ER1022 - Industrial safety switch OMRON - Free user manual and instructions

Product Type	Industrial Safety Switch
Brand	OMRON
Model	ER1022
Dimensions (approx.)	240 x 100 x 110 mm
Weight	1100 g
Housing Material	Die-cast aluminum alloy
Max. Cable Length	125 m
Protection Rating	IP67 (NEMA 6)
Safety Contacts	4 NC (normally closed)
Auxiliary Contacts	2 NO (normally open)
Indicator Light	24 VDC, flashing red (tripped) / steady green (reset)
Reset Button	Blue, manual reset
Operating Temperature	-25 to 80 °C
Mechanical Life	1,000,000 cycles min.
Standards	IEC947-5-1, IEC947-5-5, EN418, UL508, BS5304
Indicator Power Supply	24 VDC (optional)
Trip Function	Cable pull (≤ 125 N)
Reset	Blue pushbutton, manual
Maintenance	Water washable; weekly and semi-annual inspection
Spare Parts Available	Cable kits, tensioner, eyelets, pulleys, etc.
Repairability	Do not attempt to repair; replace with original parts

Frequently Asked Questions - ER1022 OMRON

How to install the ER1022 switch?

Installation must be carried out by qualified personnel following the steps in the manual. Use M5 bolts (torque 4 Nm) and appropriate cable glands. The cable tension must be adjusted so the red arrows in the viewing window are centered. Maintain a maximum spacing of 3 m between support eyelets.

How to reset the switch after tripping?

Press the blue reset button to return the switch to operating position. The switch must be manually reset after each trip.

What is the meaning of the indicator light?

The LED indicator (24 VDC) flashes red if the switch is tripped, and glows steady green if it is correctly reset. It can be connected to the wiring according to the diagrams provided.

What is the maximum cable length?

The maximum cable reach is 125 meters. Beyond that, two switches may be needed at the ends.

What are the safety contacts?

The safety contacts are 4 NC (normally closed) that open when the rope is pulled. They are accompanied by 2 NO auxiliary contacts.

How to adjust the cable tension?

Use the provided tensioner/gripper to tighten the rope until the red arrows in the window of each switch are centered. The pulling force must not exceed 125 N.

What maintenance is recommended?

Check proper operation and nominal tension weekly. Every 6 months, cut off power, remove the cover, check cleanliness and terminal tightening. Never attempt to repair the switch.

Is this switch suitable for conveyors?

Yes, the ER1022 model is designed for safety applications on conveyors, rotating machinery and hazardous areas, with a cable reach up to 125 m.

What are the certifications?

The switch is CE marked for all applicable directives, and certified UL and C-UL. It complies with standards IEC947-5-1, IEC947-5-5, EN418, UL508 and BS5304.

Can the switch be cleaned with water?

Yes, the IP67 protection rating allows water jet cleaning. Use proper cable glands to maintain sealing. Tighten cover screws to 1.5 Nm.

USER MANUAL ER1022 OMRON

Rope Pull Emergency Stop Switch

ER1022

• Long rope spans up to 125 m makes this switch ideal for applications where long rope spans are required
• Heavy-duty housing—the die-cast housing and stainless steel eye nut make the ER1022 suitable for demanding industrial applications
• IP67 (NEMA 6) enclosure enables the ER1022 switch to withstand water washdown cleaning
• Integral E-stop—the E-stop button provides emergency stopping capability at the extreme end of the installation and is field serviceable
• Tension indicator—the tension indicator makes the system easy to set up and to maintain the proper rope tension
• 4 N/C safety contacts and 2 N/O auxiliary contacts satisfy the most demanding applications
• Vibration tolerant—the snap-acting switch contacts protect against nuisance tripping due to vibration
• Long life—the ER1022 switch is designed for a minimum of one million actuations
• Indicator beacon—the indicator beacon, available in 24 VDC, can be wired to flash red to indicate a tripped switch or glow a constant green to indicate a properly reset switch

Two Sti. €1022 industrial control devices with black buttons and a white housing, no visible text or symbols on the devices themselves.

Operation

Blue Reset Button

A blue reset button is provided to easily return the unit back to its machine-run position after actuation.

Installation Hardware Available

RK Rope Tension Kit

Product photo of a black cable with multiple metal clips and a hook, no visible text or symbols

The RK Rope Tension Kit comes with all of the required hardware for most installations. A spring is required as shown in the installation example below.

Installation Hardware

Tension/Gripper Spring Turnbuckle Double Loop Clip Eyebolt Thimble Rope Pulley

Individual hardware items may be purchased for specific installation requirements.

Contact Arrangements

4NC + 2NO	Rope Slack	Tension Range	Rope Pulled
11/12
21/22
33/34
41/42
51/52
63/64

Mounting Specification

ER1022 ≤ 500 mm Every ≤ 3 m Every ≤ 3 m ≤ 500 mm Tensioner Gripper Eyebolt Support Safety Spring Wall ≤ 125 m

Note: Some installations may require a ER1022 on each end.

Applications

Typical applications are on conveyor systems and across rotating machinery, and around hazardous areas.

