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Emergency Cord Switch Type PRS Device identification No.: 91.054 033.001, /.101 and /.201 OPERATING INSTRUCTIONS

2 CE Sign and Conformity The device meets the requirements of the valid European and national regulations. Conformity has been proved and the corresponding declarations and documents are deposited at the manufacturer.

Table of Contents 3 Table of Contents 1 For Your Own Safety...5 1.1 Intended Application...5 1.2 Symbols...5 2 Transport, Packing, Storage, and Disposal...6 2.1 Transport and Packing...6 2.2 Storage...6 2.3 Disposal...6 3 Design and Function...7 3.1 Function of the Emergency Switch with all Types...7 4 Technical Data...10 4.1 General Technical Data All Types...10 4.2 Technical Data PRS 101 with Warning Lamp...11 4.3 Technical Data PRS 201 with DUPLINE Bus Terminal...11 4.4 Dimensions...12

4 Table of Contents 5 Mounting and Dismounting... 13 5.1 Scope of Supply... 13 5.2 Mounting... 13 5.2.1 Important Mounting Pointers... 13 5.2.2 KIEPE Accessories for the Mounting... 13 5.2.3 Mechanical Mounting... 14 5.2.4 Electrical Connection... 18 5.3 Dismounting... 21 6 Maintenance and Repair... 23 7 Ordering Devices and Accessories... 24 7.1 Ordering Accessories... 24 7.2 Ordering Devices... 25

1 For Your Own Safety 5 1 For Your Own Safety 1.1 Intended Application Emergency cord switches are installed in conveying systems for emergency cut-out of continuously running conveyors. The emergency cord switches comply with the high requirements of the trade associations, who obligatorily stipulate emergency devices in belt conveyors for personal security (UVV VBG 10). Applications other than specified and unauthorized modifications to the device or its components can lead to injury to persons and damage to the device for which the manufacturer is not liable. "Intended Application" means that any work performed with the device or on the device must be carried out in accordance with these operating instructions. Only qualified personnel that are familiar with the regulations for the prevention of accidents as well as the other standard safety rules, are allowed to work on the device. This will ensure that you protect yourself and prevent damage to the device! 1.2 Symbols Please pay particular attention to the text passages that are marked with the following symbols: Danger! Information that must be observed under all circumstances in order to prevent the user from being injured. Attention! Information that must be observed in order to prevent damage to the device. Helpful additional information.

6 2 Transport, Packing, Storage, and Disposal 2 Transport, Packing, Storage, and Disposal 2.1 Transport and Packing Choose a suitable packing in order to prevent damage to the device during transport or when sending devices or components to KIEPE ELEKTRIK for repair. Take great care that the device is protected against shocks and humidity. Thus, damage due to transport is prevented, for which the manufacturer is not liable. 2.3 Disposal If possible, reuse the packing material or dispose of it in an environment-friendly way. Send defective devices and components to KIEPE ELEKTRIK for correct recycling or disposal (company address see back cover). 2.2 Storage Avoid significant variations in temperature that may cause the formation of condensation water, as this might damage the device. The permissible storage temperature is between -25 C and +70 C. Attention! Keep the device clean and dry.

3 Design and Function 7 3 Design and Function Emergency cord switches are installed in conveying systems for emergency cut-out of continuously running conveyors. The devices are designed for long-term application under extreme environmental conditions. 3.1 Function of the Emergency Switch with all Types The release lever (3) of the emergency cord switch type PRS is actuated by means of a release wire (15) that is tightened along the conveying system (s. fig. 3-1). Danger! The release wire should be tightened along the conveyor system in such a way that its whole length can be seen. By operating the release lever (3) a switch cylinder jumps into the cut-out position, and the release lever (3) is disengaged. A subsequent switching process is excluded. When applying emergency cord switches equipped with a warning lamp (9), this lamp will indicate the emergency cut-out state. fastening point for swivel hook (20) reset lever (4) release lever (3) warning lamp (9) fastening point for swivel hook (20) tension spring (16) release wire (15) release wire (15) tension spring (16) max. 50 m max. 50 m Fig. 3-1: Function

