GESTRA VZ 10 User manual

Rail Hook
VZ 10
VZ 20
Original Installation Instructions
819758-00

Contents
Foreword ............................................................................................................................................3
Availability.............................................................................................................................................3
Formatting features in the document ......................................................................................................3
Safety..................................................................................................................................................4
Use for the intended purpose .................................................................................................................4
Basic safety notes .................................................................................................................................4
Information on property damage or malfunctions .....................................................................................5
Qualification of personnel.......................................................................................................................5
Protective gear......................................................................................................................................5
Typographic features of warning notes....................................................................................................5
Formatting features for warnings of property damage ..............................................................................5
Description .........................................................................................................................................5
Scope of supply.....................................................................................................................................5
Equipment specification .........................................................................................................................6
Name plate ...........................................................................................................................................8
Task and function..................................................................................................................................8
Application of European Directives..........................................................................................................9
Storing and transporting the equipment...........................................................................................9
Storing the equipment ...........................................................................................................................9
Transporting the equipment ...................................................................................................................9
Using the equipment ........................................................................................................................10
Preparing for installation ......................................................................................................................10
Adjusting the length of the rail hook......................................................................................................11
Tensioning the nose ............................................................................................................................11
Installing the rail hook..........................................................................................................................12
Removing the rail hook ........................................................................................................................12
Troubleshooting ...............................................................................................................................12
After operation .................................................................................................................................12
Removing external dirt deposits............................................................................................................12
Maintaining the equipment...................................................................................................................12
Servicing the equipment and installing spare parts ................................................................................12
Putting the equipment out of operation ..........................................................................................13
Returning the valve..............................................................................................................................13
Disposing of the equipment..................................................................................................................13
Technical data..................................................................................................................................14
Dimensions and weights ......................................................................................................................14
Operating data ....................................................................................................................................15
Pressure & temperature ratings............................................................................................................15
Manufacturer's declaration .............................................................................................................15

3
Foreword
This Installation & Operating Manual will help
ensure proper, safe and cost-efficient use of the
following equipment models:
Pneumatic rail hook VZ 10
Mechanical rail hook VZ 20
These types will be called equipment in this
document.
This installation & operating manual is intended for
anyone commissioning, using, operating, servicing,
cleaning or disposing of this equipment and, in
particular, for professional after-sales service
technicians, qualified personnel and authorised and
trained staff.
All of these persons must read and understand the
content of this installation & operating manual.
Following the instructions given in this installation &
operating manual helps avoiding danger and
increases the reliability and service life of the
equipment. Please note that in addition to the
instructions given in this installation & operating
manual you must also observe all locally applicable
rules and regulations concerning the prevention of
accidents as well as approved safety guidelines for
good professional practice.
Availability
Always keep this Installation & Operating Manual
together with the equipment. Make sure that the
Installation & Operating Manual is available to the
operator.
The Installation & Operating Manual is part of the
equipment package. Hand over this Installation &
Operating Manual if you sell or pass on the
equipment to a third party.
You can find further information, instructions and
details of equipment accessories in the respective
manufacturer documentation.
These documents are regarded as belonging to this
installation & operating manual. Keep these
documents together with this installation &
operating manual. Hand over this installation &
operating manual if you sell or pass on the
equipment to a third party.
Formatting features in the
document
Certain text elements of this installation & operating
manual feature a specific typographic design. You
can easily distinguish the following text elements:
Standard text
Cross-reference
Listing
Sub-items in listings
Steps for action.
Here you will find additional useful
information and tips serving to assist you
in using the equipment to its fullest
potential.

4
Safety
Use for the intended purpose
The rail hooks below are mounted under tank cars
on quick-release mechanisms:
Pneumatic rail hook VZ 10
Mechanical rail hook VZ 20
This equipment is used for keeping GESTRA bottom
valves on tank cars open.
The equipment may only be used within the
admissible pressure and temperature ratings.
Correct use includes compliance with the
instructions given in this installation & operating
manual, in particular obedience to all safety
instructions.
Any other use of the equipment is considered to be
improper.
Basic safety notes
Explosion hazard
Risk of explosion due to sparks if triggered in a
potentially explosive atmosphere. The impact
velocity is over 1 m/s, the impact energy is over
500 J.
Bear this in mind when dividing into zones
for explosion protection.
The proximity switch in type VZ 10 equipment is
explosion-proof.
When dividing into zones for explosion
protection, please also pay attention to the
ATEX classification of the proximity switch.
Risk of severe injuries
There is a potentially fatal risk of crushing if the
tank car rolls away.
Make sure that the tank car is secured so it
cannot roll away.
Risk of injury due to impact when attaching the
equipment under the tank car.
Wear a safety helmet.
Ensure compliance with all locally applicable
safety and accident prevention regulations.
There is a risk of fractures or bruises when the
rail hook is triggered. The impact velocity when
triggered is over 1 m/s. The impact energy is
over 500 J.
Only enter the area under the tank car to
attach or remove the rail hook.
Wear protective clothing or PPE when
working on the rail hook.
Ensure compliance with all locally applicable
safety and accident prevention regulations.
Risk of minor injuries
There is a risk of crushing if you reach into
moving parts of the equipment.
Never reach into moving parts.
Wear sturdy protective gloves.
There is a risk of crushing if the cable breaks.
Do not use the cable if it is damaged.

