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Safety Products 1

July 2001 Cable-Pull Switches

Cable-Pull Switches Reliable Cable-Pull Switches for ON/OFF and Emergency Stop
Machine Control
Contents
Overview . . . . . . . . . . . . . . . . . . . . . . 1
Model Selection, Switches . . . . . . . 4
Model Selection,
Accessories . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . 7

Cutler-Hammer Cable-Pull Switches


are designed as emergency stop
devices that operate when the
attached cable is pulled or pushed.
Also referred to as rope-pull
switches, this family offers a variety
of switch sizes to fit easily into any
application. Both latching and non-
latching switches are available to
meet your specific requirements.
Latching switches provide a palm
button or pull-chain reset depending
upon the model selected. Units pro-
vide maximum cable lengths, under
ideal conditions, from 20 feet (6m) in Product Features
one direction suitable for smaller ■ Positive opening N.C. contacts have long operational life — 1,000,000
machines, up to 245 feet (75m) in switching actions
two directions — 490 feet (150m) ■ Galvanically isolated contacts
total. These long range types are
■ Latching operation on emergency stop models ensure machine will not
ideal for conveyor installation. restart until the switch is manually reset
■ Metal housings provide long life in rough industrial environments
Ratings and Approvals ■ Long cable span lengths reduce the number of switches required per application
■ UL Listed ■ A full selection of installation hardware is available
■ CSA Certified
■ IEC 947-5-1 AC 15/DC 13 The Cable-Pull System
■ EN 418 A Cable-Pull System, also referred to as Rope-Pull, is designed to provide an emer-
■ DIN gency stop function as part of a larger safety control circuit. A typical system,
shown in Figure 1, consists of a safety rated switch, a cable, a turnbuckle and often
■ VDE 0660 T200
times a spring and cable supports. The cable is installed horizontally along a zone
■ Direct opening N.C. contacts of a machine where a point of possible hazard exists. The cable is installed with ten-
sion on it so that the switch has the ability to monitor when the cable is slack or bro-
ken, in addition to monitoring when the cable is pulled. Also, for safety use, the
switch must latch in the emergency stop position and be manually reset.
For the most current information
on this product, visit our web site at:
www.sensingsolutions.com Figure 1. Typical Cable-Pull System

4-6 inches (100-150 mm)


E48 Cable-Pull Switches Eye Bolt and Nut Eye Bolt
are only intended for
operation as a component Thimble Cable Tightening Turnbuckle Cable Clamp Switch
of an overall safety control
circuit.
For Customer Service in the U.S. call 1-800-356-1243,
in Canada call 1-800-268-3578.
For Application Assistance in the U.S. and Canada
call 1-800-426-9184.

PG.05F.05.T.E
2 Safety Products
Cable-Pull Switches July 2001

Careful consideration should be taken when designing


a system so that the switch is easily pulled at critical sec- Contacts in the
tions of the cable run. The nature of the system is such normal stand-by
mode. Normally open
that there will be certain zones of the cable run where the contacts are held
closed to monitor N.O. N.C.
sensor may or may not operate when the cable is pulled cable slack status. Contacts Contacts
(unknown action). Examples of these zones are very near
the ends of the cable or near eyebolt supports. Steps
should be taken to minimize the friction of the cable move-
ment. These include using pulleys in place of eyebolt sup- Contacts in the
cable-pulled mode.
ports, and minimizing or eliminating turns in the cable (the Normally closed
ideal run has no turns). contacts are opened. N.O. N.C.
Contacts Contacts

Switch Construction and Operation


Cable-Pull switches come in three distinct types:
Contacts in the
Basic Switches — These switches are merely momentary cable-broken mode.
Normally open
actuated switches. They are not suitable for use in safety contacts return to
N.O. N.C.
applications. The contact switching mode is referred to the normally open state. Contacts Contacts
as break before make, which means the first set of con-
tacts break before the second set makes. Break before
make contact configurations are shown below. Figure 3. Contact position based on cable status