8 3 Design and Function The length of the release wire (15) depends on the locations, however, it may not exceed a length of 50 meters on the concerned side. The tension springs (16) on both ends of the release wire (15) provide a selfmonitoring, i.e. if the release wire (15) breaks, the emergency cord switch is actuated by means of the opposite tension spring (16). A restart of the conveying system is only possible after unlocking the emergency cord switch by means of the reset lever (4). Danger! After activating and before resetting the emergency cord switch the system must be checked along the total length of the release wire, in order to determine the reason for activating of the emergency cord switch. 3.2 PRS 201 Emergency Cord Switch with DUPLINE Bus Terminal The emergency cord switch PRS type 201 differs from the types PRS 001 and PRS 101 in so far that a DU- PLINE field and installation bus node has been integrated in addition to the emergency cut-out function. The DUPLINE bus enables the direct locating of a triggered emergency cord switch type PRS 201 within the total system of a conveying system. Danger! The DUPLINE bus is a pure information bus and not a safety bus! Switching off a conveyer system must still take place by disconnecting the safety circuit! When the cut-out function is triggered, the contacts of the snap switches (7) S1 and S2 (terminals (8) X10 to X13; safety circuit) are opened to switch off the conveying system (s. fig. 3-2). When triggering the emergency cord switch type PRS 201, a further snap switch (7) S3 will be closed. The integrated bus terminal recognises this and transmits this information via the DUPLINE bus. Closing the snap switch (7) will also be indicated by the light diode (12).

3 Design and Function 9 By means of the manual coder (type GAP 1605) an address will be applied to each emergency cord switch PRS 201 via a programmable plug (13). In linkage with an external DUPLINE channel generator and an indicating device the address of the triggered emergency cord switch can be displayed. The channel generator continuously transmits the digital pulse code (the DUPLINE carrier signal) to the DU- PLINE network. The channel generator synchronises the system via the clock pulse and time control of all emergency cord switches (bus participants) connected to the system. By using the time multiplex process up to 128 independent signals can be transmitted via merely two wires of the DUPLINE bus towards any direction up to a distance of three kilometres. Simultaneously, the signal serves as an operating voltage source for the transmitting electronics of the emergency cord switch type PRS 201. snap switches (7) terminals (8) of the DUPLINE-bus S3 S2 S1 93.056052.001 F-Nr. programmable plug (13) DUP GND H1 X1 Prog. X13 X12 X11 X10 light diode (12) terminals (8) of the snap switches (7) Fig. 3-2: PRS 201 emergency cord switch with DUPLINE bus terminal

10 4 Technical Data 4 Technical Data 4.1 General Technical Data All Types Complying with the following regulations EN 60947-5-1, EN 60947-5-5, EN 0418, VDE 0110 Contamination class: 2 (internal), 4 (external), UV V VBG 10 Suitable for Controls and plants according to EN 60204 Design Plastics (casing: yellow (RAL 1004), release lever: red (RAL 3000), and reset lever: blue (similar to RAL 5010)) Fastening 2 screws M 6 Permissible ambient temperature 25 C + 70 C Switching system PRS 001 PRS 101 PRS 201 2 snap switches with forced port for emergency power off circuits (orange terminals) 1 snap switch as change-over switch for further signal circuits (grey terminals) no forced activation when resetting 1 additional snap switch as closer for the warning lamp 2 snap switches with forced port for emergency power off circuits (orange terminals), s. also fig. 3-2 Permissible insulation voltage U i AC 230 V Permissible operating voltage U e AC 230 V Conventional thermal current I th 6 A Switching capacity (1 switch element) AC-15 DC-13 230 V AC / 1.5 A 60 V DC / 0.5 A Protection class IP 65 according to DIN VDE 470, part 1 (EN 60529) Mechanical durability 10,000 switching operations

4 Technical Data 11 Supply line inlet 3 threads (M 25 x 1.5) for fitting nut Cross section for connection max. 2.5 mm 2 4.2 Technical Data PRS 101 with Warning Lamp Permissible operating voltage of the warning lamp AC 230 V (at the terminals X14 and X15; s. also fig. 5-9) 4.3 Technical Data PRS 201 with DUPLINE Bus Terminal Operating voltage Nominal current consumption when light diode is switched off when light diode is switched on Signal input drive open circuit voltage via DUPLINE bus typ. 150 µa typ. 1.2 ma 1 additional snap switch as closer (S3); s. also fig. 3-2 5.3 to 7.6 VDC

12 4 Technical Data 4.4 Dimensions 15 15 30 125 112.5 54 67.5 95 175 79.5 6 162 Fig. 4-1: Dimensions PRS