5
Information on property damage
or malfunctions
The VZ 10 equipment may malfunction if ice
forms in the cylinder.
Only use the VZ 10 rail hook if the cylinder is
functioning perfectly.
Only use the VZ 10 rail hook with dry
instrument air.
Qualification of personnel
Specialist personnel must be familiar with and have
experience inn the following areas:
Locally applicable explosion & fire protection
and occupational health & safety provisions
Working on pneumatic equipment (for work on
the VZ 10 rail hook)
Working with hazardous (hot or pressurised)
fluids
Lifting and transporting loads
All information in this Installation & Operating
Manual and other applicable documentation
Protective gear
The required protective clothing depends on the
regulations at the place of work and the fluids in the
tank car. Information on suitable protective clothing
and PPE can be found in the safety data sheet of
the fluid used.
The protective clothing basically consists of the
following items:
Safety helmet
Safety boots
Sturdy leather gloves
Typographic features of warning
notes
DANGER
Notes with the heading DANGER warn
against imminent dangerous situations that
can lead to death or serious injuries.
WARNING
Notes with the heading WARNING warn
against possibly dangerous situations that
could lead to death or serious injuries.
CAUTION
Notes with the heading CAUTION warn
against dangerous situations that could
lead to minor or moderate injuries.
Formatting features for warnings
of property damage
Attention!
This information warns of a situation
leading to prope
rty damage.
Description
Scope of supply
Delivery includes the rail hook and this Installation &
Operating Manual.
The slack rope is not included in delivery.

6
Equipment specification
Pneumatic rail hook VZ 10
No.
Designation
1
Housing
2
Spring for compensating height variation
3
Washer
4
Hook (for attaching the cable)
5
Hexagon screws (M 8 × 20)
6
Ring
7
Tube
8
Cylinder
9
Proximity switch
10
Compressed air hose
No.
Designation
11
Protective hose
12
Rail of railway track
13
Fixing lug for slack rope (slack rope not
included in delivery)
14
Nose
15
Push rod
16
Compression spring
17
Quad ring
18
Split pin (4 × 32)

7
Rail hook VZ 20
No.
Designation
18
Split pin (4 × 32)
19
Spring
20
Slack rope (not included in delivery)
21
Spacer
This model does not have component
numbers 9 to 11, but the
other
components are identical to the VZ
10 (see
previous page).

8
Name plate
The following items are indicated on the name
plate:
Manufacturer
Type designation
CE marking
Date of manufacturing
ATEX classification
With type VZ 10 equipment, the admissible air
pressure is stated on the rating plate.
Task and function
The rail hook is used for automatically closing the
rapid-action bottom valve (24) of railway tank cars
(22) if the tank car rolls away. Together with the
rapid-action bottom valve, it forms an internal
rapid-closing shutoff mechanism that acts as safety
equipment during the carriage of liquefied
flammable gases. This safety equipment fulfils the
requirements of the RID, section 6.8.3.2.3, for
filling and discharge systems for liquefied
flammable or toxic gases with a capacity of over
1 m3.
The rail hook has a PTFE fire shield. The hook
releases in the event of a fire.
The VZ 10 rail hook features a proximity switch that
enables automatic remote triggering when
connected to an I&C system.
In order to function as safety equipment, the
following conditions must be satisfied:
The bottom valve of the tank car must be
equipped with a cable (25) to DIN EN 12561-3.
The rail (12) must conform to DIN EN 13674-1
(e.g. profile 49 E 1).
If the rail does not satisfy this condition, as an
alternative the equipment may also be attached via
a suitable auxiliary device (26).
The rail hook is stretched between the cable (25)
and the rail (12) during filling and emptying. It
keeps the actuator (23) of the bottom valve (24) in
the open position. The cable is attached to the hook
(4) of the rail hook.
In the VZ 10, the nose is tensioned by compressed
air. In the VZ 20, the nose is tensioned by a spring.
In the event of danger, the I&C system releases the
cylinder so that the pneumatic VZ 10 is detached
from the rail.
The mechanical VZ 20 is pulled off the rail by
pulling the slack rope in the event of danger. The
slack rope is not included in delivery.