Safety Rated Latching Switches — This is the only type of


inch 0.04 0.12 0.2
(mm) 0 (1) (3) (5) switch recommended for safety applications. In addition to
13-14 the features mentioned above, these switches also latch
21-22 when the contacts are actuated. This requires a deliberate
N 50 70 action to reset the contacts and thus restart the machine
Figure 2. Non-overlapping contact where the hazard existed. Reset can happen by pressing or
actuation points pulling an operator located on the switch or by requiring a
key to release the switch (once an emergency stop has
occurred, manual, deliberate reset is required).
This non-overlapping configuration does not allow for
monitoring the cable status. This switch is used where All cable-pull switches offer positive-mode operated gal-
the cable is not installed under tension. As this switch vanically isolated contacts as required by IEC 947-5-1. In
is not recommended for safety applications, Cutler- applications where the cable is set up under tension, the
Hammer does not include it in its offering. normally open contacts are held closed while the normally
closed contacts remain closed. When the cable goes slack,
Overlapping Contacts, Non-latching Switches — Unlike
the normally open contacts (held closed) will open. When
the basic switch, overlapping contact switches carry
the cable is pulled, both sets of contacts open. This is
contacts that make before break. These contacts allow
described in Figure 3. Wiring the contacts in series will
cable status monitoring. As seen above right, when the
give indication of cable actuation in either case.
contacts are wired in series, indication of cable status
can be determined electrically. The risk in using this In the case of overlapping contacts, the travel of overlap
non-latching switch is that if the cable is pulled, then is described in the contact configuration drawing (see
released, the action that was stopped by pulling the Figure 4). It is important that the cable travel under nor-
cable could possibly be restarted. mal operating conditions does not exceed this distance
to avoid nuisance tripping. Expansion of the cable under
varying ambient temperatures can also be a cause of nui-
sance tripping. An explanation of this effect is described
in the next section.

PG.05F.05.T.E
Safety Products 3
July 2001 Cable-Pull Switches

A conveyor in the shipping area of a food processing


0.46 (11.8)
plant has maximum temperature fluctuations of 20°C.
inch 0.08 0.43 0.51 The cable run on the conveyor is 20 meters.
(mm) 0 (2) (11) (13)
13-14 Our Data:
25-26
N 50 180 K = 0.012 mm / degree C / m
Latch: 0.49 (12.5)
T differential = 20 degrees C
Figure 4. Overlapping contact
configuration, the overlapping L cable = 20m
gap is measured as 9 mm
Expected cable expansion = 0.012 x 20 x 20 = 4.8 mm
Based on this result, it is vital that the overlap in the
switch contacts is greater than 4.8 mm. Linear expansion
Cable Considerations is usually not a factor in applications where the cable run
The cable is the actual interface with the user, it is plastic is not long and the ambient temperature does not fluctu-
coated and is typically less than 4 mm in diameter. The ate more than 10°C.
cable is installed between the switch and the support at
the opposing end. It is important that the support for the Another consideration of the cable is that when pulled
cable be sturdy enough to handle the force required to with great force, the cable can initially expand or stretch
operate the switch. and affect system setup. It is usually recommended that
the cable be forcefully pulled prior to tuning the cable
Temperature effects on the cable are important to note tension with the turnbuckle. This will expose areas in the
when configuring a system that has long cable runs system that will initially stretch or expand. Adjustments
(greater than 18 meters). The expansion and contraction can then be made to take up the added slack.
properties of the cable are referred to as its Coefficient of
Linear Expansion (K).
Coefficient of Linear Expansion (K) =
6.89 x 10-6 inches per degree F per inch
(0.012 mm per degree C per meter)
Since contact overlap is critical in the switch operation,
the expansion of the cable can be a source of nuisance
tripping in installations where the ambient temperature
changes greatly. Let’s look at an example:

PG.05F.05.T.E
4 Safety Products
Cable-Pull Switches July 2001

Model Selection — Cable-Pull Switches


Contacts Contact Operation ■ CLOSED ■ OPEN Power Switching Catalog Number
Handling Frequency
Short Range Span Length
20 foot (6m) Span Length 1N.O./1N.C. 500V AC 50/minute E48CSP106
Plastic Body 0.16 (4) 10A maximum
Non-latching 
inch 0.05 0.13 0.2
ON/OFF 13 14 (mm) 0 (1.2) (3.2) (5)
Switching 25 26 13-14
only — not 25-26
for human
N 40 70
safety use
20 foot (6m) Span Length 1N.O./1N.C. 500V AC 50/minute E48CSM106
0.17 (4.4)
Metal Body 10A maximum
Non-latching 
inch 0.06 0.14 0.2
ON/OFF 13 14 (mm) 0 (1.6) (3.6) (5)
Switching 25 26 13-14
only — not 25-26
for human N 50 70
safety use
20 foot (6m) Span Length 1N.O./1N.C. 500V AC 17/minute E48CSM106B
Metal Body 0.16 (4) 10A maximum
Latching
inch 0.05 0.13 0.19
13 14 (mm) 0 (1.2) (3.2) (4.8)
25 26 13-14
25-26
N 50 70
Latch: 0.18 (4.5)

