECIFICATIONS
Sensor Type : Shielded, Inductive
Operating Voltage : 10-30 V DC
Outputs : 1 NO NPN Sensor and 1 NO PNP Sensor
Operating Temperature : -13° to 158°F (-25° to 70°C)
Cable: 6.7' (2 m) of Prewired 3-Conductor Flexible Cable (14 AWG)
Sensor Dimensions: 0.71" Diameter (M18 x 1 Thread Size) x 2" Long (50.8 mm)
TECHNICAL SPECIFICATIONS
Power Supply: 24 V AC/DC or 115/230 V AC
Relay Outputs: 2 NO and 1 NC
Maximum Switching Ability: 4 A @ 250 V AC or 2A @ 30 V DC
Replaceable Fuse: 500 mA
Mounting: 35-mm DIN Rail
Operating Temperature: 14° to 131°F (-10° to 55°C)
Part No. CMC-086 Stopped-Motion Detector Assembly (24 V AC/DC)
Part No. CMC-079 Stopped-Motion Detector Assembly (115/230 V AC)

TIMER
The timer is designed to be used with locking safety switches (see above) that are applied to machines or robots with a consistent coastdown time.
The timer is a compact unit designed to energize and unlock guard interlocking devices. It is housed in a 1.8" (45 mm) wide, DIN-rail-mounted enclosure. The cover can be removed to access the DIP switches and the potentiometer which control the timing. The on-delay can be adjusted between 0.1 second and 40 minutes through a series of four time ranges.
TECHNICAL SPECIFICATIONS
Power Supply: 24 V AC/DC and 115/230 V AC
Relay Outputs: 2 NO and 1 NC
Maximum Switching Ability: 4 A @ 250 V AC or 2A @ 30 V DC
Replaceable Fuse: 500 mA
Mounting: 35-mm DIN Rail
Operating Temperature: 14° to 131°F (-10° to 55°C)
Part No. CMC-080 Adjustable Timer

6024918 Safety Relay

SAFETY RELAY
TYPICAL APPLICATIONS

  • Interlocked Guards
  • Machine Input/Output Signals

A safety relay is designed to connect safety devices, such as interlock switches, to the machine control circuit. It provides a switching action from the safety interlock switch, and can act as an intermediate relay to distribute a signal to multiple devices. The relay compares input and output signals, and provides failure to a safe condition if there is a failure in the interlocking interface control circuit.
Without a safety relay, faults and short circuits in a safety interlock switch can go undetected and can create a hazardous situation. The potential for faults exists in the power supply, relays, and switches as well as their associated wiring.
When using a safety relay, the wiring is monitored and compared. If a failure occurs in one area, it will be detected and a stop signal will be sent to the safeguarded machine.
This dual-channel safety relay has 1 NC or 2 NC dual-channel safety inputs. It is designed for use with guard interlock switches or a light curtain.
This safety relay has 3 NO safety outputs and 1 NC auxiliary output. The safety outputs have independent and redundant internal contacts to help the safety function. The auxiliary contact is a nonsafety output intended to provide an external signal about the status of the safety outputs.

TECHNICAL SPECIFICATIONS
Supply Voltage: 24 V DC
Safety Outputs: 3 NO
Auxiliary Output: 1 NC
Safety Input Contact Arrangement: 1 NC or 2 NC
Maximum Switching Ability 6 A @ 230 V AC or 2A @ 24 V DC
Mounting: 35-mm DIN Rail
Operating Temperature: -13° to 131°F (-25° to 55°C)
Part No. 6024918 Safety Relay (24 V DC)
Coded Magnetic Safety Switch and Control Unit   Connection Diagram for Coded Magnetic Safety Switch and Control Unit

CODED MAGNETIC SAFETY SWITCH AND CONTROL UNIT
TIlls high-integrity system consists of an electromagnetically coded magnetic safety switch. actuator. and control unit. The switch and actuator can be used as a stand-alone system for low-power. low-risk machines or with the control unit for applications requiring a higher level of integrity. The control unit should be used when monitoring and checking of the circuit is required. The 11S/230-V AC unit monitors and checks up to six coded magnetic safety switches (wired in series); the 24-V AC/DC unit monitors up to fifteen coded magnetic safety switches (wired in series). If a failure is detected in any switch or in the control unit at a machine off/on cycle. a stop signal will be sent to the guarded machine. The control unit also provides monitoring of the machine's control contactor.

