Installation Instructions for the
MICRO SWITCH™ CLSX Series
Explosion-Proof Maintained Cable-Pull Limit Switch
ISSUE 5
PK 81593

WARNING
IMPROPER INSTALLATION

• Consult with local safety agencies and their requirements when designing a machine control link, interface, and all control elements that affect safety.
• Strictly adhere to all installation instructions.

Failure to comply with these instructions could result in death or serious injury.

GENERAL INFORMATION (FIGURE 1)

• Explosion-proof switches are designed specifically for use in hazardous location applications. Flame paths within the switch housing cool exploding gases below the autoignition temperature of the atmosphere
• Complies with NEMA standards: 1, 3, 4, 7, 9, 13. UL listed and CSA certified: Div. 1 & 2, Class I, Groups B, C, & D; Div. 1 & 2, Class II, Groups E, F, & G
• The CLSX explosion-proof maintained a cable-pull limit the switch is designed for use in emergency stop applications
• A Single-head cable pull limit switch is designed to forcibly disconnect a set of direct-acting switch contacts
• Direct-acting switch contacts are held closed when actuating cables are under proper tension. When the cable is pulled, slackened, or broken, a cam positively opens the switch contacts
• Switch contacts remain open until the switch is reset by manually depressing the reset button located on the actuated operating head
• When direct acting switch contacts open, auxiliary contacts also actuate: open contacts close and closed contacts open
• Head may be positioned in any of four directions

FIGURE 1: MAINTAINED SWITCH

AUXILIARY CONTACTS

• Additional contacts are electrically isolated from the direct acting switch contacts. They are used for monitoring or signaling, i.e., indicators, pilot lights, and alarms

MAXIMUM ACTUATING CABLE LENGTH

• Depending upon variations in ambient temperature, the maximum cable length is 60 m [200 ft]

TENSION INDICATOR

• Convenient tension indicator line on the switch plunger indicates maximum preset cable tension

OTHER AVAILABLE FEATURES:

• Conduit opening options
• Hardware kits and cables for various length installations

FIGURE 2. INSTALLATION

SWITCH MOUNTING, WIRING, AND SEALING

Step 1 – Ensure you have the following:

• Switch
• (2) 1/4-20 or (2) 5/16-18 screws

• 14 AWG to #16 AWG stranded or #16 AWG to #18 AWG solid wire

Step 2 – Mount switch:
CAUTION
SWITCH DAMAGE
Do NOT mount the switch upside down or at the low point of conduit runs. Condensation problems may develop.
Failure to comply with these instructions may result in product damage.

• Mount using (2) 1/4-20 screws from the front of the switch, or with (2) 5/16-18 screws from the back of the switch. Torque to 43 in-lb to 52 in-lb (4.9 N-m to 5.9 N-m)

Step 3 – Wire switch:

• With a bar or screwdriver in the cover wrenching lugs, loosen and remove the circular cover on the front of the switch
• Connect a stranded or solid wire to switch’s pressure-type connector terminals. (Refer to the circuit diagram on switch housing. The diagram depicts switch contacts when the cable is at the proper tension.) Torque terminal screws and ground screw to 7-9 in-lb (0,8-1 N-m)
• Reassemble cover and tighten securely

Step 4 – Seal conduit connection:
Proper sealing ensures explosion-proof integrity of the conduit system.

• Seal in accordance with National Electrical Code paragraphs 500-2 and 501-4

WARNING
IMPROPER SYSTEM PERFORMANCE

• Ensure the attendant circuitry is such that only the momentary interruption of the control circuit cable pull contacts is required to open and hold open the control circuit until such time as both the cable pull switch and the attendant circuitry are manually reset.
• The user is SOLELY RESPONSIBLE for determining the appropriate level of risk warranting this type of circuitry.
• Maintained cable-pull limit switches must be installed in a fashion that complies with all codes and standards that are applicable to the particular application of the device.

Failure to comply with these instructions could result in death or serious injury.

