Emergency Stop Button

Hello there, for safety's sake, I am looking for a stop/start button for my plunge router, so that I can table mount it (in order for it to work as a table mount router I would need to attach a cable tie to the trigger).

I swear I saw an emergency start/stop button a while ago somewhere which you could plug an appliance into like a normal socket, but now that I am trying to find it again I can't see it anywhere.

Does anyone know where I can locate such a device? I don't like the idea of having to hardwire.

Use a suitably rated foot switch. Router only runs when your foot is pressing the pedal.



Something like this where the cover prevents the pedal being accidently operated by something falling on it.

Your are going to do some installation/wiring work, so I don't see why hardwiring the appliance would be much more hassle, providing you protected it with a fused spur.

Thank you for your replies.

Foot switch sounds like a good idea except when feeding a long length past the router bit which would require me to move around and prevent operation of the router.

When I made reference to an emergency on/off switch I was talking about something which acts like a socket, but it actually designed like an extension lead in that it plugs into a normal socket itself, meaning no wiring is required.

The table mount I have is portable so that set-up needs to also be portable, along with the ability to operate the plunge router normally by dismounting occasionally.

Is this not possible?

In the main an emergency stop button is wired into a system which likely includes a safety relay and other safety switches. If there is likely hood of irreversible damage to the human body then everything needs to be doubled up so failure of any single wire or relay will not stop it working with the exception of the special safety relay. Some times the switches are double normal closed other times they are one normally closed and one normally open.

I just can't see how this would be built into a plug in device.

The process in industry involves risk assessments and method statements and can become complex. With the exception of the special safety relay semi-conductors are not permitted and it was to me a problem ensuring only the right bits turned off. For example turning off air supply was in the main good but in some cases it would cause items to fall which could trap people so that air was not turned off.

It was a major headache trying to arrange guards so it would stop the machine if something shifted the guard but not when the product passed it. It also involved things like motor brakes to stop the energy from flywheels still causing damage and fitting switches which needed holding so operator could not have a free hand.

We had problems with domestic equipment being brought into the work place. Grinders were a good example with domestic there was often a button which could keep the grinder running hands free but this was not permitted in industry. One work around was the active RCD so if there was a power failure and the equipment was put down with trigger pressed then it would not restart until RCD was reset.

As a DIY what you need is a method of switching off the unit without using your hands. Be it you knee or your foot you want something you need to press to run the machine which once released will stop it. Some thing as simple as this foot switch will do the job to an extent. Both this switch and this one can help but they need to be used after some thought as to if they are good enough. I would have always considered a guard with switch is also required.

I've got the axminister plug in nvr switch linked above on my table router. Works a treat

nickjb said:

I've got the axminister plug in nvr switch linked above on my table router. Works a treat

Click to expand...

Though it's not clear from the image or the link, there are separate start/stop buttons behind the emergency stop button, which hinges down:

http://www.charnwood.net/files/shop/products/rw/1755-4_750.jpg

Do you want an Emergency Stop switch or a Safe to Run switch ?

An emergency stop switch has to be accessible at all times so the machine can be stopped as quickly as possible. On some equipment such as open conveyor belts the switch is a tensioned cord between two switches and running the length of the conveyor. Pulling it sideways will operate one or both switches to stop the machinery. ( also cutting the cord will release the tension and one or both switches will operate.

That is very different from a Safe to Run switch which is little more an ON - OFF switch oerted manually though some other safety switches may be involved to prevent the machine staring if machine guards or covers are open or other un-safe conditions are present.

bernardgreen said:

Do you want an Emergency Stop switch or a Safe to Run switch ?

An emergency stop switch has to be accessible at all times so the machine can be stopped as quickly as possible. On some equipment such as open conveyor belts the switch is a tensioned cord between two switches and running the length of the conveyor. Pulling it sideways will operate one or both switches to stop the machinery. ( also cutting the cord will release the tension and one or both switches will operate.

That is very different from a Safe to Run switch which is little more an ON - OFF switch oerted manually though some other safety switches may be involved to prevent the machine staring if machine guards or covers are open or other un-safe conditions are present.

Click to expand...

I am looking for a switch which has an easy to operate off button, but also incorporates an on button as well. I suppose therefore that I am looking at the latter safe to run?

davelx said:

nickjb said:

I've got the axminister plug in nvr switch linked above on my table router. Works a treat

Click to expand...

Though it's not clear from the image or the link, there are separate start/stop buttons behind the emergency stop button, which hinges down:

http://www.charnwood.net/files/shop/products/rw/1755-4_750.jpg

Click to expand...