5 Mounting and Dismounting 13 5 Mounting and Dismounting 5.1 Scope of Supply The emergency cord switches are supplied ready for operation without any accessories (s. section 7.1). 5.2 Mounting 5.2.1 Important Mounting Pointers By all means the pointers given below are to be considered during the mounting to ensure correct operation of the emergency cord switches. In case of deviating conditions you have to consult KIEPE ELEKTRIK (see back cover for company address). Only use KIEPE accessories for the mounting. The operating temperature range of the emergency cord switches and the activating arrangement is between 25 C and + 70 C. Mounting has to be carried out at an ambient temperature of about + 15 C. The emergency cord switch has to be mounted concentrically between the fastening points. Deviation of up to maximum 3 % of the distance between the emergency cord switch and the fastening point is permitted. It is not allowed that the distance between the fastening point exceeds 100 m. The fastening points for the swivel hooks (20) have to be mechanically stable structural parts. It is not allowed that the distance between the eyebolts (19) exceeds 2.5 m (s. fig. 5-1). 5.2.2 KIEPE Accessories for the Mounting The emergency cord switches must be installed to the belt conveyor structure with the KIEPE accessories. In order to mount the emergency cord switch, the following accessories are required (s. fig. 5-3): two screws M 6 (5) for fastening the emergency cord switch (s. fig. 5-2) fitting nut (10), M 25 x 1.5 (s. fig. 5-7) release wire (15) made of flexible steel wire (red), plastic-covered, 3mm tension springs (16), 170 x 20 mm rope tension jacks (17) egg-shaped brackets (18) eyebolts (19) M 12 x 60 swivel hooks (20) M 10

14 5 Mounting and Dismounting 5.2.3 Mechanical Mounting Danger! Before mounting, disconnect the belt conveyor system from the voltage supply, and prevent it from being switched on again. Danger! The release wire should be tightened along the conveyor system in such a way that its whole length can be seen. Attention! The emergency cord switches may only be integrated into control circuits. Mounting the emergency cord switch onto the conveyor belt 1. Before mounting, disconnect the conveyor belt system from the voltage supply, and prevent it from being switched on again. egg-shaped brackets (18) eyebolts (19) distance: max. 2.5 m reset lever (4) release lever (3) egg-shaped brackets (18) eyebolts (19) distance: max. 2.5 m tension spring (16) release release wire (15) tension spring (16) wire (15) rope tension rope tension rope loop (21) jack (17) jack (17) rope loop (21) fastening point for swivel hook (20) fastening point for swivel hook (20) max. 50 m (± 3 %) max. 50 m (± 3 %) Fig. 5-1: Fastening to the belt conveyor structure

5 Mounting and Dismounting 15 2. Fasten the emergency cord switch concentrically between the fastening points to the conveyor belt construction (s. fig. 5-1). Here the release lever (3) has to show towards the belt. Fasten the emergency cord switch with two screws M 6 (5) through the sockets (11) (s. fig. 5-2). 3. The mounting points for the swivel hooks (20) have to be mechanically stable structural parts, from which the swivel hooks (20) cannot tear out when the release wire (15) is actuated. Attach the swivel hooks (20) to the fastening points (s. fig. 5-1). 4. Hang the tension spring (16) into the swivel hook (20) (s. fig. 5-3). 5. Stick one end of the release wire (15) through the eye of the tension spring (16). Pull the release wire (15) approximately 450 to 500 mm through the eye so that you can form a rope loop (21) from this end as a conclusion of the mounting (s. fig. 5-3). The rope loops (21) limit the actuator travel of the release wire (15) and prevent overstretching of the tension springs (16). Maximum stretch of a tension spring (16) is about 400 mm. release lever (3) Side face of belt socket (11) for screw M 6 (5) swivel hooks (20) tension spring (16) release wire (15) max. 400 + 170 mm egg-shaped brackets (18) socket (11) for screw M 6 (5) reset lever (4) plan 450 to 500mm release wire (15) for the rope loop (21) Fig. 5-2: Fastening the emergency cord switch Fig. 5-3: Fastening the release wire to the tension spring

16 5 Mounting and Dismounting 6. Fasten the release wire (15) to the tension spring (16) with an egg-shaped bracket (18) (s. fig. 5-3). 7. Attach the eyebolts (19) to the conveyor belt construction for the guidance of the release wire (15) (s. fig. 5-4). Distance between the eyebolts (19): max. 2.5 m 8. Pull the release wire (15) through the eyebolts (19) (s. fig. 5-4). Adjusting the spring load Due to the symmetrical arrangement, the neutral position of the release lever (3) is not affected by variations in temperature. Stretching and retraction of the release wire (15) caused by variations in temperature is equalized by the tension springs (16) (s. fig. 5-4). Attention! The emergency cord switch must be operated by pulling the release wire from the tension spring on the opposite side. egg-shaped brackets (18) eyebolts (19) distance: max. 2.5 m reset lever (4) release lever (3) egg-shaped brackets (18) eyebolts (19) distance: max. 2.5 m tension spring (16) release release wire (15) tension spring (16) wire (15) rope tension rope tension rope loop (21) jack (17) jack (17) rope loop (21) fastening point for swivel hook (20) fastening point for swivel hook (20) max. 50 m (± 3 %) max. 50 m (± 3 %) Fig. 5-4: Fastening to the belt conveyor structure and adjusting the spring load