ACTUATING CABLE INSTALLATION

Step 1 – Ensure you have the following (Figure 2):

• Plastic coated aircraft cable 3,18 mm [1/8 in] to 4,76 mm [3/16 in] dia. Use a distinctive color, such as red, to differentiate  actuating cable from other wires or cables in the area
• Thimbles, U-bolt clamps
• Cable supports (eyebolts)

Step 2 – Attach cable to switch:

• Ensure cable is fully seated and tightly fitted in the thimble groove
• Attach using two U-bolt clamps. U-bolt clamps should be installed as close as possible to thimble
• Tighten U-bolts to 0,51 N-m [4.5 in-lb] for 3,18 mm [1/8 in] cable and 0,85 N-m [7.5 in-lb] for 4,76 mm [3/16 in] cable

Step 3 – Install cable supports:
CAUTION
SWITCH DAMAGE
Do NOT allow excessive side loads that could bend the switch operating shaft.
Failure to comply with these instructions may result in product damage.

• Install cable support as close as practical to the end of the shaft without interfering with switch operation
• If cable tension adjusting turnbuckle is in mid-span of cable, the first cable support should be in line with, and no further than, 30 cm [12 in] from the end (eye) of the shaft. If adjusting turnbuckle is attached directly to the shaft eye, this distance may be increased to 46 cm [18 in]
• Support cable at intervals no greater than 2,4 m [8 ft]

REQUIRED END SPRING AND TURNBUCKLE INSTALLATION (Figure 3)

Step 1 – Ensure you have the following

• Handspring, turnbuckle, jam nuts (supplied with switch).
• Thimbles, U-bolt clamps

Step 2 – Install endspring
Reduces the effects of ambient temperature fluctuations and provides a measure of protection against the excessive force being applied to the cable.

• Install an end spring within cable span, preferably at the end of cable opposite switch (see Actuating Cable Installation, Step 2)

REQUIRED GROUNDING

The internal grounding terminal must be used for the equipment grounding connection.

Figure 3: Switch with Turnbuckle and Handspring

Step 3 – Install turnbuckle:
Ensures proper cable tension.
WARNING

IMPROPER INSTALLATION

Do NOT install turnbuckles too closely to cable supports or other barriers that may hinder proper operation. Failure to comply with these instructions could result in death or serious injury.

• Install within cable span in the same manner as and spring. Use jam nuts to maintain adjustment

REQUIRED CABLE TENSION ADJUSTMENT

Step 1 – Align colored tension indicator line:

• Tighten turnbuckle until colored tension indicator line on switch plunger starts to appear from within switch operating head

Step 2 – Ensure proper adjustment (Figure 4):

• Ensure tension indicator line is visible and aligned with the end of guide bushing on operating head
• Periodically check and adjust cable tension as necessary

Figure 4: Cable Tension at Proper Setting

With and spring installed, switch/cable will operate satisfactorily over a temperature range of ±12 °C [±25 °F], up to a maximum
cable length of 60 m [200 ft]. Adjust cable tension when the ambient temperature is near the mid-point of expected temperature extremes.

OPTIONAL CORNER INSTALLATION

To route actuating cable around a corner, use a free-running pulley with a minimum of 10 cm [4 in] dia. The cable should bend no more than 30 degrees as it passes through cable supports spaced no closer than 15 cm [6 in] apart.

OTHER ADJUSTMENTS

To reposition the operating head, loosen the four captive screws, place the head in the desired position. Securely tighten the four screws to 1,36 N-m to 1,80 N-m [12 in-lb to 16 in-lb].

RECOMMENDED REPLACEMENT

Replace the entire switch every 100,000 operations.

WARRANTY/REMEDY

Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Honeywell’s standard product warranty applies unless agreed to otherwise by Honeywell in writing; please refer to your order acknowledgment or consult your local sales office for specific warranty details. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace, at its option, without charge those items it finds defective. The foregoing is the buyer’s sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. In no event shall Honeywell be liable for consequential, special, or indirect damages.
While we provide application assistance personally, through our literature and the Honeywell website, it is up to the customer to determine the suitability of the product in the application.
Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use.

SALES AND SERVICE

Honeywell serves its customers through a worldwide network of sales offices, representatives and distributors. For application assistance, current specifications, pricing, or name of the nearest Authorized Distributor, contact your local sales office or:
E-mail: info.sc@honeywell.com
Internet: sensing.honeywell.com
Phone and Fax:
USA/Canada +1-800-537-6945
International +1-815-235-6847
Fax +1-815-235-6545
Sensing and Control
Honeywell
1985 Douglas Drive North
Golden Valley, Minnesota 55422
honeywell.com
81593-5-EN IL50 GLO Printed in the USA
January 2014
© 2014 Honeywell International Inc. All Rights Reserved

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