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OPERATING INSTRUCTIONS
Legal notice Operating Instructions (Translation of original) Document no.: 94.064 131.191 Pull-rope emergency stop switch, Type PRS Equipment item no.: various Date of issue: 21.11.2008 Update status: Index 0
CE conformity certificate The device complies with the relevant European and national regulations. CE conformity has been certified; the relevant records are in the hands of the manufacturer.
Protective note (as per DIN ISO 16016:2002-5) Forwarding and duplicating this document, as well as using or revealing its contents are prohibited without written approval. Noncompliance is subject to compensatory damages. All rights reserved with regard to patent claims or submission of design or utility patent.
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Table of contents
1
1.1 1.2
2
2.1 2.2 2.3
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3.1
Description........................................................................................................................9
How the emergency stop function works for all types...................................................................................9
4
4.1 4.3
5
5.1 5.2 5.2.1 5.2.2 5.2.3
Operating Instructions
4 5.2.4 5.2.4.1 5.2.4.2 5.3 Electrical connection .................................................................................................................................. 21 Preparation work ........................................................................................................................................ 21 Connecting types PRS 001 and PRS 101.................................................................................................. 22 Dismounting ............................................................................................................................................... 23
6 7
7.1 7.2
Maintenance and repair.................................................................................................. 25 Ordering devices, replacement parts and accessories .................................................. 26
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1
1.1
Pull-rope emergency stop switches are used in conveyor systems for emergency stop of continuous conveyors. The pull-rope emergency stop switches meet the very high requirements of industry safety regulations, which stipulate that emergency stop equipment on conveyor systems must be used to ensure worker's safety (VBG 10/BGI 710). The device is intended for use in stationary installations and in vehicles. The documentation at hand is to be considered part of the product and must be retained and be available to the respective owner/user for the entire service life of the product. The documentation must be passed on to each subsequent owner of the product. The manufacturer is not liable for personal injury and property damage arising from non-intended use of the device or unauthorized modifications to the device and its components. Make sure that the intended use is not impaired in any way even after unexpected outside influence on the device. Intended use refers specifically to the operation of the device in accordance with these operating instructions. Work on this device may only be carried out by qualified personnel who are familiar with accident preOperating Instructions
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1.2
Design of warnings
Risks are classified in accordance with ISO 3864-2 and ANSI Z535.6 using the keywords Danger, Warning, and Caution in the case of bodily injury, Beware in the case of property damage, and Note to convey general information. In this documentation, the Risks and Notes are classified and presented as follows:
Caution!
indicates a possibly dangerous situation. Failure to avoid this dangerous situation can result in light or minor injuries.
Beware!
Danger!
indicates the immediate threat of danger. Not avoiding this danger will result in death or extremely serious injury (crippling).
Note! Note indicates advice on use and other especially helpful information.
Warning!
indicates a possibly dangerous situation. Not avoiding this dangerous situation could result in death or extremely serious injury (crippling).
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indicates a possibly harmful situation. If this harmful situation is not avoided, the product or something in its vicinity could be damaged.
Icons The following icons are used to more clearly define the sources of danger. The icons can appear in reference to any level of danger.
Icon Type of danger Dangers of all types, except those that are labeled with the following icon Injuries caused by dangerous voltages and currents. Damage caused by electrostatic discharges (ESD protection)
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Operating Instructions
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2.1
Select suitable packaging when sending the device or components of the device to Vossloh Kiepe GmbH, e.g. for repairs. In particular, ensure that the components are kept clean and protected from shock and moisture. This prevents damage to the components that may occur during transport, for which the manufacturer accepts no liability.
2.2
Storage
Avoid major temperature fluctuations, as these can lead to condensation that can cause damage to the device and its components. The approved storage temperature ranges from -25C to +70C.
2.3
Disposal
Only materials that are not considered hazardous according to current engineering practice are used for Vossloh Kiepe GmbH products. Furthermore, we develop products that can be recycled after intended use. In our selection of raw materials and components, we favor reusable materials. This choice of materials used does not compromise product safety in any way.
