Pull Switch Trip Identification and

Prestart Warning System

Installation, Operating and

Maintenance Manual

Pull Switch Identification and Prestart Warning System

1. Introduction
The Electrotron Pull Switch Trip Identification and Prestart Warning System is
a fail-safe system capable of protecting a conveyor belt system from
operational faults as well as protecting the operators working with or near the
conveyor belt system.
The slack rope system provides personnel with an emergency latching
tripping mechanism that is accessible on either side of the conveyor belt. The
tripping mechanism spans the entire length of the conveyor belt, providing a
continuous tripping mechanism.
This is achieved by the installation of pull switches on both sides of the
conveyor belt at 100m intervals. Each pull switch is interlinked via a pull-cable
on the one side of the conveyor belt. Pull switches mounted on the opposite
side of the conveyor belt are interlinked via steel wire rope.
Each trip switch also sounds an audible alarm via two piezo-resistive buzzers,
warning operators and personnel working in the vicinity of the conveyor belt
of an impending conveyor belt start up.
In addition to providing a continuous tripping mechanism, the system also
makes provision for the integration of belt fault detection systems such as
misalignment, belt tear, spillage and rip detectors.
The functionality provided by the system ensures that conveyor down time
due to stoppages resulting from operational faults, system faults or
emergencies is minimized by providing maintenance personnel with detail
information about the cause and location of stoppages via SCADA as well as
via an LCD Display.

A typical conveyor belt tripping and protection system consists of the

following components

1.1 Intelligent Safe-line Relay (iSLR)

1.2 Power Supply
1.3 Intelligent Pullkeys
1.4 Standard Pull-keys (mounted on opposite side of conveyor)
1.5 Blue-line cable (Interconnection of the Pullkeys and Intelligent
Safeline Reilay is done via this cable and also provides a
mechanical means of tripping the Pull-keys.)
1.6 Conveyor Protection Devices (Mis-alignment switches, Rip
detectors, Dead-pan switch, Speed switch etc.)
1.7 Termination Module

The figure below illustrates the concept

Pull Switch Identification and Prestart Warning System

 Std Std Std Std Std Std
Pullkey Pullkey Pullkey Pullkey Pullkey Pullkey

CONVEYOR

1 2 3 4 5 6 7 8 9
Rip ID ID ID ID
Alignment Alignment
Detector Pullkey Pullkey Pullkey Pullkey
Key
Blue Line Cable

Steel Wire Rope

Head End
Mis-alignment
Control Panel Switch

Rip Detector

Figure 1. A typical conveyor belt tripping and protection system

Pull Switch Identification and Prestart Warning System

2. Principle Of Operation

This system is comprised of a microprocessor-based controller (iSLR) at the

head end of the conveyor belt, trip switch controller modules in each trip
switch and a termination unit installed at the last trip switch. System integrity
is monitored by transmitting a 16 bit digital signal at regular intervals to the
termination unit via a physical wire (Safeline) that connects the normally
closed contacts of each trip switch. A valid response from the termination unit
indicates that none of the switches have been tripped and that the physical
connection between the controller, which is installed at the head of the
conveyor, is free of any open or short circuits.

Figure 2. Trip Switch Identification and Pre-start Management System

Diagram

Upon reception of a Start Signal from any compatible host, the iSLR
(intelligent safe-line relay) signals each trip switch controller to activate their
respective sirens. Successful sounding of the sirens results in each controller
transmitting a prestart OK message to the iSLR. If a siren fails to produce any
audio signal, the iSLR will report a ‘prestart proving’ error as well as the
location of the failed siren. This function is achieved by measuring the audio
generated by the siren at each trip switch controller module.

Pull Switch Identification and Prestart Warning System

3. System Components and Specifications

3.1 Intelligent Safeline Relay

The Intelligent Safeline Relay is a two-wire system that continuously checks

the integrity of the ‘hardwire’ safeline. The unit continuously tests the
‘Safeline’ for the following conditions

a. Short Circuit
b. Open Circuit

Any violation of the loop integrity results in a system trip by de-energizing the
‘Safeline Healthy’ relay contact. The ‘Safeline Healthy’ signal is generated via
two NO Relay Contacts wired in series. Both relays are driven by separate
edge time circuits to prevent an inadvertent faulty state in the event of a
microprocessor pin latch. An external watchdog monitors the microprocessor.