TECHNICAL SPECIFICATIONS
Sensor and Actuator
Supply Voltage: 24 V DC
Safety Contacts: 2 NC
Maximum Switching Ability: 30 mA @ 30 V DC
Safety Contact Operating Distance: Make 0.28" (5 mm). Break 0.35" (15 mm)
Case: Molded ABS Plastic
Operating Temp: 14° to 131°F (-10° to 55°C)
Cable: Prewired. 10' (3 m), 6-Conductor
Part No. 6025080 Sensor and Actuator

Control Unit
Supply Voltage: 24 V ACIDC or 110/230 V AC
Safety Inputs: 1 NO and 1 NC
Relay Outputs: 2 NO
Maximum Switching Ability: 4 A @ 250 V AC or 2A @ 30 V DC
Mounting: 35-mm DIN Rail
Operating Temp: 14° to 131°F (_10° to 55°C)
Part No. 6025082 Control Unit
Safety contacts are normally open (NO) when the actuator is not actuating the switch.
Magnetic Safety Switch  Magnetic Safety Switch Usage Diagrams

MAGNETIC SAFETY SWITCH

These reed-type switches are magnetically actuated and offer non contact reliability along with tolerance for misalignment. They are totally submersible, which makes them ideal for environments where hygiene is important. Each switch is supplied with a prewired 13-foot cable.
On presenting the magnetic actuator to the switch, the high intensity field, from the actuator, causes the internal reed-switch safety contact(s) to close. On removing the actuator, the safety contact(s) open.

TECHNICAL SPECIFICATIONS
Rated Current: 2 A, fuse externally 1.6 A quick acting
Rated Voltage: 250 V AC
Safety Contact Operating Distance: Make 0.47" (12 mm), Break 0.91" (23 mm)
Operating Temp: 14° to 149°F (-10° to 65°C)
Cable: 13 Feet of Prewired 2-Conductor Flexible Cable (CMC-097)
Cable: 13 Feet of Prewired 6-Conductor Flexible Cable (CMC-098)
CMC-097: 3.3" H x .75" W x .6" D (84Hx19Wx16Dmm)
CMC-098: 3" H x 1.2" W x .6" D (76 H x 30 W x 15 D mm)
Part No. CMC-097 Magnetic Safety Switch With Actuator (1 NO Safety Contact)
Part No. CMC-098 Magnetic Safety Switch With Actuator (2 NO Safety Contacts and 1 NC Auxiliary Contact)

SPARE PARTS
Part No. CMK-096 Spare Actuator for CMC-098
Part No. CMK-075 Spare Actuator for CMC-097
Safety contacts are normally open (NO) when the actuator is not actuating the switch.

Cable and Push Button E-Stop  
Cable & Push Button E-Stop Diagram

CABLE AND PUSH-BUTTON E-STOP
This switch is a cable and push-button emergency­stop device. At the same time it is used to provide an awareness barrier on exposed machinery, such as conveyors.
This device enables this system to accommodate cable spans up to 248 feet (75 m).
The switch has a unique cam operation of the contact mechanism to give rapid, positive operation of the contacts. This mechanism also provides a failure to the safe condition if the cable goes slack or is cut, but is immune to nuisance tripping due to machine vibration. Should the cable be pulled, the contacts are opened, isolating machine power, and the latch engages. The machine cannot restart until the hazard has been corrected and the switch is reset. The switch is reset by turning the blue reset dial from the off position to the run position. This switch also incorporates a cable-tension indicator. This indicator assists in installation and maintenance of the switch. A red mushroom-head emergency-stop button is provided on each switch. Optionally available is an indicator light as shown.
A cable tension kit, which includes thimbles, cable clamps and a turnbuckle, must be used with this switch (see below). This kit includes the components to properly tension the cable. When installing this switch on cable runs over 12 feet, one switch should be installed at both ends of the cable. The cables should be supported by eye bolts every 6-1/2 to 10 feet (2 to 3 m) along its length. They should also be used about one foot from each switch to ensure that all emergency-pull movement is transmitted to both units in a linear fashion. If this assembly is to go around a corner, a free-moving pulley should be used. Please consult the factory if this is required.
TECHNICAL SPECIFICATIONS
Safety Contacts: 2 NO
Auxiliary Contact: 2 NC
Switching Ability: 2 A @ 250 V AC, 2 A @ 24 V DC
Case: Heavy-Duty Die-Cast Zinc
Operating Temperature: -13° to 176°F (-25° to 80°C)
Part No. 6024884: Cable and Push-Button E-Stop Device Only
OPTIONAL ACCESSORIES
Part No. CMK-064: Indicator Light Without Bulb
Part No. CTT-335: Bulb for Above Indicator (24 V AC/DC)
Part No. CTT-336: Bulb for Above Indicator (115 V AC)
Part No. FSL-024: Red PVC-Covered Steel Cable
Part No. CMK-039: Tension Kit (See below)

