Rope Pull Swicht Manual
Rope Pull Swicht Manual
Rope Pull Swicht Manual
LineStrong-series
Emergency Stop Grab Wire Safety Switch
2 Overview .............................................................................................................................................. 5
General description ................................................................................................................................................... 5
Safety regulations ..................................................................................................................................................... 5
Function description for the variants ......................................................................................................................... 6
3 Connections ...................................................................................................................................... 10
4 Installation and maintenance ........................................................................................................... 11
5 Application example.......................................................................................................................... 16
6 Model overview.................................................................................................................................. 17
Accessories............................................................................................................................................................. 19
7 Technical data ................................................................................................................................... 20
LineStrong1............................................................................................................................................................. 20
LineStrong2 series .................................................................................................................................................. 21
LineStrong3 series .................................................................................................................................................. 23
8 EC Declaration of conformity ........................................................................................................... 25
Audience
This document is intended for authorized installation personnel.
Prerequisites
It is assumed that the reader of this document has knowledge of the following:
• Basic knowledge of ABB/Jokab Safety products.
• Knowledge of machine safety.
Special notes
Pay attention to the following special notes in the document:
Safety regulations
Warning!
Carefully read through this entire manual before using the device.
The devices shall be installed by a trained electrician following the Safety regulations, standards and the Machine
directive.
Failure to comply with instructions, operation that is not in accordance with the use prescribed in these instructions,
improper installation or handling of the device can affect the safety of people and the plant.
For installation and prescribed use of the product, the special notes in the instructions must be carefully observed
and the technical standards relevant to the application must be considered.
In case of failure to comply with the instructions or standards, especially when tampering with and/or modifying the
product, any liability is excluded.
LineStrong1 is a compact and small, yet robust switch that can handle wires up to 30 meters on a single switch
(50 meters on two switches).
When someone pulls the wire of Linestrong1 or if the wire is broken, the switch goes to a safe state, e.g. the
machine is emergency-stopped. After a emergency stop the LineStrong1 needs to be reset to be able to run again
and this is made on the local reset button. LineStrong1 is equipped with an indication of how taut the wire is, which
make the installation or adjustment easy.
The LineStrong1 is made of a rugged die cast housing with a rating of IP67.
A positive forced connection provides a forced disconnect of the safety contacts when the wire is being pulled or
broken. The design of the LineStrong1 ensures that the contacts will not fail or be held in a normally closed
position, due to failure of the spring mechanism or that welding/sticking of the contacts can occur. The LineStrong1
switch has 2NC and 2NO contacts.
Up to 50 m
500 mm Every 3 meter Every 3 meter 500 mm
eyebolt
Up to 50 m
LineStrong2 is a robust switch that can handle wires up to 80 meters on a single switch (100 meters on two
switches). When someone pulls the wire of LineStrong2 or if the wire is broken, the switch goes to a safe state, e.g.
the machine is emergency-stopped. After a emergency stop the LineStrong2 needs to be reset to be able to run
again and this is made with the local reset button. Additional features on the LineStrong2 are a "normal" emergency
stop that is fitted on the side of the grab wire safety switch and also a two coloured LED for indication. LineStrong2
is equipped with an indication of how taut the wire is, which make the installation and adjustment easy.
Depending on the environment where the switch will be used, different material can be chosen for the LineStrong2.
The basic version has a rugged yellow die cast housing with a rating of IP67. In severe applications as for food
processing and chemical industry there is a LineStrong2Z with a total rugged stainless steel 316 body. This version
has IP69K enclosure protection (maintained by a double seal lid gasket and seals) and can be high pressure hosed
with detergent at high temperature.
LineStrong2 also exist in a version(LineStrong2ZX) with certified explosion proof contact block. LineStrong2ZX is in
stainless steel and can be used in European Zone 1, 2, 21,22 enviroments. (Gas and Dust)
A positive forced connection provides a forced disconnect of the safety contacts when the wire is being pulled or
broken. The design of the LineStrong2 ensures that the contacts will not fail or be held in a normally closed
position, due to failure of the spring mechanism or that welding/sticking of the contacts can occur. The LineStrong2
switch has 2NC and 2NO contacts.