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Dirt or water getting into the device and exposure to weather (e.g. buildup of condensation in the device, sunlight) damage the device and lead to faster deterioration. Protect the device by storing it in a clean, dry place under stable ambient conditions. If possible, store the device in its original packaging.
3 Description
Description
Pull-rope emergency stop switches are used in conveyor systems for emergency stop of continuous conveyors. The devices are designed for long service lives under severe environmental conditions.
Warning!
The tear rope should be stretched along the conveyor system so that it is visible along its entire length. Actuating the trigger lever (3) causes the switch cylinder to move to the Off position, so that the trigger lever (3) is decoupled. At this point, no further switching operation is possible. When inserting a pull-rope emergency stop
3.1
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The trigger lever (3) for the PRS pull-rope emergency stop switch is actuated via a tear rope (15) which is stretched along the conveyor system (see fig. 3-1).
Attachment point for anchor hooks (20)
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3 Description
switch with signal lamp (9), it displays the emergency stop status. The tear rope length (15) may vary according to local conditions; however, it must not exceed 50 m on either side. The tension springs (16) at both ends of the tear rope (15) ensure that the tear rope is foolproof, i.e. if the tear rope (15) is broken, the pull-rope emergency stop switch is actuated by the tension spring (16).
Warning!
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After actuating and before resetting the pull-rope emergency stop switch, the installation must be checked along the entire length of the tear rope (15) in order to establish why the pull-rope emergency stop switch was actuated. The conveyor system can only be restarted if the reset lever (4) has been used to unlock the pull-rope emergency stop switch at the installation site.
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4 Technical data
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4
4.1
Technical data
General technical data
EN 60947-5-1, EN 60947-5-5, EN 0418, VDE 0110 degree of pollution: 2 (inside), 4 (outside), VBG 10/BGI 710 Controls and installations according to EN 60204 Plastic (casing: yellow (RAL 1004), trigger lever: red (RAL 3000) and reset lever: blue (similar to RAL 5010) 2 screws M 6 -25C +70C 2 snap-acting switches with forced opening for emergency stop circuits (orange terminals) 1 snap-acting switch as normally open contact for the signal lamp AC 230 V AC 230 V 6A AC 230 V, 1.5 A DC 60 V / 0.5 A
In compliance with the following standards and regulations Suitable for Version Mounting
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Permissible ambient temperature Switching system PRS 001 PRS 101 Rated insulation voltage Ui Rated operating voltage Ue Conventional thermal current Ith Breaking capacity AC -15 DC-13
Protection standard IP 67 according to DIN VDE 470, part 1 (EN 60529) Mechanical service life
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4 Technical data
Conductor infeed
Threaded hole for 3 x M 25 x 1.5 1x screwed cable gland M 25 x 1.5; sealing area 9 mm to 17 mm 2 x dummy plug M25 x 1.5 Max. 2.5 mm2
4.2
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4 Technical data
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4.3
Dimensions
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95
175 6
54
162
Abb. 4-1: Dimensions
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80,5
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5
5.1
The pull-rope emergency stop switches are delivered ready to operate. The screws for mechanical fastening are not included in the scope of delivery. One cable gland (10) and two dummy plugs (11) are included in the scope of delivery (see fig. 5-1).
Use only screwed cable glands and dummy plugs recommended by the manufacturer and supplied with the device.
5.2.1
Thread (M 25 x 1.5) for 1 cable gland (10) and 2 dummy plugs (11) Abb. 5-1: Scope of delivery
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Observe the following notes while mounting to ensure that the pull-rope emergency stop switches are operated properly. If conditions should deviate from those indicated, consult Vossloh Kiepe GmbH (see legal notice for company address). When mounting, only use KIEPE accessories. This applies in particular to the cable gland (10) and the dummy plug (11). Mount at an ambient temperature of approx + 15C. The pull-rope emergency stop switch must be mounted in the middle between the attachment points. Deviation of up to 3 % of the distance between the
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Beware!
