Pacific Automation’s Smart Series Pull Wire Switches are now even smarter and fully optimised for Australian conditions and compliance, with enhanced design features based on end-user feedback.
Built for the demands of bulk material handling
When the company first introduced the Smart Series Pull Wire Switch, it brought a smarter and more robust approach to conveyor safety. But Pacific Automation’s goal was never to stand still. Over the past year, its product team worked closely with engineers, maintenance teams, and safety officers across Australia to understand how the product performed in the field.
From iron ore operations in Western Australia to coal and mineral processing sites nationwide, the Smart Pull has been shaped by conversations with the people who work in some of the most demanding environments in Australia.
Pacific Automation engaged directly with maintenance teams, safety managers, and control system engineers working in bulk material handling operations — where vibration, heat, dust, and long conveyor runs are part of daily life. These discussions revealed exactly where standard pull wire switches fall short, and what’s needed to maintain safety compliance without compromising up time or reliability.
Those insights directly informed the updates now available in the Smart Pull Wire Switch — a switch built not just for compliance, but for the rugged realities of Australian mining.
Common problems with conventional pull wire switches:
- Frequent false or nuisance tripping due to slack lanyards and thermal expansion
- Loose terminations leading to electrical faults and unreliable signals
- Contact corrosion causing intermittent or failed operation
- Complex setup processes and the need for regular manual adjustment
- Non-compliance with evolving Australian safety standards
- IMAC and Ringway systems that require separate enclosures due to limited internal space
These issues contribute to unplanned downtime, increased maintenance load, safety risks, and operational inefficiencies.
Pacific Automation’s Smart Series is a purpose-built conveyor safety system designed to resolve these issues. Central to this system is the enhanced Smart Series Pull Wire Switch—now delivering even greater reliability, ease of installation and reduction of ongoing maintenance.
What’s new in the Smart Pull Wire Switch?
The Smart Series Pull Wire Switch is now Safety Integrity Level 2 (SIL2) capable under IEC 61508. This certification affirms its suitability for deployment in safety-critical applications, such as emergency stop systems across extensive conveyor installations.
AS/NZS 4024.361:2015 compliant
The Smart Series range meets stringent Australian machinery safety standards, supporting smoother audits, system integration, and project approvals for safety-focused operations.
Enhanced resistance to false tripping
Design improvements reduce the risk of nuisance tripping, especially under fluctuating temperatures or high-vibration environments. The system maintains integrity over time, helping reduce maintenance interruptions and system resets.
Monitoring compatibility built-in
Unlike many other models that require a separate enclosure for safety monitoring modules, the Smart Pull has been purpose-built with space inside the housing to accommodate a range of monitoring and detection solutions including IMAC, Ringway to suit the site requirements or preferences. This integration simplifies installation and wiring, especially in constrained or retrofit applications.
Support for brownfield installations
The Smart Pull is designed with flexibility in mind, making it suitable for brownfield upgrades where replacing outdated or non-compliant pull wire switches is required. Compatible mounting options and internal monitoring support make integration faster and more cost-effective.
Simplified and more effective tensioning kit
The updated tensioning kit now includes visual compliance indicators and refined mechanical design that:
- Enables quick visual confirmation that tension is within the safe operating range
- Reduces setup time during installation
- Eliminates the need for frequent manual adjustment, saving time across large-scale sites
- Improves long-term stability, particularly in operations exposed to environmental variability
These improvements make it easier to install, manage, and maintain, especially across sites with multiple conveyor lines or remote monitoring needs.
The Smart Series Conveyor Safety System offers a complete solution. The Smart Pull Wire Switch is part of the broader Smart Series range, which includes:
- Belt misalignment detectors
- Belt speed detectors
- Spillage detectors
- Belt rip detectors
- Blocked chute and tear/spillage feed and return detectors
- Essentials includes: Pigtails, lanyard pull wire, control cable, E/stop labels, tension kits and accessories.
Together these components enhance safety, reliability and productivity for all of a site’s operational needs.
Smart Series Pull Wire Switches are already installed at mining and processing sites across Australia, delivering tangible results including:
- Reduced false trips and system interruptions
- Decreased maintenance callouts
- Faster inspection and compliance processes
- Improved reliability in extreme operating conditions
- Easier integration with new or existing monitoring systems
Backed by Pacific Automation’s technical expertise and local support, the Smart Series offers dependable safety solutions tailored for Australian industry.
Click here to learn more about the Smart Series.