5 Mounting and Dismounting 17 9. Completely release the rope tension jack (17) (s. fig. 5-5). 10. Pull one end of the release wire (15) through the eye of the rope tension jack (17), and hook the rope tension jack (17) into the release lever (3) (s. fig. 5-5). Attention! Both ends of the release wire must have a length of max. 50 meters. 11. Tighten the release wire (15) so that the tension spring (16) is stretched by 35 mm (s. fig. 5-4). release lever (3) reset lever (4) Fig. 5-5: rope tension jack (17) Fastening the rope tension jack release wire (15) egg-shaped bracket (18) 12. Fasten this end of the release wire (15) by means of an egg-shaped bracket (18) (s. fig. 5-5). 13. Unhook the rope tension jack (17). Unlock the emergency cord switch by means of the reset lever (4) (s. fig. 5-4). 14. Repeat steps 5. to 12. to mount the release wire (15) on the opposite side of the emergency cord switch (s. fig. 5-4). 15. Hook in both rope tension jacks (17), and actuate the release lever (3) of the emergency cord switch (s. fig. 5-4). The release lever (3) can be moved. 16. Align the release lever (3) into a neutral position by means of the rope tension jacks (17) and set the lengths of the tensioned tension springs (16) to about 210 mm (s. fig. 5-4). Attention! By all means form the rope loops on both tension springs. The rope loops are to limit the actuator travel of the release wire and to prevent overstretching of the tension springs (s. fig. 5-6). Maximum stretch of a tension spring is about 400 mm.

18 5 Mounting and Dismounting swivel hook (20) 50 mm tension spring (16) release wire (15) egg-shaped bracket (18) rope loop (21) 17. Form the rope loops (21) on both tension springs (16) in the following way: a. Place the part of the release wire (15) provided for the rope loop (21) along the tension spring (16) (s. fig. 5-6, upper part). b. Form a fastening loop with the end of the rope loop (21), which ends approximately 50 mm from the end of the tension spring (4) (s. fig. 5-6, upper part). c. Fasten the rope loop (21) to the swivel hook (20) with an egg-shaped bracket (18) (s. fig. 5-6, lower part). swivel hook (20) tension spring (16) release wire (15) egg-shaped brackets (18) rope loop (21) 5.2.4 Electrical Connection 1. Open the hinged cover (2) of the emergency cord switch by loosening the two screws (6) (s. fig. 5-7). 2. Screw one fitting nut (10) into one of the three threads (M 25 x 1.5) of the emergency cord switch (s. fig. 5-7). 3. Pull the connection cable through the fitting nut (10). Fig. 5-6: Forming rope loops

5 Mounting and Dismounting 19 Connecting types PRS 001 and PRS 101 1. Connect the cable to the terminals (8) according to the wiring diagram: PRS 001 without warning lamp (9): s. fig. 5-8 PRS 101 with warning lamp (9): s. fig. 5-9 2. Close the hinged cover (2) of the emergency cord switch, and refasten the two screws (6) (s. fig. 5-7). PRS 001 without warning lamp 10 11 12 13 14 15 16 17 18 19 23 24 21 22 Fat strokes: Connections for the PRS 001. hinged cover (2) screw M 6 (5) Auxiliary signal circuit: terminals (8) X16 X18, X23, X24 (grey) screws (6) thread (M 25 x 1.5) for fitting nut (10) screw M 6 (5) warning lamp (9) Fig. 5-7: Connection of the emergency cord switch Emergency power off circuit: terminals (8) X10 X13 (orange) Fig. 5-8: Assignment of the terminals of the PRS 001