The device must only be operated when all three holes are closed with the supplied cable gland (10) and both dummy plugs (11). Only use the supplied cable gland (10) and dummy plugs (11), otherwise the seal can no longer be guaranteed.
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pull-rope emergency stop switch and the attachment point is permitted. The distance between the attachment points may not exceed 100 m. The attachment points for the anchor hooks (20) must be constructed from sturdy mechanical components. The distance between the eyebolts (19) must not exceed 2.5 m (see figure 5-2, page 16).
5.2.2 KIEPE mounting accessories Pull-rope emergency stop switches must be fastened into place on the conveyor structure using KIEPE accessories. You will require the following accessories to mount the pull-rope emergency stop switch (see figure 5-4, page 17)): two M 6 screws (5) for securing the pull-rope emergency stop switch into place (see figure 5-3, page 17) Cable gland (10), M 25 x 1.5 (see figure 5-8, page 22) A tear rope (15) made of red, flexible steel wire, plastic coated, 3 mm Tension springs (16), 170 x 20 mm Turnbuckles (17)
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16 5.2.3
Warning!
Work on the device may be performed only by a qualified electrical technician. Prior to working, switch off the power supply to the system. Ensure that the system cannot be accidentally switched on. Mask any neighboring components that may be live to prevent contact.
The tear rope should be stretched along the conveyor system so that it is visible along its entire length.
Beware!
The emergency cord switches are to be used in control circuits only. 1. Prior to working, switch off the power supply to the system. Ensure that the conveyor system cannot be
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Tension spring Tear rope (15) (16) Rope loop (21) Attachment point for rope loop (21) max. 50 m ( 3 %) Abb. 5-2: Mounting on the conveyor structure
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Turnbuckle (17)
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accidentally switched on. Mask any neighboring components that may be live to prevent contact. 2. Secure the pull-rope emergency stop switch in the middle between the attachment points on the conveyor structure (see figures 4-1 and 5-2). In doing so, the actuating lever (3) must point towards the belt. Secure the pull-rope emergency stop switch with two screws M 6 (5) through the sockets (13) (see fig. 5-3).
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Beware!
The attachment points for the anchor hooks (20) must be constructed from sturdy mechanical components, which the anchor hooks (20) cannot break away from when actuating the tear rope (15). 3. Place the anchor hooks (20) on the attachment points (see fig. 5-2). 4. Hook the tension springs (16) onto the anchor hook (20) (see fig. 5-4).
Tension spring (16)
Belt side Trigger lever (3) Socket (13) for screws M 6 (5) Anchor hooks (20)
max. 400 mm + 170 mm Egg-shaped clamp (18) Allow 450 to 500 mm of the tear rope (15) for the rope loop (21) Abb. 5-4: Attaching the tear rope onto the tension spring
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5. Thread the end of the tear rope (15) through the eye of the tension spring (16). Pull the tear rope (15) about 450 to 500 mm through the eye, so that it can form a rope loop (21) at that end to complete the mounting procedure (see fig. 5-4). Note The rope loops (21) are designed to limit the actuating travel of the tear rope (15) when actuated and prevents the tension springs (16) from overextending. The maximum extension of a tension spring (16) is approximately 400 mm.
Egg-shaped clamp (18) Eyebolts (19) Distance: max. 2.5 m Tension spring Tear rope (15) (16) Rope loop (21) Attachment point for rope loop (21) max. 50 m ( 3 %)
6. Secure the tear rope (15) on the tension spring (16) using an egg-shaped clamp (18) (see fig. 5-4).Fix the eyebolts (19) to the conveyor structure to guide the tear rope (15) (see fig. 5-5). Distance between eyebolts (19): max. 2.5 m 7. Put the tear rope (15) through the eyebolts (19) (see fig. 5-5). Setting the spring force Centering the trigger lever (3) makes it resistant to temperature changes. The tension springs (16) compensate for any extension or contraction of the tear rope (15) caused by temperature changes (see fig. 5-5).