9
Application of European Directives
ATEX Directive
The equipment has classification:
CE Ex II 2G Ex h IIC T6 Gb.
For use in potentially explosive atmospheres in
zones (surrounding atmosphere to Directive
1999/92/EC) 1 and 2, please read and pay
attention to the following information:
The equipment is made of non-sparking material
(bronze/brass). When triggered, the equipment can
produce sparks mechanically due to impacts with
metal or similar. The impact velocity when triggered
is over 1 m/s. The impact energy is over 500 J. The
plant manufacturer or owner must take this into
consideration when dividing into zones.
If used in potentially explosive atmospheres, the
plant manufacturer or owner is responsible for
discharging or preventing possible static charge.
The ATEX classification of the proximity switch in
the VZ 10 pneumatic rail hook is included on the
VZ 10 sub-assembly rating plate.
Read and pay attention to the information in the
Installation & Operating Manual of manufacturer
Pepperl & Fuchs.
You can find this on the manufacturer’s website
(www.pepperl-fuchs.com).
Storing and transporting the
equipment
Attention!
Storing or transporting the equipment
incorrectly can damage it.

Make sure the equipment remains dry
and is protected against corrosive
atmospheres.

Please contact the manufacturer
if you
wish to transport or store the
equipment in different conditions.
Storing the equipment
Please observe the following items when storing
the equipment:
Do not store the equipment for more than 12
months.
The equipment and all components must be
protected against jolts and impacts.
Store the equipment only in closed rooms that
meet the following environmental conditions:
Air humidity below 50 %, not condensing
Indoor air: clean, salt-free and non-corrosive
Temperature 5–40 °C.
Make sure that all these requirements are
always met when storing the equipment.
Please contact the manufacturer if you cannot
comply with the recommended storage
conditions.
Transporting the equipment
Meet the requirements for storage also when
transporting the equipment.
For short distances (only a few metres) you can
transport the equipment unpacked.
When transporting the equipment over larger
distances use the original packaging.
If you do not have the original packaging use a
box that protects the equipment adequately
against corrosion and physical damage.

10
Using the equipment
DANGER
Risk of explosion due to sparks if triggered
in a potentially explosive atmosphere!
The impact velocity is over 1
m/s, the
impact
energy is over 500 J.

Bear the impact velocity in mind when
dividing into zones for explosion
protection.

When dividing into zones for explosion
protection, please also pay attention to
the ATEX classification of the proximity
switch.
DANGER
Risk of potentially fatal crushing if the tank
car rolls away!

Before commencing work in the
vicinity of the tank car, make sure it is
secured so it cannot roll away.
WARNING
Risk of injury due to impact when attaching
the equipment under the tank car.

Wear a safety helmet.

Ensure compliance with all locally
applicable safety and accident
prevention regulations.
WARNING
Risk of fractures or bruises when the rail
hook is triggered.
The impact velocity when triggered is over
1
m/s. The impact energy is over 500 J.

Wear protective clothing or PPE when
working on the rail hook.

Ensure compliance with all locally
applicable safety and accident
prevention regulations.

O
nly enter the area under the tank car
to attach or remove the rail hook.
Preparing for installation
If the rail of the railway track does not have a 49 E1
profile, you cannot attach the rail hook to this rail. In
this case, you will need to provide a suitable
auxiliary device, with the following features:
The auxiliary device must be designed to
withstand the rail hook retention force of
1,100 N.
A tube (26) measuring 69 to 73 mm must be
available for fastening the nose of the rail hook.
The tube must be positioned parallel to the rail
(12).
WARNING
Risk of fractures or bruises if the rail hook
slips.

Ensure compliance with all locally
applicable safety and accident
prevention regulations.
With the VZ 10 rail hook, you need to take the
following steps before attaching it:
Adapt the Festo PP-6 compressed air hose to
the on-site compressed air supply.
Connect the proximity switch cable to the on-
site emergency stop system.

11
Adjusting the length of the rail
hook
Make sure that the rail hook has the correct length
for the distance between the rail (or auxiliary device)
and the tank car. After installation, dimension X
between the washer (3) and tube (7) must be
approximately 40–50 mm.
To adjust the distance, proceed as follows:
Measure the distance from the cable lug to the
attachment point on the rail or auxiliary device.
Subtract dimension X from this measured
distance. This is the nose - hook dimension to
be set.
Undo the two hexagon screws (5) using a
size 13 open-ended spanner.
Adjust the hook (4) to get the correct dimension.
Tighten the two hexagon screws (5) to a torque
of 4 Nm.
Tensioning the nose
To tension the nose of the VZ 10, proceed as
follows:
Using the compressed air hose (10), subject the
cylinder to pressure between 4.5 bar and 9 bar.
Press the push rod (15) back and turn the nose
(14) at right angles to the longitudinal axis of the
rail hook.
The push rod tensions the nose.
To tension the nose of the VZ 20, proceed as
follows:
Press the push rod (15) back and turn the nose
(14) at right angles to the longitudinal axis of the
rail hook.
The push rod tensions the nose.

