For more information visit our web site:

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44.45

28.6

19

57.15 15.9

Data Sheet 1.2 Technical Bolt Interlock (Multi Key) - KL

For more information visit our web site: http://www.castell.com

53.5 KL 64.6 QKL

The L Dimension is the bolt protrusion from the end face of the KL lock with the key in the trapped position. Standard L dimensions are 0, 6.35, 12.7, 19.05 and 25.4mm.

Bolt travel is 19.05mm from the key trapped to key free position.

APPROX. 114.3

4 MTG.HOLES DIA.7mm

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Data Sheet 4.0 Technical

Powersafe 20amp Switch - KS20

For more information visit our web site: http://www.castell.com

CASTELL SAFETY INTERNATIONAL LTD.

Q LOCK 105 FS LOCK 92

81 DEEP

Tel: 0181-200-1200 Fax: 0181-205-0055 London NW9 8UR International Ltd.

Kingsbury Road Castell Safety

50 CTRS 94

Ø13mm

50 CTRS 94

MOUNTING HOLES 4 OFF Ø5 BLIND

CABLE GLAND M20

FS LOCK 13 Q LOCK 26

Ø34.9

REF. X

45°

2 MOUNTING HOLES Ø7

50.8 SWITCH Ø43 MAX.

12 POLES 104.6mm DIMENSION REFERENCE 'X'

6 POLES 4 POLES

8 POLES 10 POLES No. OF POLES

85.6mm 95.1mm 76.1mm 66.6mm LENGTH

Surface Mount

Panel Mount

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K BOLT LOCK / KL BOLT LOCK

INSTALLATION - MAINTENANCE INSTRUCTIONS TECHNICAL SPECIFICATION

IMPORTANT: The unit must be installed by a competent and qualified person who has read and understood these instructions. Please retain this document.

GENERAL:

The Castell bolt interlock range are used on control of switchgear, valve control &

precipitators to inhibit movement of cams, toggles or levers.

.

Install K bolt /KL bolt issue 1

1 4

PICTORIAL REPRESENTATION: (for reference only)

Castell Safety International Limited 217Kingsbury Road

London NW9 9PQ

Tel: 020 8200 1200 Fax: 020 8205 0055 http://www.castell.com

e-mail: sales@castell.co.uk

K BOLT LOCK

The K bolt lock is a key operated mechanical bolt interlock suitable for the control of electrical switchgear. The standard unit comes with a 16mm diameter bolt of variable length (to be specified), that is used to control the rotation of movement of operating handles or toggles. The bolt movement is directly controlled by the rotation of the key. The bolt length should be specified on ordering by quoting the ‘L’ dimension, this being the length of the bolt protruding from the end face with the key in the trapped position & bolt retracted.

OPERATION:

The length of bolt can be varied to suit the application but travel of the bolt is always 19mm. The key is free when bolt is extended, insertion and rotation clockwise of the key will retract the bolt. The key will be trapped in bolt retracted position.

K BOLT LOCKS

KL BOLT LOCK OPERATION Continue

Double key: The primary & secondary key are free and bolt is extended.

Insert and rotation of both keys will, retracts the bolt. Both keys are trapped in bolt with bolt retracted.

INSTALLATION:

The housing of the interlock should normally be mounted to a panel using suitable M6 fasteners. See page 2 for mounting detail.

IMPORTANT:

Interlock should be mounted using anti-tamper fasteners to prevent unauthorised removal.

LOST / REPLACEMENT KEYS:

Records of key & lock coding will be maintained at Castell. If you lose a key or require replacement keys then please contact the Castell sales team for advise. You may be asked to complete a disclaimer to take responsibility for lost / replacement keys.

KL BOLT LOCK OPERATION:

KL Lock is multi-key operated bolt.

Exchange: The primary key is trapped, secondary key free with bolt extended.