Trigger lever (3) Egg-shaped clamp (18) Eyebolts (19) Distance: max. 2.5 m Tension spring (16) Rope loop (21)
Turnbuckle (17)
Abb. 5-5: Mounting on the conveyor structure and setting the spring force
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Beware!
If the tear rope tears on one side, the pull-rope emergency stop switch must be actuated by the tension spring on the other side. 8. Release the tension of the turnbuckle (17) completely (see fig. 5-6). 9. Put one end of the tear rope (15) through the eye of the turnbuckle (17) and hook the turnbuckle (17) into the trigger lever (3) (see fig. 5-6).
14. Now hook both turnbuckles (17) into place and operate the actuating lever (3) of the pull-rope emergency stop switch (see fig. 5-5). The trigger lever (3) can now be moved. 15. Place the actuating lever (3) in the middle using the turnbuckles (17) and adjust the tightened tension springs (16) so that they are 210 mm long (see fig. 5-5).
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Beware!
Trigger lever (3) Turnbuckle (17) Tear rope (15)
The tear rope (15) may be maximum 50 meters long in each direction. 10. Tighten the tear rope (15) so that the tension spring (16) is extended by 35 mm (see fig. 5-5). 11. Attach this end of the tear rope (15) using an eggshaped clamp (18) (see fig. 5-6). 12. Remove the turnbuckle (17) again. Unlock the pullrope emergency stop switch by using the reset lever (4) (see fig. 5-5). 13. Repeat steps 5 - 12 for installing the tear rope (15) on the other side of the pull-rope emergency stop switch (see fig. 5-5).
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Beware!
50 mm
Ensure that rope loops are formed on both tension springs. The rope loops are designed to limit the actuating travel of the tear rope and prevent the tension springs from overextending (see figure 5-7, page 20). The maximum extension of a tension spring is approximately 400 mm. 16. Form the rope loops (21) on both tension springs (16) as follows: a. place the section of tear rope (15) provided for the rope loop (21) along the tension spring (16) (See figure 5-7, above). b. Use the end of the rope loop (21) to make a fastening loop that stops about 50 mm from the end of the tension spring (16) (See figure 5-7, above). c. Use an egg-shaped clamp (18) to attach the rope loop (21) to the anchor hook (20) (See figure 5-7, below).
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5.2.4
5.2.4.1 Preparation work 1. Prior to working, switch off the power supply to the system. Ensure that the conveyor system cannot be accidentally switched on. Mask any neighboring components that may be live to prevent contact. 2. Open the cover (2) of the belt pull-rope emergency stop switch by unscrewing the two screws (6) (see fig. 5-8).
Work on the device may be performed only by a qualified electrical technician. Prior to working, switch off the power supply to the system. Ensure that the system cannot be accidentally switched on. Mask any neighboring components that may be live to prevent contact.
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Beware!
Danger!
The penetration of dust and moisture into the pull-rope emergency stop switch must be prevented at all costs. As required, remove any dust which has entered the unit. Seal the cover immediately after making the electrical connection.
The device must only be operated when all three holes are closed with the supplied cable gland (10) and both dummy plugs (11). Only use the supplied cable gland (10) and dummy plugs (11), otherwise the seal can no longer be guaranteed. 3. Turn the cable gland (10) into one of the threaded holes M 25 x 1.5 of the pull-rope emergency stop switch. 4. Close the other two holes with the dummy plugs (11) 5. Pull the connection cable through the cable gland (10).
Danger!
Only use connection cables with a diameter of between 11 mm and 16 mm. The permissible conductor crosssections can be found in Chapter 4: Technical data", page 11.
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5.2.4.2 Connecting types PRS 001 and PRS 101 1. Connect the connection cable to the connection terminals (8) according to the connection diagram: PRS 001 without signal lamp (9): See figure 5-9 PRS 101 with signal lamp (9): See figure 5-10 2. Close the cover (2) of the belt pull-rope emergency stop switch, and tighten both screws again (6) (see fig. 5-8).