12
Installing the rail hook
To install the rail hook, proceed as follows:
For the VZ 20 rail hook, fasten the slack rope to
the nose (14).
Make sure that the slack rope (20) is in perfect
condition and is securely attached in the lug
(13).
Affix the hook (4) to the cable (25).
Pull the rail hook to the fastening point (12 or
26).
Align the rail hook so it is at right angles to the
rail (12).
Hook the rail into the fastening.
Removing the rail hook
WARNING
Risk of fractures or bruises when the rail
hook is triggered.
The impact velocity when triggered is over
1
m/s. The impact energy is over 500 J.

Wear protective clothing or PPE when
working on the rail hook.

Ensure compliance with all locally
applicable safety and accident
prevention regulations.

Only enter the area under the tank car
to attach or remove the rail hook.
Remove the rail hook from the rail after loading.
If you wish to empty or fill other tank cars, you can
keep the VZ 10 rail hook connected to the
compressed air supply.
If the VZ 10 rail hook will not be used for a
longer period, disconnect it from the
compressed air supply.
Troubleshooting
In the event of equipment malfunction, please
contact the manufacturer.
After operation
Removing external dirt deposits
Use fresh water and a cloth to remove dirt and
contaminants from the equipment body.
Maintaining the equipment
The equipment is maintenance-free.
Servicing the equipment and
installing spare parts
GESTRA offers equipment repairs in the event of
wear or damage. No spare parts are supplied.

13
Putting the equipment out of
operation
Returning the valve
You can return the equipment to your contractual
partner.
Make sure that all harmful substances are
removed from the equipment.
Pay attention to the instructions in section
"Transporting the equipment" from page 9.
Pack the equipment in its original packaging or
in suitable transport packaging.
The transport packaging must protect the
equipment from damage in the same way as the
original packaging.
Send the completed and signed
decontamination declaration with the
equipment. The decontamination declaration
must be attached to the packaging so that it is
accessible from outside.
Register the return delivery with your contractual
partner before returning the equipment.
Disposing of the equipment
CAUTION
Environmental damage may be c
aused by
poisonous fluid residues.

Before disposing of the equipment
make sure that it is clean and free of
fluid residues.

For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
The equipment is made from the following
materials:
Component
VZ 10, VZ 20
Housing
CC333G (2.0975.01)
Push rod
CW614N-M (2.401)
Nose
CC333G (2.0975.01)
Tube
CW614N-M (2.401)
Hook
CW614N-M (2.401)

14
Technical data
Dimensions and weights
Dimension
VZ 10
VZ 20
L1 [mm]
12
12
L2 [mm]
690
690
L3 [mm]
540
540
L4 [mm]
500
500
L5 [mm]
135
135
W [mm]
100
100
Weight [kg]
see table below
5.7
Weight of VZ 10, depending on hose length
Hose length [m]
Weight [kg]
6
7.9
10
9.4
15
11.2

15
Operating data
Retention force
350–1,100 N
Compressed air supply of VZ 10
Minimum
4.5 bar
Maximum
9 bar
Proximity switch (Pepperl & Fuchs) characteristics, VZ 10
Type
NJ 10-30 GK-N
NJ 10-30 GK-SN
NJ 5-30 GK-S1N
Rated voltage [V]
8
8
8.2
Power consumption [mA]
Active surface not covered
≥ 3
≥ 3
≤ 1
Active surface covered
≤ 1
≤ 1
≥ 3
Admissible ambient temperature [°C]
–25 / +100
–50 / +100
–25 / +100
IP rating
IP66/IP68
IP68
IP68
Pressure & temperature ratings
You can find the values for your equipment on the
rating plate.
Manufacturer's declaration
For more information on the Conformity
Assessment according to European rules refer to
our Declaration of Conformity or our Declaration by
Manufacturer.
To download the current Declaration of Conformity
or Declaration by Manufacturer go to
www.gestra.com/documents or contact:
GESTRA AG
Münchener Straße 77
28215 Bremen
Germany
Telefon
[phone]
Telefax
[phone]
E-Mail
[email protected]
Web
www.gestra.de
This declaration is no longer valid if modifications
are made to the equipment without consultation
with us.

16
Agencies all over the world: www.gestra.de
GESTRA AG
Münchener Strasse 77
28215 Bremen
Germany
Phone
[phone]
Fax
[phone]
e-mail
[email protected]
Web
www.gestra.com
819758-00/08-2020_kx_mm (809106-00) © GESTRA AG Bremen Printed in Germany