Insert secondary key and rotate, this enables rotation and removal of the primary key which retracts the bolt. The secondary key is now trapped in bolt FSK LOCK FORM 1,2,3&4. SHOWN

WITH BOLT EXTENDED

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2 3

DIMENSIONS: (for reference only)

MAINTENANCE:

Periodic visual checks should be carried out by the site manager / safety officer. Do not lubricate lock barrel with oil or grease, use CK Dry Powder Graphite if necessary.

SERVICES:

Castell engineers are able to carry out risk assessment, install, repair and commission safety systems as well as provide operator and maintenance training.

TECHNICAL SPECIFICATION Size Refer to drawings on pages 3 & 4

Weight 0.7 Kg

Working. temperature Min -40ºC (ice free) Max Q type +107 ºC FS type +140 ºC

bolt material Stainless steel or brass Housing material Stainless steel or brass Lock material Stainless steel or brass

K BOLT LOCK KL BOLT LOCK

SHOWN KL BOLT WITH FS LOCK,FORM 4, ONE SECONDARY LOCK, EXCHANGE KEY CONDITION. L=LENGTH OF BOLT WHEN RETRACTED.

SHOWN K BOLT WITH FS LOCK FORM 4.

L=LENGTH OF BOLT WHEN RETRACTED.

Install K bolt /KL bolt. Page 2 of 2

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KS20

INSTALLATION - MAINTENANCE INSTRUCTIONS TECHNICAL SPECIFICATION

IMPORTANT: The unit must be installed by a competent and qualified person who has read and understood these instructions. Please retain this document.

GENERAL: The Castell KS20 is a key operated interlock switch designed to meet European directives on machine safety, and to provide a safe access control system when installed as part of the power or control circuits of dangerous machinery.

OPERATION:

When the machinery is in operation the isolation key is trapped and the switch contacts closed. To release the key the switch must be turned, isolating the power to the machine. The key can now be transferred to the access interlock and the guard opened.

Optional contact conditions are supplied as standard with the following

conditions:-

Key trapped - 4 N/C contacts Key free - 4 N/C contacts

Key trapped - 2 N/O & 2 N/C contacts Key trapped - 3 N/O & 3N/C contacts See wiring diagrams for clarification.

.

install KS20 issue 1 ECR 2046

1 4

DIMENSIONS: (for reference only)

Castell Safety International Limited 217 Kingsbury Road

London NW9 9PQ

Tel: 020 8200 1200 Fax: 020 8205 0055 http://www.castell.com

e-mail: sales@castell.co.uk

INSTALLATION:

1. Installation should be carried out by a qualified electrical engineer.

2. Front of panel units should be mounted to a flat surface using 4 off suitable fixing screws. Offer up back box of enclosure in desired position and use mounting holes as a drilling template (see page 4).

3. Back of panel units should be mounted to a flat surface. A &36mm hole & two off &7mm holes should be drilled in the panel to accept the lock mounting. (see page 2). The lock face should be sealed to the panel for ingress protection.

4. Cables should be connected to the switch (via the cable gland for front of panel) in accordance with the applicable wiring diagrams (see page 2).

5. Ensure that the unit is bonded for earth continuity.

KS20 FRONT OF PANEL

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2 3

MAINTENANCE:

Periodic visual checks should be carried out by the site manager / safety officer.

Do not lubricate lock barrel with oil or grease, use CK Dry Powder Graphite if necessary.

TECHNICAL SPECIFICATION

Size Refer to diagrams on page 4

Working temp. Min. -5

^o

C Max. +55

^o

C Ice free.

Weight 0.5Kg

Related standards IEC 947/3, VDE 0660 part 107/09.82

.Approvals BS,CSA,UL & VDE.

Motor ratings 400mA to 20amps @ nominal voltage 690V

3 x 380v-440v AC23A 7.5Kw or AC3 5.5Kw

Enclosure Front panel mounting only IP65

protection with M20 cable gland.