20 5 Mounting and Dismounting PRS 101 with warning lamp PRS 201 with DUPLINE bus Prog. 10 11 12 13 14 15 16 17 18 19 23 24 Fine strokes: Additional connections for the PRS 101. 21 22 Auxiliary signal circuit: terminals (8) X16 X19, X21 X24 (grey) Warning lamp (AC 230 V): terminals (8) X14, X15 (grey) Emergency power off circuit: terminals (8) X10 X13 (orange) 10 11 12 13 GND DUP Emergency power off circuit: terminals (8) X10, X11: S1 X12, X13: S2 programmable plug (13): Prog. Prog. X1 H1 X13 X12 X11 X10 DUP GND 93.056052.001 F-Nr. DUPLINE bus (grey) terminals (8) DUP: Plus GND: Minus S3 S2 S1 Fig. 5-9: Assignment of the terminals of the PRS 101 with warning lamp Fig. 5-10: Assignment of the terminals of the PRS 201 with DUPLINE bus

5 Mounting and Dismounting 21 Type PRS 201 1. Connect the cable to the terminals (8) according to the wiring diagram (s. fig. 5-10). Danger! The DUPLINE bus is a pure information bus and not a safety bus! Switching off a conveyer system must still take place by disconnecting the safety circuit! Therefore, always connect the snap switches (7) S1 and S2 (terminals (8) X10 to X13) too. An address must be applied to each emergency cord switch type PRS 201 by means of the manual coder (Typ GAP 1605). 2. Program the emergency cord switch type PRS 201 on the required address on your system (see also section 3.2 PRS 201 Emergency Cord Switch with DUPLINE Bus Terminal ). 3. Close the hinged cover (2) of the emergency cord switch, and refasten the two screws (6) (s. fig. 5-7). 5.3 Dismounting Danger! Before starting the mounting, disconnect the belt conveyor system from the voltage supply and prevent it from being switched on again. 1. Before dismounting, disconnect the conveyer belt system from the voltage supply and prevent it from being switched on again. 2. Open the hinged cover (2) by loosening the two screws (6) (s. fig. 5-7). 3. Separate the electrical connections. 4. Loosen the two screws M 6 (5), and remove the device (s. fig. 5-7).

22 5 Mounting and Dismounting

6 Maintenance and Repair 23 6 Maintenance and Repair The emergency cord switches type PRS are maintenance-free. Defective devices can be sent to KIEPE ELEKTRIK for disposal (company address see back cover).

24 7 Ordering Devices and Accessories 7 Ordering Devices and Accessories 7.1 Ordering Accessories With every purchase order, please quote (company address see back cover): 1. Order text e. g. eyebolts M 12 x 60 2. Order number e. g. 94.045 727.001 release wire (15) rope tension jack (17) egg-shaped bracket (18) Fig. 7-1: Accessories egg-shaped brackets (18) egg-shaped brackets (18) eyebolts (19) eyebolts (19) tension spring (16) rope tension rope tension jack (17) jack (17) tension spring (16) release wire (15) release wire (15) swivel hook (20) swivel hook (20) Fig. 7-2: Accessories

7 Ordering Devices and Accessories 25 Item Order text Order number 15 Release wire red, flexible steel wire, plastic covered (available in rolls of 50, 100 or 500 m) 3mm 5mm 16 Tension spring of V2A 170 mm x 20 mm 230 mm x 20 mm 17 Rope tension jack (metal, 1 hook, 1 eye) 94.045 731.001 94.045 731.002 94.000 026.681 94.000 026.683 215.22.80.02.01 18 Egg-shaped clamp for release wire 3mm for release wire 5mm 94.047 869.001 94.047 869.002 19 Eyebolt M 12 x 60 M 12 x 200 94.045 727.001 94.045 727.002 20 Swivel hook M 10 94.045 728.001 7.2 Ordering Devices With every purchase order please quote (company address see back cover): 1. Type designation of the emergency cord switch (s. rating plate on the casing lid): e. g. PRS 001 2. Device identification number (s. rating plate on the casing lid): e. g. 91.054 033.001 Emergency cord switch type Device identification number PRS 001 (without warning lamp) 91.054 033.001 PRS 101 (with warning lamp) 91.054 033.101 PRS 201 (with DUPLINE bus, 91.054 033.201 without warning lamp)

26 7 Ordering Devices and Accessories

KIEPE ELEKTRIK GmbH & Co. KG Bublitzer Straße 28 D-40599 Düsseldorf Tel.: +49 (0) 211 74 97 0 Fax: +49 (0) 211 74 97 300 Internet: http://www.kiepe-elektrik.com E-Mail: Info@Kiepe-Elektrik.com Doc. Ident. No.: 94.053 962.192 Edition: 06.12.2000 Modification Index: E Copyright reserved Subject to changes