3D rendering of a simple bench with black frame and blue horizontal bar (no text or symbols)

3D illustration of a conveyor belt system with multiple cubes on both sides (no text or symbols)

Ordering information

Rope Pull Emergency Stop Switch

E-Stop	Indicator Beacon	Contacts	Wiring Entry	Model
Included	Included (24 VDC)	4 N/C + 2 N/O	4 x M20	ER1022-042MELL
Included	Included (24 VDC)	4 N/C + 2 N/O	4 x M20	ER1022-042MELR

Accessories

Item	Model
Replacement Lid/LED, 24 VDC	SM06-SL710
Rope Kit, 5 m, Stainless Steel	RK5
Rope Kit, 10 m, Stainless Steel	RK10
Rope Kit, 20 m, Stainless Steel	RK20
Rope Kit, 50 m, Stainless Steel	RK50
Rope Only, 5 m	R5M
Rope Only, 10 m	R10M
Rope Only, 20 m	R20M
Rope Only, 50 m	R50M
Rope Only, 100 m	R100M
Rope Only, 126 m	R126M
Tensioner Gripper, Stainless Steel	SM06-TG00
Eye Bolt, Stainless Steel, 8 per pack	SM06-EB10
Double Loop Clip, Stainless Steel, 4 per pack	SM06-DL20
Thimble, Stainless Steel, 4 per pack	SM06-THSS
Turnbuckle, Stainless Steel	SM06-TB30
Spring, Stainless Steel	SM06-SP50
Rope Pulley, Stainless Steel	SM06-RPSS
E-Stop Mechanism	SM06-ES60

Specifications

Electrical	Contact Configurations	4 N/C + 2 N/O
	Safety Contacts	4 N/C
	Switching Ability	AC: 240 V–3 A, 120 V–6 A, InductiveDC: 24 V–2.5 A, Inductive
	Auxiliary Contacts	2 N/O
	Max Switching Current/Volt/Amp	240 V/720 VA
	Minimum Current	5 V, 5 mA DC
	Electrical Life	1,000,000 minimum
	LED Indicator Beacon	24 VDC
Mechanical	Mounting	Any position
	Mounting Hardware	4 x M5 screws
	Actuator Travel for Positive Opening	See diagrams on previous page
	Max Rope Span	125 m
	Operation Force	< 125 N
	Tensioning Force to Run Position	130 N typical
	Case Material	Die-cast aluminum alloy
	Eye Nut Material	Stainless steel
	Wiring Entry	4 x M20
	Weight	1100 g
	Color	Yellow
	Mechanical Life	1,000,000 minimum
Environmental	Protection	IP67 (NEMA 6)
	Operating Temperature	-25 to 80°C
	Cleaning	Water washdown
Compliance	Standards	IEC947-5-1, IEC947-5-5, EN418, UL508, BS5304
	Approvals/Listings	CE marked for all applicable directives, UL and C-UL

Note: The safety contacts of the Omron STI switches are described as normally closed (N/C)—i.e., with the rope properly tensioned and the machine able to be started.

Dimensions

Illustration of right ER1022-042MI 223 MIN - 240 MAX 96 4 mounting holes clearance for M5 screws 86 100 27.50 34

143 110 29 92 10 25 60 Note

Note: The designation of the ER1022 switch as left-sided or right-sided is based upon the mounted position of the switch, in the installation.

Operating instructions

Installation must be in accordance with the following steps and stated specifications and should be carried out by suitably competent personnel. Adherence to the recommended maintenance instructions forms part of the warranty.

WARNING

Do not defeat, tamper, remove or bypass this unit. Severe injury to personnel could result.

Optional 24 VDC Indicator Beacon

When +24VDC is applied to the red wire, the beacon will illuminate red and flash.

When +24 VDC is applied to the green wire, the beacon will illuminate green.

(+24VDC) Red Black (0 V) (+24VDC) Green

Optional 120 VAC Indicator Beacon

When +120VAC is applied to the red wire, the beacon will illuminate red and flash.

When +120 VAC is applied to the green wire, the beacon will illuminate green.

(120VAC) Red Black (common) (120VAC) Green

Tension Indicator

Indicator shown with steel rope properly adjusted.

Technical line drawing of a mechanical assembly with spring and housing (no text or symbols)

WARNING

1. Installation of all Safety Rope 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. Rope support eyebolts must be fitted at 2.5 m. min. to 3 m. max. intervals along all rope lengths between switches. The rope must be supported no more than 500 mm from the switch eyebolt or Safety Spring (if used). It is important that this first 500 mm is not used as part of the active protection coverage.
3. 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 correct sizing glands for conduit entry and cable outside diameter.
4. Tensioning of rope is achieved by use of tensioner / gripper assemblies. Upon installation, tension to mid-position as indicated by the red arrows in the viewing window of each switch. Check operation for all switches and the control circuits by puling the rope at various locations along the active protection area and resetting each switch by depressing the Blue Reset button. Ensure each time that the switches latch off and require manual resetting by depressing the Blue Reset button. Increase the system tension further, if required, depending upon the checks along the active length of coverage. If fitted with a Mushroom type E-Stop button (Red) then test and reset each switch to ensure function of control circuits. Typical operational conditions for successful operation of system is less than 75 N. pulling force and less than 150 mm deflection of rope between eyebolt supports. If the optional LED is fitted but is not used, ensure that the conductors remain coiled and tied to the tie hole in the LED flange.
5. Every week: Check correct operation of system at locations along all coverage length. Check for nominal tension setting, re-tension rope if necessary. Every 6 months: Isolate power and remove cover. Check screw terminal tightness and check for signs of moisture ingress. Never attempt to repair any switch.

ALL DIMENSIONS SHOWN ARE IN MILLIMETERS.

To convert millimeters into inches, multiply by 0.03937. To convert grams into ounces, multiply by 0.03527.

Cat. No. E51E-EN-01

In the interest of product improvement, specifications are subject to change without notice.