This configuration provides a fail-safe interface to any host controller i.e.

during a power failure, one of the relay contact ‘freezing’ or during a
microprocessor lock up.
The following figure illustrates the Intelligent Safeline Relay

Figure 3. Islr Block Diagram

Pull Switch Identification and Prestart Warning System

Figure 4. Image depicting ISLR 2

Electrical Specifications

No Parameter Specification
1 Supply Voltage: 24VDC
2 Current Consumption 200ma
3 Relay Outputs (16 A @ 250 V) Safe-line Healthy
Pre-Start/Prestart Proving
OK

4 Digital Input Start

5 Analogue output Pull-key indication
6 Display LCD, 2 Line, 16 Character

7 SCADA Capability Modbus RTU - RS 232 Serial

Port
Table 1 ISLR Specification

Pull Switch Identification and Prestart Warning System

3.2 Trip Switch Controller Module

The following diagram illustrates the Trip Switch Controller Module.

This unit is housed in an enclosure. Refer to section 2.4 for more details.

Figure 5. Trip Switch Controller Module Block Diagram

The Trip Switch Controller Module fulfils three functions i.e.

a. Provides switch trip location information for 2 switches

b. Dual drive audio sirens
c. Measures siren audio outputs for pre-start proving

The Trip Switch Controller module is capable of monitoring two trip switches.
This feature allows trip switches mounted on both sides of the conveyor belt
to be monitored without having to utilise two modules. In the event of a trip
switch being activated, the trip location will be reported as 1L or 1R indicating
a left or right trip. Each module has a unique address that is set by means of
the 2 rotary switches on the module. The left hand rotary switch is used to
set the address in tens and the second rotary switch is used to set the units.
This will be the number displayed if a trip switch is activated. The RX and TX
leds indicate communication status of the device.

Pull Switch Identification and Prestart Warning System

Figure 6 Trip Switch Controller Module mounted on motherboard

3.3 Trip Switch Termination Module

The Termination Module is fitted in the last trip device on the Safe-line. This
module is constantly transmitting to the ISLR relay to indicate that the Safe-
line is healthy. The transmission status is indicated by the TX LED on the
Termination Module. In the event of a safety device being activated the
Termination Module will stop transmitting, thus causing the ISLR to be
activated

Figure 7. Termination Module

Pull Switch Identification and Prestart Warning System

3.4 Intelligent Trip Switch

The Intelligent Trip Switch is modular in construction. The unit consists of a

Standard Pullkey with a Trip Switch Controller Module housed in an enclosure
and mounted below the Standard Pullkey. The two units are mounted on
rugged mounting base plate.
The controller module is mounted on a motherboard making replacement of a
module easy.
In the event of a trip, the ‘Safeline’, which is routed via the NC closed contact,
is broken. This event is detected by the iSLR and results in a trip condition.
Two leds mounted on either side of the unit together with a beeping audio
tone provide visual and audio trip indication.
The unit generates an audio tone via the buzzers mounted on either side of
the Trip Switch to indicate an impending conveyer belt start up.
An extra voltage free NC contact that can be used as a ‘hardwire’ Interlock is
available. The figure below illustrates the Intelligent Trip Switch

Figure 8. Intelligent Pullkey

Pull Switch Identification and Prestart Warning System

Technical specifications are tabulated below

No Parameter Specification
Mechanical Specification
1 Material Bayblend (50% Polycarb + 50% ABS)
2 Colour Orange
3 IP Rating IP66
4 Tripping Force 15-20 Newton
5 Dimensions 330mm (h) x 190mm (w) x 125mm (d)
6 Weight 4-5 Kg

Electrical Specifications
7 Switch 2 NO and 2 NC Contacts
UI = 660V
Ith = Amp
Contact Tip Sealed

Table 2 Intelligent Trip Switch and Standard Trip Switch

Specifications

Pull Switch Identification and Prestart Warning System

3.5 Standard Trip Switch

The Standard Trip Switch consists of a switch. Refer to table 2 for details on
the specification.

The figure below illustrates the Standard Trip Switch

Figure 9. Standard Trip switch

Pull Switch Identification and Prestart Warning System

4. Installation

4.1 Intelligent Interface

Figure 10. Image illustrating motherboard

The intelligent pullkey connection interface is illustrated below.

Figure 10 Intelligent Pullkey terminal interface

Pull Switch Identification and Prestart Warning System

4.2 Standard Pullkey Interface

The standard pullkey connection interface is illustrated below

Figure 11 Standard Pullkey terminal interface

Pull Switch Identification and Prestart Warning System

4.3 Head End Panel Interface

The Head End Panel connection diagram is illustrated below

Pull Switch Identification and Prestart Warning System