Mid Range Span Length


40 foot (12m) Span Length 1N.O./1N.C. 400V AC 50/minute E48CSM112
Metal Body 0.19 (4.8) 16A maximum
Non-latching 
inch 0.08 0.16 0.24
ON/OFF 13 14 (mm) 0 (2) (4) (6)
Switching 25 26 13-14
only — not 25-26
for human
safety use N 90 120

40 foot (12m) Span Length 1N.O./1N.C. 400V AC 20/minute E48CSM112B


0.19 (4.8)
Metal Body 16A maximum
Latching
inch 0.08 0.16 0.24
13 14 (mm) 0 (2) (4) (6)
25 26 13-14
25-26
N 90 120
Latch: 0.22 (5.5)

59 foot (18m) Span Length 1N.O./1N.C. 400V AC 50/minute E48CSM118


Metal Body 0.25 (6.3) 16A maximum
Non-latching 
inch 0.06 0.22 0.28
ON/OFF 13 14 (mm) 0 (1.5) (5.5) (7)
Switching 25 26 13-14
only — not 25-26
for human
N 150 240
safety use
 Non-latching models are for ON/OFF switching only and are not suitable for human safety applications.

PG.05F.05.T.E
Safety Products 5
July 2001 Cable-Pull Switches

Model Selection — Cable-Pull Switches (Continued)


Contacts Contact Operation ■ CLOSED ■ OPEN Power Switching Catalog Number
Handling Frequency
Mid Range Span Length (Continued)
59 Foot (18m) Span Length 2N.O./1N.C. 400V AC 20/minute E48CSM418B 
0.27 (6.8)
Metal Body 16A maximum
Latching inch 0.08 0.24 0.26 0.32
13 14 (mm) 0 (2) (6) (6.5) (8)
25 26 13-14
25-26
33 34 33-34
N 80 200
Latch: 0.3 (7.5)

2N.O./2N.C. 400V AC 20/minute E48CSM218B 


0.27 (6.8)
16A maximum
inch 0.08 0.24 0.32
13 14 (mm) 0 (2) (6) (8)
25 26 13-14
33 34 25-26
33-34
45 46 45-46
N 80 200
Latch: 0.3 (7.5)

115 Foot (35m) Span Length 1N.O./1N.C. 500V AC 20/minute E48CSM135B 


Metal Body 0.46 (11.8) 16A maximum
Latching
inch 0.08 0.43 0.51
13 14 (mm) 0 (2) (11) (13)
25 26 13-14
25-26
N 50 180
Latch: 0.49 (12.5)

Long Range Span Length


230 Foot (70m) Span Length 1N.O./1N.C. 500V AC 20/minute E48CSM170B 
Metal Body 0.82 (20.8) 16A maximum
Latching
inch 0.08 0.79 0.95
13 14 (mm) 0 (2) (20) (24)
25 26 13-14
25-26
N 180 320
Latch: 0.87 (22)

490 Foot (150m) Span Length 1N.O./1N.C. 250V AC 10/minute E48CSM375R 


(245 Foot [75m] Each each direction L R 10A maximum
Direction) 25° 25°
Metal Body 23 24 30° 20° 12° 0 12° 20° 30°
Latching
11 12 11-12
23-24
11 12 11-12
23-24
23 24
Latch Normal Latch

490 Foot (150m) Span Length 1N.O./1N.C. L R


500V AC 10/minute E48CSM375RC 
(245 Foot [75m] Each each direction 10A maximum
Direction) 25° 25°
Metal Body 23 24 30° 20° 12° 0 12° 20° 30°
Latching 11 12 11-12
23-24
11 12 11-12
23-24
23 24
Latch Normal Latch
 Unit available with optional 24 – 208V AC/DC LED indicating light. To specify add –LUV to end of Catalog Number. Contact factory for availability.

PG.05F.05.T.E
6 Safety Products
Cable-Pull Switches July 2001

Model Selection — Accessories Specifications


Mechanical 1 million cycles
Short and Mid Range System
4-6 inches (100-150 mm) Life
Eye Bolt and Nut Eye Bolt
Reset Pushbutton (for models ending in
Method “B”); Pull ring (for models ending
Thimble Cable Tightening Turnbuckle Cable Clamp Switch
in “R” or “RC”)
Protection NEMA 1, 2, 3, 4, 12 (IP65)
Long Range System Class
4-6 inches (100-150 mm) Switching 1N.O./1N.C., 2N.O./1N.C. or 2N.O./
Spring Pulley Cable Cable Clamp
Contacts 2N.C., Forced disconnection of
N.C. contacts
Control Wire 14 AWG maximum recommended
16 feet max (5 m) Thimble Tightening 16 feet max (5 m) Size
Switch Turnbuckle
Utilization AC15, DC13
Category
Description Switches Used With: Catalog Number
Tempera- -22° to 176°F (-30° to 80°C)
Cable Plastic coated steel cable, red Short and Mid Range E48CARD2 ture Range
color, sold in meter increments  Housing Plastic or cast aluminum
Long Range E48CARD4
Material
Eye Bolt and Nut Used for supporting cable All E48CABM8