LOST / REPLACEMENT KEYS:

Records of key & lock coding will be maintained at Castell. If you lose a key or require replacement keys then please contact the Castell sales team for advise.You may be asked to complete a disclaimer to take responsibility for lost / replacement keys.

SERVICES:

Castell engineers are able to carry out risk assessment, install, repair and commission safety systems as well as provide operator and maintenance training.

KS20 BACK OF PANEL

WIRING DIAGRAMS

Q LOCK 26 FS LOCK 13 SU LOCK 13

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For more information visit our website: http://www.castell.com

SYSTEMS DESCRIPTION

The electrical and pneumatic supplies to the machine are switched on and the access doors to the hazardous area are locked closed. The initial key is trapped in the AV pneumatic switch.

To enter the area, the pneumatic supply is turned to the 'off' position and the key released, locking the supply off. The electrical supply is then turned off and the initial key inserted into the KL, which extends the bolt and allows the removal of the secondary key. The pneumatic and electrical supplies are now locked in the off position.

This key is then inserted into the 'X Key Exchange Box' to release a further two keys which are used to open the 'AI' access locks on the doors. Whilst these keys are out of the 'X box', the electrical supply key cannot be removed, ensuring that the power cannot be switched on whilst the access doors are open.

GENERAL DESCRIPTION

The KL Lock is a multi-key operated mechanical bolt interlock suitable for the control of electrical switchgear. The standard unit comes with a 16mm diameter bolt of variable length, that is used to control the rotation or movement of operating handles or toggles of electrical switchgear. Many suppliers of switchgear equipment have mounting kits available for Castell interlocks. The lock is manufactured in brass or stainless steel making it ideally suited to use in harsh or corrosive environments.

Data Sheet 1.2

Bolt Interlock: KL

secondary key and rotate, this enables rotation and removal of the primary key which retracts the bolt. The secondary key is now trapped in the lock.

Double Key: The Primary and Secondary Key are free and the bolt is extended. Insertion and rotation of both keys will retract the bolt.

TYPICAL SYSTEMS

The KL is designed to operate as part of an integrated safety system, controlling the operation of HV/LV switchgear. A typical example is shown below.

OPERATION

The bolt movement is directly controlled by the rotation of the keys. The bolt length can be varied to suit the application but the travel of the bolt from extended to retracted is always 19mm. The bolt length should be specified on ordering by quoting the 'L' dimension, this being the length of the bolt protruding from the end face with the key in the trapped position and the bolt

retracted.

Key Exchange:The Primary Key is trapped, the Secondary Key is free and the bolt is extended. Insert 1.1 to 10.2 Doc rev. 27/9/99 12:52 pm Page 5

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CASTELL SAFETY INTERNATIONAL LIMITED

Kingsbury Road London NW9 8UR • Tel: 020 8200 1200 Fax: 020 8205 0055 • http://www.castell.com E-mail: sales@castell.co.uk

Whislt every effort has been made to ensure the accuracy of the information provided, no liability can be undertaken for any errors or omission.

Castell Safety International Limited reserves the right to alter specifications and introduce improvements without prior notice.

Data Sheet 1.2 Type: KL

FEATURES

• Robust construction suitable for heavy duty or harsh environments.

• Suitable for fitting to a wide range of standard electrical switchgear.

• Exchange key or double key condition.

• Bolt projection to suit your requirements.

MATERIALS AND FINISHES

• Standard Model Brass or stainless steel.

OPTIONS

• See data sheet N^o. 11.0 TECHNICAL DIMENSIONS

• Product dimensions available from our web site, via e-mail, fax or telephone.

ORDERING INFORMATION REQUIRED SPECIFY

Product Type:

Lock Portion Type:

Lock Portion Symbol: Primary lock

Secondary lock

Form: See diagram 1, 2, 3, 4

L Dimension: 0, 6.4, 12.7, 19.1, 25.4 Bolt protrusion when withdrawn.