Up to 80 m LineStrong2
Up to 100 m LineStrong2Z
eyebolt
Up to 60 m LineStrong2
Up to 80 m LineStrong2Z
LineStrong3 is a quite robust switch that can handle long wires, up to 200 meters on a single switch. When
someone pulls the wire of LineStrong3 or if the wire is broken, the switch goes to a safe state, e.g. the machine is
emergency-stopped. After a emergency stop the LineStrong3 needs to be reset to be able to run again and this is
made on the local reset button. Additional features on the LineStrong3 is a "normal" emergency stop fitted on the
top of the grab wire safety switch and also a two coloured LED for indication. LineStrong3 is equipped with an
indication of how taut the wire is, which makes the installation and adjustment easy.
Depending on the environment where the switch will be used, different materials can be chosen for the
LineStrong3. The basic version has a rugged yellow die cast housing with a rating of IP67. In severe applications
as for food processing and chemical industry, there is a LineStrong3Z with a total rugged stainless steel 316 body.
This version has IP69K enclosure protection (maintained by a double seal lid gasket and seals) and can be high
pressure hosed with detergent at high temperature.
LineStrong3 also exist in versions with certified explosion proof contact block(X-versions).
LineStrong3LZX/RZX/DZX are in stainless steel and can be used in European Zone 1, 2, 21,22 enviroments. (Gas
and Dust)
A positive forced connection provides a forced disconnect of the safety contacts when the wire is being pulled or
broken. The design of the LineStrong3 ensures that the contacts will not fail or be held in a normally closed
position, due to failure of the spring mechanism or that welding/sticking of the contacts can occur. The LineStrong3
switch has 4NC and 2NO contacts.
Single wire - LineStrong3L/3R and LineStrong3LZ/3RZ
The Linestrong3L/3R are two different versions depending on installation.
L - "Left hand" - is the version of LineStrong3 where the placement of the grab wire switch is to the left in the
installation.
R - "Right hand" - is the version of LineStrong3 where the placement of the grab wire switch is to the right in the
installation.
LineStrong3L/3R have die-cast housings and are robust to manage severe indoor or outdoor use.
LineStrong3L/3R are designed to protect a length up to 100 meters on a single switch. If two switches are used
together, up to 125 meters.
LineStrong3LZ/3RZ are in stainless steel 316 housings and are designed specifically to withstand the tough
environments found in the food and pharmaceutical industries. LineStrong3LZ/3RZ are designed to protect a length
up to 100 meters on a single switch. If two switches are used together, the wire can go up to 125 meters.
NB! The picture shows the left hand version NB! The picture shows the right hand version
Up to 125 m
eyebolt
Up to 100 m
Up to 125 m Up to 125 m
500 mm 500 mm 500 mm 500 mm
500 mm Every 3 meter Every 3 meter
eyebolt
Up to 100 m Up to 100 m
1) Several LineStrong3D
2) LineStrong3D with safety springs
Connections
Contact blocks
1. The installation of all Emergency Stop Grab Wire Safety Switch systems must be in accordance with a risk
assessment for the individual application. Installation must only be carried out by competent personnel and
in accordance with these instructions.
2. According to ISO 13850, corner pulleys may only be mounted such that a complete length of the wire can
be observed.
3. Wire support eyebolts must be fitted at 2.5 m. min. to 3m. max.intervals along all wire lengths between
switches. The wire must be supported no more than 500mm from the switch eyebolt or Safety Spring (if
used). It is important that this first 500mm is not used as part of the active protection coverage.
4. M5 mounting bolts must be used to fix the switches. Tightening torque for mounting bolts to ensure reliable
fixing is 4 Nm. Tightening torque for the lid screws,conduit entry plugs and cable glands must be 1.5 Nm to
ensure IP seal. Only use the correct size gland for the conduit entry and cable outside diameter.
