Your complete conveyor safety solution
Mining conveyors demand more than standalone safety devices, they require a coordinated protection system that reduces downtime, improves safety compliance, and protects critical assets.
Smart Series is Pacific Automation’s integrated Mining Conveyor Safety & Protection System. It combines emergency stop devices, belt drift monitoring, rip detection, speed sensing, blocked chute detection, and motor protection into a single intelligent architecture with distributed control and real-time diagnostics.
By treating conveyor protection as a system, not a collection of parts, Smart Series delivers faster fault identification, reduced installation complexity, and improved operational visibility across the entire conveyor.
Conveyor Control Systems for Mining and Industrial Applications
We supply ultra-reliable Smart Series devices for conveyor safety, protection & monitoring.
Full Conveyor Safety Solution
Smart Series is more than just a Pull Wire Switch. Whether you're after conveyor protection, or essential products to keep your operation up and running, Smart Series has you covered.
Pull Wire Switches
BK400PS
Smart Series BK400PS Pull and Slack Trip Pull Wire Switch, Aluminium, SIL2, IP66/67, Orange
BK500PS
Smart Series BK500PS Pull and Slack Trip Pull Wire Switch, Glass Reinforced Nylon, SIL2, IP66/67, Black
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Conveyor Protection Devices
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Conveyor Essentials
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Introducing Smart Series
Borne from over 20 years of engineering experience working on conveyor belts within the mining and industrial sectors, Pacific Automation are the exclusive channel partner of Smart Series.
Smart Series offer conveyor control, safety, and monitoring devices designed to AS 1755 including belt rip detectors, emergency pull wire switches, blocked chute switches, drift detectors and more.
Conveyor Control and Safety for Mineral Processing
Conveyors play a critical role across mineral processing plants, from primary crushing through to screening, stockpiling and load-out. In these environments, continuous material flow is essential to maintain throughput and avoid bottlenecks across the plant.
Dust, vibration, moisture and abrasive materials increase the risk of belt misalignment, slip, blockages and mechanical wear. Without integrated monitoring and shutdown protection, minor faults can quickly impact downstream processing equipment.
Our conveyor control systems and safety accessories are suited to mineral processing applications including crushers, transfer points, reclaim systems and plant feed conveyors. By integrating belt protection, speed monitoring and emergency stop systems into your plant control architecture, operators gain better visibility and faster response to faults.
This helps protect high-value processing equipment, maintain plant throughput and reduce unplanned downtime across the site.
Belt Protection Integration with Conveyor Control Systems
Belt protection devices are most effective when they are fully integrated into your conveyor control system. In mining environments, a belt tear, misalignment or slip can quickly escalate into major downtime if faults are not detected early.
By integrating belt misalignment switches, rip detection, zero speed switches, pull wire emergency stops and blocked chute detection into your PLC and SCADA systems, you gain real-time visibility and immediate fault response. This enables automated shutdown sequences, clear diagnostics and faster maintenance intervention.
The result is reduced secondary damage, improved fault response times and better protection of critical conveyor assets.
Pull wire switches that self-clean
With high vibration levels and temperature changes common on mining conveyor belts, terminal connections have a tendency to loosen over time.
To counteract this, Smart Series pullkeys use spring loaded push-in wire terminals, which helps eliminate nuisance trips from poor connections.
Self-cleaning 'knife-action' switch contacts wipe themselves clean every single time they switch. It's a simple design. No maintenance is required.
Get timely detection of belt rips and tears
Conveyor belt rips are highly expensive to repair, even before you factor in the cost of lost production. Smart Series offers a range of solutions that work together to monitor your belt for rips and tears during operation.
The Smart Series Rip Detector is part of the overall conveyor fault detection system, and extends the lifetime of your belt. With an enclosure as well as individual contacts rated at IP66/IP67, it's built to last. You can set and forget - it'll withstand the dust, mud, and chemicals common on mining conveyors.
Essentials to keep you up and running
Keeping stock on hand of essential parts and accessories isn't just a good idea - it's a necessity.
The Smart Series essentials range includes pigtails, eye bolts, tensioning springs, wire rope grips, turnbuckles and cable wedge clamps. Steel pull wire rope is available galvanised or in stainless steel lengths cut to size. The black line pull monitoring cable is available to suit various monitoring systems.
All accessories and spares are built to last and designed for tough mining conditions.
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Get In TouchBulk Handling Applications
Bulk handling operations place continuous strain on conveyor systems. Heavy loads, abrasive materials, long conveyor runs and harsh site conditions increase the risk of belt drift, blockages and mechanical wear.
Our conveyor control and safety accessories are selected for demanding applications including coal handling, iron ore processing, quarry operations, ports and stockyards. Devices are built to withstand dust, vibration and moisture, and are suited to long-distance and distributed conveyor systems.
This helps maintain safe, reliable material movement while reducing unplanned stoppages across mining and heavy industry sites.
Monitoring and Controlled Shutdown
Small conveyor faults often become major failures when they are not monitored correctly. Belt drift, slip or blockages can cause structural damage, belt failure and extended downtime if left unchecked.
Integrated monitoring provides continuous feedback on belt alignment, speed and material flow. When faults are detected, control systems can trigger early warnings or initiate controlled shutdown sequences to protect equipment.
Early detection and managed shutdown helps reduce equipment damage, extend belt life and minimise maintenance costs, while improving overall system reliability.
CASE STUDY | 3 MIN READ
Real results: Smart Series transforms WA mining site
In this case study, you'll learn how a WA mine eliminated nuisance trips and improved conveyor safety with the Smart Series system.
Speak with our team about your conveyor safety needs to receive tailored recommendations based on your unique layout, risk points,
and compliance requirements.