Key Condition: Double key or key exchange

Key Required:

Options:

FAX BACK ON 020 8905 9378 FOR IMMEDIATE QUOTATION Lock Portion Options Mounting Details

1.1 to 10.2 Doc rev. 27/9/99 12:52 pm Page 6

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For more information visit our website: http://www.castell.com

Data Sheet 4.0

Powersafe Electrical Switch: KS-20

GENERAL DESCRIPTION

The KS20 is a key driven 20amp electrical switch suitable for the isolation or switching of low (20 amp maximum) current. This type of isolator should be used for short term, off load isolation and operated by suitably qualified personnel. The KS20 is manufactured from either brass or stainless steel making it suitable for use in standard or harsh corrosive environments where the lock is subject to heavy use. The unit is supplied suitable for mounting into an existing panel or for surface mounting within its own IP65 rated polycarbonate enclosure.

TYPICAL SYSTEM.

The KS20 is designed to operate as part of an integrated safety system, controlling access to

hazardous areas. A typical example of machine isolation and access control is shown below.

SYSTEM DESCRIPTION

The removal of the isolation key in the KS20, changes the condition of the electrical supply to the machine to a safe condition. This key is then used to unlock the interlock on the access door. The guard can only be opened when the electrical supply has been switched into a safe condition.

OPERATION

Under normal operating conditions the key is retained in the lock portion. Rotation and subsequent removal of the key will alter the condition of the contacts within the switch, this may be changing from all of the contacts closed to open or as a changeover i.e. 2 contacts from closed to open and 2 contacts from open to closed. The switch condition cannot be changed without the

correctly coded key.

1.1 to 10.2 Doc rev. 27/9/99 3:04 pm Page 53

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FEATURES

• Key driven,force break 20 amp 4 pole switch conforming to IEC947/3

• Number of poles and contact arrangement to suit your requirement.

• Suitable for panel mount or surface mount (IP65 Polycarbonate enclosure)

• UL, CSA approved in accordance with BS and VDE.

• Power isolation - 400 MA - 20A / Motor isolation AC - 23A 7.5KW or AC3 5.5KW MATERIALS AND FINISHES

OPTIONS

Data Sheet 4.0 Type: KS-20

Product Type:

Lock Portion Type:

Lock Portion Symbol:

Key trapped, contacts closed, key free, contacts open.

Switch Condition: Key trapped, contacts open, key free, contacts closed.

Key trapped, contacts open and closed (change over).

Switch Poles: 4 pole standard, if otherwise please specify.

Mounting: Panel or surface.

Key Required:

Options:

FAX BACK ON 020 8905 9378 FOR IMMEDIATE QUOTATION Lock Portion Options Mounting Details

1.1 to 10.2 Doc rev. 27/9/99 3:04 pm Page 54

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For more information visit our website: http://www.castell.com

Data Sheet 8.0

Keys

GENERAL DESCRIPTION

A selection of keys are available to suit a range of applications, from the basic nickel plated FK4 to the stainless steel FKW6 sealing key. The ‘FK’ range of keys fit the figure style lock portion whilst the ‘QS’ fits the ‘Q’ style lock.

FK RANGE

A maximum of three (3) characters are permissable, letters or numbers or a combination of both.

The figures are in predetermined positions within the key.

Q RANGE

A maximum of six (6) characters are permissable, letters or numbers or a combination of both.

This is a non-masterable lock that Castell holds a record of all key codes issued.

FKW6

FKW3

QS

1.1 to 10.2 Doc rev. 27/9/99 4:00 pm Page 101

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C A S T E L L S A F E T Y IN T E R N A T IO N A L L IM IT E D

K ingsbury R oad London N W 9 8U R • Tel: 020 8200 1200 Fax: 020 8205 0055 ¥ http://www.castell.com E-mail: sales@ castell.co.uk

W hislt every effort has been m ade to ensure the accuracy of the inform ation provided, no liability can be undertaken for any errors or om ission.

Castell S afety International Lim ited reserves the right to alter specifications and introduce im provem ents without prior notice.