The safety contacts are normally open (NO) when the E-stop button is pushed, or if the cable is slack or pulled as shown in the illustration above.

Cable and Push Button E-Stop Assembly
Cable and Push Button E-Stop usage illustration

CABLE AND PUSH-BUTTON E-STOP ASSEMBLY
Operators and other employees are exposed to point-of-operation hazards if they enter the backside area of press brakes. shears or other machines. A cable and push-button e-stop assembly can be used to warn them of the exposure.
This cable and push-button e-stop assembly can be used with the cable-operated switch described above. It stops the machine if someone pulls or loosens the cable. The sign warns them of danger.
The switch that interlocks the cable is arranged so that if someone either pulls on the cable or removes the cable from the hook. the machine becomes inoperable. The switch must be electrically interfaced with the cycle control of the machine.
ORDERING INFORMATION
Part No. CML-510 Cable and Push-Button E-Stop
Switch Assembly Includes:
• Part No. 6024884 Cable and Push-Button E-Stop
• Part No. CMK-064 Indicator Light
• Part No. CTT-336 Bulb for Above Indicator (115 V AC)
• Part No. 5312998 M20 to 1/2" Conduit Adapter
• Part No. FSL-024 7 Yards of Red PVC-Covered Steel Cable
Part No. CMK-039 Assembly Consisting of:
1 Turnbuckle
1 Hook Bolt
4 Cable Thimbles
4 Cable Clamps
• Part No. FSL-026 Mounting Tabs for Sign (2)
OPTIONAL ACCESSORIES
Part No. FSL-028 Pulley
Part No. KSC-056 10" x 12" X .055" thick Danger Sign for Miscellaneous Machines
Part No. KSC-064 10" x 12" X .055" Danger Sign for Down-Acting Machines

Pressure Sensitive Safety Mats

Safety mats are intended to be used as auxiliary or additional safeguarding equipment to protect oper­ators and other employees in the machine area. They must not be used as the primary method of safeguarding except when all other means are not applicable.
These mats can safeguard many types of machines. Consider the following when choosing mats:

  1. How is the mat to be interfaced to the exist­ing motor control or equipment? Does a new control or starter need to be added?
  2. Can the motion of the machine that is creat­ing the point-of-operation hazard be stopped quickly? If it can, what kind of clutch and brake arrangement does it have? Is the machine hydraulically or pneumatically oper­ated? Is it operated by any other means?

Before applying a safety mat to any machine, make sure it will be interfaced correctly with the machine control and make sure it does not inter­fere with productivity. The whole machine system must be considered, including safeguarding, machine control, disconnects, starters, covers for rotating parts, auxiliary parts, feeding and retrieving of workpieces, etc.
The pressure-sensitive, heavy-duty safety mats described on these pages are highly resistant to wear, oils, grease, acids and most common chemicals.
These mats function in two different ways. One way is that the machine will not start if someone or some object is on the mat. Another way is that if the machine is already operating or cycling, it will stop if someone steps onto the mat. In this case, the machine needs to be restarted once the mat has been cleared.
The mat(s) must be located so an operator or other employee, when stepping onto the mat, cannot reach into the point-of-operation hazard prior to the machine's hazardous motion coming to a stop. See ANSI/RIA R15.06 robot safety standard for detailed gUidelines on mat safety distance. Also see the ANSI B 11.19 for gUidelines on mat control system reliability.