6. Recommended wire span options and fittings - (subject to an individual risk assessment for the installation)
See Function description for correct wire span for each variant.
Warning! All the safety functions must be tested before starting up the system.
When setting up an Emergency stop grab wire system from ABB Jokab Safety it is recommended to do the
tensioning of the wire by using of ABB Jokab Safety Tensioner / Gripper accessory. The installation of the
tensioner accessory reduces the installation time. The eyehook, tensioner thimble and the wire strength gripper are
in one assembly which enables rapid connection to the switch eyebolts and fast and accurate tensioning of the
wire. Thanks to the switch viewing window, systems can be accurately and quickly tensioned. The double clamp
mechanism prevents wire slippage.
The end of the safety wire is fed through a central hole in a cone shaped guide which protrudes from the main
housing. After being fed through the guide hole, the wire enters the main housing by going through a feed hole and
then is looped back through 180 degrees and is fed through a second feed hole on the opposite side of the
mechanism. The wire is then pulled for maximum tension and is locked in position by a locking bar inside the main
housing which is moved by turning an Allen type locking bolt.
Because of the added friction on the eyebolts and wire when navigating corners, a corner pulley can be used to
navigate inside or outside corners without causing damage to the wire.
1. Tension to mid position as indicated by the green arrows in the viewing window of each switch
2. The tensioner thimble allows immediate accurate and final tensioning of the wire, whilst viewing the tension
marker through the viewing window on the switch
3. For systems up to 50 meter Quick Link termination is provided for easy connection to either a Safety spring
or Switch eyebolt. (Note for systems above 50 meter a Tensioner / Gripper is required each side).
Outside Outside
corners corners
Inside
corners
1. 2.
3. 4.
5. 6.
7. 8.
11.
12. 13.
14.
Warning! The safety functions and the mechanics shall be tested regularly.
Warning! In case of breakdown or damage to the product, contact the nearest ABB/Jokab Safety Service Office or
reseller. Do not try to repair the product yourself since it may accidentally cause permanent damage to the product,
impairing the safety of the device which in turn could lead to serious injury to personnel.
Caution! ABB/Jokab Safety will not accept responsibility for failure of the switch functions if the installation and
maintenance requirements shown in this sheet are not implemented. These requirements form part of the product
warranty.
Dimensions
LineStrong1
LineStrong2 / LineStrong2Z(X)
4 Mounting
Holes for M5
screws
LineStrong2 series
Manufacturer
Address ABB AB / JOKAB SAFETY
Varlabergsvägen 11
SE-434 39 Kungsbacka
Sweden
Electrical characteristics
Contact type IEC/EN60947-5-1 double break Typ Zb
Contact material Silver
2
Termination Clamp up to 2.5 mm conductors
Utilisation category AC15 A300 3A 240VAC 3A/120VAC 6A/24VDC 2.5A inductive
Thermal current (lth) 10 A
Rated insulation/withstand voltages 500VAC / 2500VAC
Short circuit overload protection Fuse externally 10 A (FF)
Explosion Proof version (X)
Classification Ex d IIC T6 (-20°C ≤ Ta ≤ +60°C) Gb
Ex tb IIIC T85°C (-20°C ≤ Ta ≤ +60°C) Db
Rated Voltage 250V AC/DC
Rated Current 2 pole 4A
4 pole 2.5A
General
Wire span
LineStrong2 Up to 80 m
LineStrong2Z(X) Up to 100 m
Wire tension devise ABB Jokab Safety Wire Tensioner
Wire type PVC sheath steel wire 4.0 mm outside diameter
Torque settings Mounting M5 4.0Nm
Lid T20 Torx M4 1.5Nm
Terminals 1.0Nm
Tension force (typical mid setting) 130 N
Tension operating force (wire pulled) < 125N < 300 mm deflection
The Jokab Safety branded product with articlenumber beginning with 2TLJ is fully compatible with the ABB
branded product with articlenumber beginning with 2TLA.
www.abb.com/lowvoltage