D a t a S h e e t 8 . 0 K e ys

F K 4

The basic figure lock brass key supplied in nickel plated finish. S uitable for internal applications in a dry environment.

F K W 6 -N I

S upplied with a neoprene seal and flange to prevent ingress into the lock portion. S upplied in nickel plate or nylon coated finish (red, blue or green). S uitable for external application. A stainless steel version is available if required.

F K W 3

T-handle key with a neoprene seal and flange.

S upplied in nickel plate or nylon coated finish (red, blue or green). S uitable for external applications where either gloved operation or high torque is required.

K S D

E xtended T-handle key with a neoprene seal and flange. S upplied in nylon coated finish. S uitable for the K S D range of electrical switches.

Q S

Q lock portion brass key with a neoprene seal.

S upplied in standard brass or nickel plate finish.

S uitable for internal applications.

1.1 to 10.2 Doc rev. 27/9/99 4:01 pm Page 102

F K W 6 -S

S tainless steel version. S upplied with a neoprene seal and flange to prevent ingress into the lock portion. S uitable for external application.

.

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Data Sheet 1.1 Technical Bolt Interlock

For more information visit our web site: http://www.castell.com

53.5 K 64.6 QK

The L Dimension is the bolt protrusion from the end face of the k lock with the key in the trapped position. Standard L dimensions are 0, 6.35, 12.7, 19.05 and 25.4mm.

Bolt travel is 19.05mm from the key trapped to key free position.

59.5 15.9

19.05

44.45

28.6 BOLT SHOWN EXTENDED

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For more information visit our website: http://www.castell.com

Data Sheet 1.1

Bolt Interlock: K

GENERAL DESCRIPTION

The K Lock is a key operated mechanical bolt interlock suitable for the control of electrical switchgear.

The standard unit comes with a 16mm diameter bolt of variable length, that is used to control the rotation or movement of operating handles or toggles of electrical switchgear. Many suppliers of switchgear equipment have mounting kits available for Castell interlocks. The lock is manufactured in brass or stainless steel making it ideally suited to use in harsh or corrosive environments.

TYPICAL SYSTEM

The K is designed to operate as part of an integrated safety system, controlling the operation of HV/LV switchgear. A typical example is shown below.

OPERATION

The bolt movement is directly controlled by the rotation of the key. The bolt length can be varied to suit the

application but the travel of the bolt from extended to retracted is always 19mm. The bolt length should be specified on ordering by quoting the ‘L’ dimension, this being the length of the bolt protruding from the end face with the key in the trapped position and the bolt retracted.

System Description

The power supply to the machine is switched on and the access doors to the hazardous area are locked closed. The initial key is trapped in the K Lock whilst the switch is on.

To enter the area, the isolator is turned to the ‘off’ position and the key released, locking the isolator off.

The key is then inserted into the ‘X Key Exchange Box’ to release a further two keys which are used to open the ‘AI’

access locks on the doors. Whilst these keys are out of the ‘X Box’, the initial power key cannot be removed, ensuring that the power cannot be switched on whilst the access doors are open.

1.1 to 10.2 Doc rev. 27/9/99 12:45 pm Page 3

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Data Sheet 1.1 Type: K

FEATURES

• Robust construction suitable for heavy duty or harsh environments.

• Suitable for fitting to a wide range of standard electrical switchgear.

• Front face or end face mounting.

• Bolt projection to suit your requirement.

MATERIALS AND FINISHES

OPTIONS

Product Type:

Lock Portion Type:

Lock Portion Symbol:

Form: See diagram 1, 2, 3, 4

L Dimension: 0, 6.4, 12.7, 19.1, 25.4 Bolt protrusion when withdrawn. (please specify) Key Required:

Options:

FAX BACK ON 020 8905 9378 FOR IMMEDIATE QUOTATION Lock Portion Options Mounting Details

1.1 to 10.2 Doc rev. 27/9/99 12:46 pm Page 4