Pressure Sensitive Safety Mat Usage

Pressure Sensitive Safety Mats
Pressure Sensitive Safety Mat

The single-piece molded construction of these safety mats means these mats will not delaminate. The mats encase conductive plates which provide stop/restart signals when pressure is applied or released. Each mat top surface has a rib pattern running parallel with the mat length which helps prevent slipping. yet is easy to clean.
All mats are supplied with a 20' single-jacketed. four-wire cord exiting from the width end of the mat. The outside edge of each mat has a lip to attach either an aluminum ramp or a blunt edge. The lip can also be removed when joining two mats with a mat connector. The mat dimensions provided are for the active area of the mat.
These mats can be supplied individually or in multiple configurations. They are available in various sizes and can be tied together (electrically) in series.
The part numbers listed in the chart below do not include any ramps. blunt edges. or connectors. Follow the instructions below the chart to add ramp edging.
Note: A mat control box Part No. RKR-062. or Zone Monitor Part No. RKR-103 or RKR-107 must be used with the mats. See below.

The heavy-duty pressure-sensitive safety mats offered have been successfully used to provide auxiliary safeguarding for the hazard areas that exist in many industrial environments. Some of these include:

  • Robotic welding
  • Laser welding/cutting
  • Water jet machines
  • Pick-and-place robots
  • Plastics molding machines
  • Assembly machines
  • Automated material handling
  • Packaging machinery
  • Textile machinery
  • Conveyors
  • Paper converting machinery
  • CNC punches and tube benders
MAT SPECIFICATIONS
Operating Temperature: -35° to 120°F (-3]0 to 49°C)
Individual Mat Sizes: 12" x 12" to 48" x 72"
Activation Force: 3 to 5 ft/lb (normal foot traffic)
Mat Cover Material: Molded vinyl
Shore A Hardness: 72 ± 2
Mat Cable Length: 20 ft
Load Capacity: 3,000 psi
Applicable Standards Designed to meet or exceed ANSI 811.19. OSHA 1910.212. and ANSI/RIA R15.06
Electrode Assembly:
  • Normally open switch
  • High-durability 24-gauge steel
  • 18-gauge. 4-wire. single-jacketed lead wires and optional application-specific wiring options
  • Hermetically encapsulated switch and lead wires
  • Designed to meet IP67 and NEMA 6
  • Water-tight and totally submersible

For a complete chemical resistance chart. contact the factory.

Pressure Sensitive Safety Mats
Pressure Sensitive Safety Mat PSM-2436-1 (Includes EDG-1000 Series Ramp Edging)

SAFETY MATS AND RAMP EDGING

These heavy-duty pressure-sensitive safety mats are constructed of molded vinyl material. The molding encases two separated parallel steel plates. These plates make contact when the mat is stepped on. They have a black, ribbed pattern top surface to help prevent slipping and are easy to clean.
The mats are active over the entire surface, except the narrow border. They are designed for low-voltage (24-V DC) control circuits.
All standard size safety mats can be modified, i.e., with notches, cutouts, angles, or holes. Various configured layouts of any dimension can be supplied. Various colors, sizes, and shapes of mats are available along with different wiring options to meet your requirements. To obtain a proposal to meet your needs, submit a layout drawing complete with all dimensions and a list of your specific requirements.

PRESSURE-SENSITIVE MATS CHART

Part No.

Width

Length

PSM-1212

12"

12"

PSM-1224

12"

24"

PSM-1236

12"

36"

PSM-1248

12"

48"

PSM-1260

12"

60"

PSM-1272

12"

72"

PSM-1636

16"

36"

PSM-1824

18"

24"

PSM-1836

18"

36"

PSM-1848

18"

48"

PSM-1860

18"

60"

PSM-1872

18"

72"

PSM-2420

24"

20"

PSM-2424

24"

24"

PSM-2430

24"

30"

PSM-2436

24"

36"

PSM-2442

24"

42"

PSM-2448

24"

48"

PSM-2456

24"

56"

PSM-2460

24"

60"

PSM-2472

24"

72"

PSM-2828

27-1/2"

27-1/2"

PSM-2833

27-1/2"

32-1/2"

PSM-2843

27-1/2"

43"

PSM-2856

27-1/2"

56"

PRESSURE-SENSITIVE MATS CHART (continued)

Part No.