Tightening Adjusts cable system length to Short and Mid Range E48CATM5
Turnbuckle properly position switch contacts

Long Range E48CATM6

Thimble Used where cable is attached to Short and Mid Range E48CATD2
switch, turnbuckle or at end
anchor point
Long Range E48CATD3

Pulley Recommended when a 90° turn is All E48CAPUL


required for cable configuration

Cable Clamp Clamps cable at Short and Mid Range E48CACD2


termination points

Long Range E48CACD3

Spring 24N (2.4 N/mm coefficient) E48CSM375R or E48CAS24 or


18.8N (1.26 N/mm coefficient) E48CSM375RC E48CAS18

 Quantity ordered indicates length, for example, a quantity of 5 equals five meters of cable.

PG.05F.05.T.E
Safety Products 7
July 2001 Cable-Pull Switches

Approximate Dimensions in Inches (mm)


E48CSP106 0.98 0.63 E48CSM106 0.98 0.63
(25) (16) (25) (16)
0.59 0.59
(15) 0.20 (5) (15) 0.20 (5)

2.20 0.28 2.24 0.30


(56) (7) (57) (8)
5.33 5.41
4.84 (135.5) (137.5)
(123)
2.36 2.36
(60) (60)

1.18 0.08 0.20 (5.2) 0.08


(30) (2) Dia. 1.18 (2)
(30)

E48CSM106B 0.98 0.63 E48CSM112 and E48CSM118


(25) (16)
0.59 0.94 (24)
(15) 0.20 (5)
0.59 (15) 0.81 (20.5)
0.20 (5)

2.36 2.83
2.89 (60) (72)
(73.5) 0.21 0.33
0.20 (5.4)
0.30 (5) (8.5)
(7.5) 4.88
6.36 (124) 4.41
(161.5) (112)

1.57 0.20
(5) 2.20
(40) (56) 0.12
2.36 3.27
(83) (3)
(60)

0.28 3.23 1.73


(7) (82) (44)
0.20 (5.2) 0.08
Dia. 1.18 (2)
(30)

E48CSM112B E48CSM135B, E48CSM218B and E48CSM418B


0.94 (24) 1.79
0.59 (15) 0.81 (20.5) (45.5)
0.94 (24)
0.81
0.20 (5) 0.59 (15) (20)
0.20 (5)
2.83
(72)
2.36 0.21 0.33
(60) 0.20 (5.4) (8.5) 0.21
(5) 2.43 (5.4)
(62) 0.33
(8.5)
6.08
5.61
1.57 0.20 (154.5) (142.5)
(5) 2.20
(40) (56)
0.30 7.65
(7.5) (194.2) 7.17
3.76 (182.2)
0.28 (95.5)
(7) 1.38
(35)
Dia.
3.23 2.58
(82) (65.5)
0.47
(12)
1.38
(35)
Dia. 2.58
2.83 (72) (65.5)
3.23 (82)

PG.05F.05.T.E
8 Safety Products
Cable-Pull Switches July 2001

Approximate Dimensions in Inches (mm) (Continued)


E48CSM170B E48CSM375R L R
1.42 (36)
0.79 (20) 0.79 (20)
0.35 (9) 0.79 (20)

0.20 3.74
(5) (95) 0.51 (13)
Dia.

10.59 3.94 4.21


1.38 (35) (269) 1.18 (107)
5.91 (100) (30)
Dia.
(150) 2.36
7.20 (60)
6.50 (183)
(165)

0.28 (7)
Dia.
0.26 0.31 5.47
(6.5) (8) (139)
2.17 1.89
(55) (48)
3.35 4.72
3.86 (120)
(85) (98)

0.47
(12)

E48CSM375RC 3.43 1.85


L R (87) (47)
0.98
(25)

1.93
(49)

5.39
4.90 (137)
(124.5)
0.96
2.28 (24.5)
(58)
1.02
(26)

8.11
0.39 (206)
(10)

7.32
(186)

2.56
(65)

3.94 3.54 2.36


(100) (90) (60)

3.70
(94)

0.39
(10)
1.10
(28)

0.65
(16.5)

PG.05F.05.T.E