This, and the second picture in Eric's post, is the kind of switch that is built into my router table and I think it covers your requirements.

You lift the cover to press the on button, then the cover flips down to present an emergency stop button - when you whack the cover it presses the off button underneath the cover.
Note, as well, that the actual switches are encased in rubber to keep wood and metal filings out.

You'll still have to hard wire the actual router switch to be permanently on, of course. Either some combination of cable ties or by removing the switch and permanently making the feed live.

The switches are called No Voltage Release (NVR) switches - selection can be found here https://www.google.co.uk/search?q=n...0l5.2495j0j4&sourceid=chrome&es_sm=0&ie=UTF-8 for hard wiring, or here for ones with 13A sockets attached; https://www.google.co.uk/search?q=n...es_sm=0&ie=UTF-8#q=nvr+switch+with+13a+socket

Finally, the benefit of a NVR switch is that it will also disconnect if the power is cut. So if you have a power failure (MCB trips or fuse blows) then the device won't switch on again when power returns.

skotl said:

davelx said:

nickjb said:

I've got the axminister plug in nvr switch linked above on my table router. Works a treat

Click to expand...

Though it's not clear from the image or the link, there are separate start/stop buttons behind the emergency stop button, which hinges down:

http://www.charnwood.net/files/shop/products/rw/1755-4_750.jpg

Click to expand...

This, and the second picture in Eric's post, is the kind of switch that is built into my router table and I think it covers your requirements.

You lift the cover to press the on button, then the cover flips down to present an emergency stop button - when you whack the cover it presses the off button underneath the cover.
Note, as well, that the actual switches are encased in rubber to keep wood and metal filings out.

You'll still have to hard wire the actual router switch to be permanently on, of course. Either some combination of cable ties or by removing the switch and permanently making the feed live.

The switches are called No Voltage Release (NVR) switches - selection can be found here https://www.google.co.uk/search?q=n...0l5.2495j0j4&sourceid=chrome&es_sm=0&ie=UTF-8 for hard wiring, or here for ones with 13A sockets attached; https://www.google.co.uk/search?q=n...es_sm=0&ie=UTF-8#q=nvr+switch+with+13a+socket

Finally, the benefit of a NVR switch is that it will also disconnect if the power is cut. So if you have a power failure (MCB trips or fuse blows) then the device won't switch on again when power returns.

Click to expand...

Thank you for your reply, I really appreciate your practical advice.

Given that the example you have given is identical to my scenario, could you please kindless take photographs of the setup and all its component so I get a better idea?

I would, but the garage is currently full with 50sq m of Kingspan so I can't get to anything!

Mine has a unit very similar to this one (which is what I think Eric first linked to). The router is designed to be fitted to a table so has a latch for the switch so that it can be permanently powered on. On the assumption that yours doesn't I'd either be inclined to dismantle the handle that houses the switch and wire it to be always on or I'd use cable ties to pull the switch in.

TBH, the latter approach may be safer, surprisingly, in that at least it's b***y obvious that the switch is permanently on if anyone ever removes the router from the table.

Other than that, there's not much to it - plug the router's standard plug into the socket on the NVR switch and you're good to go - on/off handled by the new switch.

The ones with a sprung flap on the front, as in Eric's second photo, and (unfortunately) used on many small machines from Axminster and similar, do not meet the European and international standards for emergency stop devices. There's a case before the European Commission, trying to have them banned, but they're cheap, and people don't like to spend money on proper safety devices. At least, they don't until they've had an accident!

However, will an emergency stop lessen the risk? My big router stops quicker when switched off using its own switch, than it does if the power is removed by e.g. unplugging it, due to the electronic braking.

stillp said:

However, will an emergency stop lessen the risk? My big router stops quicker when switched off using its own switch, than it does if the power is removed by e.g. unplugging it, due to the electronic braking.

Click to expand...

Is not the issue that of accessibility? Even though operating the router's own switch might result in it stopping more quickly, in the OPs (common) situation, that switch would be hidden away under the table, whereas an 'emergency stop' would presumably be mounted somewhere 'immediately accessible' to the user?

Kind Regards, John

Yes, that's one of the issues to be considered, but with a large cutter like a panel raising cutter, cutting the power will have little effect.
What's needed here is not one of those silly flappy things, but a proper e-stop button with trigger action so that it will not fail to both latch, and break the circuit. However I'm not aware of anyone who supplies a good e-stop in a box with a 13 A socket-outlet.