Width

Length

PSM-3030

30"

30"

PSM-3036

30"

36"

PSM-3042

30"

42"

PSM-3048

30"

48"

PSM-3060

30"

60"

PSM-3072

30"

72"

PSM-3432

33-1/2"

32"

PSM-3444

33-1/2"

44"

PSM-3456

33-1/2"

56"

PSM-3636

36"

36"

PSM-3642

36"

42"

PSM-3648

36"

48"

PSM-3660

36"

60"

PSM-3672

36"

72"

PSM-4132

40-7/8"

31-3/16"

PSM-4144

40-7/8"

43-3/16"

PSM-4156

40-7/8"

55-3/16"

PSM-4848

48"

48"

PSM-4872

48"

72"

The pressure-sensitive safety mat information in the chart is for mats without EDG-1000 Series ramp edging. To include mitered ramp edging on all four sides of the mat, add a -1 to the part number and add 4" to both the width and length provided in the chart.
All mats are furnished with a 20' four-wire cord that exits the mat at the width end.

Pressure Sensitive Safety Mats
Mat Selection Guide

RAMP EDGING, BLUNT EDGING, AND MAT CONNECTORS
An aluminum ramp-edged mat system can be customized to fit any shape or size area. Custom-made mats can fit most areas and even provide cutouts for machine legs, posts, or other obstructions. Send us a layout drawing with complete dimensions of the area the mats need to cover, and, we will provide a proposal for the required mats and accessories.

MAT CONTROLS
MAT CONTROL BOX-PART NO. RKR-062
This mat control box provides an interface for the safety mats to the existing machine control. If someone steps on the mat while the machine is operating or cycling, the control is designed to provide a stop signal; or, if some­one is on the matts), the stop signal will not allow the machine to start a cycle. If special applications of this control are required, please consult the factory.
This mat control is furnished in a dust- and oil-tight NEMA 12 enclosure and includes a selectable latch-out feature. When the latch-out feature is turned on, the machine will not automatically be able to restart until the latch-out has been cleared. This is accomplished with the use of the key­operated selector switch. When the latch-out feature is turned off, the machine can be restarted when the mat is cleared.
CONTROL BOX SPECIFICATIONS
Voltage: 115 V AC, 60 Hz
Output-Relay Contacts Rating: A, 115 V AC Resistive

Mat Control Box

Pressure Sensitive Safety Mats

If the MAT CONTROL BOX PART NO. RKR-062 is not required, a DIN-rail mounted control module is available. Each control module has 4 NO safety contacts and 1 NC auxiliary contact. The control module allows operation in either automatic or manual reset modes.

Mat Control RKR-104 DIN rail mount control module
Part No. Description
RKR-104 120 V AC, 24 V DC control module
RKR-105 240 V AC, 24 V DC control module

MAT JUNCTION BOXES
If multiple mats are grouped together to provide auxiliary or perimeter (work-envelope) safeguarding, junction boxes may be required to facilitate the installation. Use of the mat junction boxes with either the mat control box RKR-062 or a DIN-rail mount control module from above. Each mat junction box includes 20' of four-wire cord.

Part No. RKR-021
This mat junction box can provide wiring for up to 10 mats for easy tie-in to the mat control. (Cover has been removed for photo.)

Mat Junction Box
Part No. Description
RKR-020 Mat junction box to accommodate from 2-5 safety mats
RKR-021 Mat junction box to accommodate from 2-10 safety mats

ZONE MONITOR
For applications where multiple safety mats are needed, a zone monitor can be used. It acts as a control box, while eliminating the need for a junction box for multiple safety mat installations. Additionally, it has a diagnostic feature to determine which mat or mats have been tripped. The zone monitor is available in two models: one which monitors 1-4 safety mats, and another which monitors 1-8 safety mats.
If the diagnostics of an entire perimeter safeguarding system are required, a latch-out/reset zone-control unit may be required. Please consult the factory.

Zone Monitor
Part No. Description
RKR-103 Zone monitor for 1-4 safety mats
RKR-107 Zone monitor for 1-8 safety mats

Danger Signs

The signs offered in this catalog are .055" thick linear polyethylene. They are semi-rigid plastic and are capable of withstanding a temperature range of -60º to 130°F. They are resistant to tears and may be mounted with nails. rivets. screws. bolts. nylon lock-straps. double-face adhesive tape. etc. Each sign is protected from fading. chipping. scratching. weather extremes. physical abuse. grease. oil. moisture. chemicals and acids. These signs do not rust, dent. or corrode. They do not curl up or rip and are lightweight and easy to handle.

Machine Safety Signs

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