Local distribution company Referro Systems has added the latest Dual Head range of Allen-Bradley’s Guardmaster Lifeline 5 Safety Pull Switches to its portfolio.
Used extensively in material handling, conveyor systems and manufacturing lines, Lifeline 5 is ideal for protecting long stretches of equipment where quick access to a safety pull switch and emergency stop is vital. “These systems can easily be overlooked in an industrial environment, but we have found that it becomes an integral part of a working system, as it continuously monitors cable tension to prevent false trips caused by thermal expansion, sag and/ or contraction, ensuring dependable operation in varied industrial settings, even under rigorous environmental conditions,” explains Adrian van Wyk, MD of Referro Systems.
The key enhancement in the Dual Head Lifeline 5 is its expanded maximum cable span. While the existing single-head Lifeline 5 supports cable lengths up to 100 metres, the new dual-head model extends this reach to 200 metres. This allows plants and conveyor systems with large footprints to protect longer sections using a single integrated safety system, reducing complexity and installation costs.
The dual-head configuration means two microprocessor-based switches operate on the same pull rope, improving system reliability and safety through redundancy. “If one switch encounters an issue, such as a trapped or snagged rope, the second switch on the opposite end can still detect cable pulls or slack, maintaining continuous protection. This redundancy is particularly vital in environments where obstacles or wear and tear create a higher probability of cable entrapment,” adds Van Wyk.
Both single and dual-head Lifeline 5 units share advanced diagnostics and safety features. The switches monitor rope tension actively, compensating for thermal expansion, sag and false trips to ensure accurate signalling. Their design includes highly visible 270° LED indicators that assist technicians in tensioning the cable properly and provide clear status feedback continuously. The switches meet stringent safety standards with PLe Category 4 and SIL 3 certifications, guaranteeing top-tier protection for conveyor systems and other machinery.
Referro Systems offers the Lifeline 5 units housed in robust die-cast aluminium or stainless steel enclosures, the latter intended for use in harsh, corrosive, high wash down areas, and food and beverage environments. Both models operate reliably across the same temperature and environmental ratings, providing consistent performance regardless of installation conditions. Wiring options remain compatible with standard industrial connectors such as M12, though dual-head systems require careful wiring and safety circuit design to manage two switch heads.
“The choice between the single-head and the new dual-head Lifeline 5 depends on site-specific safety risk assessments,” notes Van Wyk. Single-head units offer a simple and cost-efficient solution ideal for shorter spans. In contrast, the dual-head Lifeline 5 is designed to meet the needs of large-scale facilities that require extended cable lengths, added safety redundancy or higher resistance to trapped cable scenarios.
“By adding the latest iterations of these cable pull switches to our product line up, we continue our commitment to improving and enhancing industrial safety standards, protecting lives and businesses alike,” Van Wyk concludes.