10 11 12 13 14 15 16 17 18 19 21 22
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Thick lines: Circuit for the PRS 001. Cover (2) Screw M 6 (5)
Thread (M 25 x 1.5) for 1 cable gland (10) and 2 dummy plugs (11)
Emergency stop circuit: connection terminal (8) X10 X13 (orange) Abb. 5-9: Assignment of the connection terminals of the PRS 001
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5.3
Dismounting
Danger of fatal electric shock
10 11 12 13 14 15 16 17 18 19 21 22
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Work on the device may be performed only by a qualified electrical technician. Prior to working, switch off the power supply to the system. Ensure that the system cannot be accidentally switched on. Mask any neighboring components that may be live to prevent contact. Danger of fatal electric shock
Auxiliary signal circuit: connection terminal (8) X16 X19, X21 X22 (gray) Signal lamp (AC 230 V): connection terminals X14, X15 (gray) Connection terminal (8) X10 X13 (orange)
Prior to dismounting, ensure that the conveyor system is de-energized. Ensure that the unit cannot be accidentally switched on. Danger of fatal electric shock Open the pull-rope emergency stop switch only after it has been de-energized. 1. Prior to working, switch off the power supply to the system. Ensure that the conveyor system cannot be accidentally switched on. Mask any neighboring components that may be live to prevent contact.
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2. Open the cover (2) of the belt pull-rope emergency stop switch by unscrewing the two screws (6) (see fig. 5-11). 3. Unscrew the cable gland (10). 4. Disconnect all electrical connections and pull the cables out of the cable gland (10) (see figure 5-9, page 22). 5. Unscrew both screws M 6 (5), and remove the device (see fig. 5-11).
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Cover (2)
Screw M 6 (5)
Thread (M 25 x 1.5) for 1 cable gland (10) and 2 dummy plugs (11)
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1. Check the pull-rope emergency stop switch and the tear rope system at regular intervals (approximately every three months) to ensure that they are in proper condition and function smoothly.
Danger!
A damaged pull-rope emergency stop switch or damaged components (e.g. cable glands, gaskets) are not to be used. Damaged pull-rope emergency stop switches must always be replaced
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Egg-shaped clamp (18) Eyebolts (19) Distance: max. 2.5 m Tension spring (16) Rope loop (21) Attachment point for rope loop (21) max. 50 m ( 3 %)
Egg-shaped clamp (18) Eyebolts (19) Distance: max. 2.5 m Tension spring (16) Rope loop (21)
Turnbuckle (17)
Abb. 6-1: Mounting on the conveyor structure and setting the spring force
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7
7.1
Type of pull-rope emergency stop Product number switch PRS 001 (without signal lamp) PRS 101 (with signal lamp) 91.054 033.001 91.054 033.101
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Please provide the following data with every order (see legal notice for company address): 1. Pull-rope emergency stop switch type (see rating plate on casing cover): e.g. PRS 001 2. Product number (see rating plate on casing cover): e.g. 91.054 033.001
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7.2
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Please provide the following data with every order (see legal notice for company address): 1. Pull-rope emergency stop switch type (see rating plate on casing cover): e.g. PRS 001 2. Product number (see rating plate on casing cover): e.g. 91.054 033.001 3. Order information and order number (see table): e.g. eye bolts M 12 x 60, 94.045 727.001
Egg-shaped clamp (18) Eyebolts (19) Egg-shaped clamp (18) Eyebolts (19)
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Abb. 7-2: Accessories Item 15 Order information Tear rope red, flexible steel wire, plastic coated 3 mm Roll 50 m Roll 100 m Roll 500 m Tension spring V2A 170 mm x 20 mm Turnbuckle (metal, 1 hook, 1 eye) Egg-shaped clamp for tear rope of 3 mm Order number 94.045 731.001 94.045 731.011 94.045 731.021 94.045 731.031 94.000 026.681 215.22.80.02.01 94.047 869.001
16 17 18
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