Kiepe Elektrik SEG User manual

OPERATING INSTRUCTIONS
Pull-rope emergency stop switch
Type SEG

Legal Notice
Operating Instructions (Original)
(Translation of the German version dated 14.04.11,
Index 0)
Document No.: 94.067229.191
Pull-rope emergency stop switch, Type SEG
Product Number: 91.056400.xxx
Date of Issue: 27.04.2011
Update Status: Index 0
Protection notice (in accordance with DIN ISO
16016:2002-5)
Any distribution and reproduction of this document, utili-
zation or disclosure of its contents are prohibited unless
expressly authorized. Offenders will be held liable for the
payment of damages. All rights reserved in the event of
the grant of a patent, utility model or designmodel regis-
tration.
CE mark and conformity
The EC declaration of conformity is issued by Vossloh
Kiepe GmbH, Kiepe-Platz 1, 40599 Düsseldorf. It is
signed by a person appointed by the general manage-
ment. The person appointed with responsibility for docu-
mentation has authority to compile the technical
documentation.
The declaration of conformity declares that pull-rope
emergency stop switch, type SEG, ID no.: 91.056400.xxx
conforms to Machinery Directive 2006/42/EG and the
harmonized standards DIN EN ISO 13850:2008,
DIN EN 60204-1:2006 in addition to DIN EN ISO 12100-
1:2003 and DIN EN ISO 12100-2:2003.
Where applicable, the requirements set out in
DIN EN ISO 13849 Parts 1 and 2 : 2008 were taken into
account. The safety objectives of Low Voltage Directive
2006/95/EG are complied with in accordance with annex
I, section 1.5.1 of the MachineDirective.
www.kiepe-elektrik.com Tel.: [phone]
Fax: [phone]
Vossloh Kiepe GmbH
Kiepe-Platz 1
40599 Düsseldorf
Germany

3
Operating Instructions SEG
Table of Contents
Table of Contents
1 Safety................................................................................................................................7
1.1 Intended use .................................................................................................................................................7
1.2 Layout of safety instructions .........................................................................................................................8
1.3 Safety instructions ......................................................................................................................................10
1.3.1 Exclusion of liability and warranty...............................................................................................................10
1.3.2 Safety instructions for avoiding personal injury ..........................................................................................11
1.3.3 Safety instructions for avoiding property damage.......................................................................................12
1.4 Personal safety equipment .........................................................................................................................14
2 Transport, storage, and disposal ....................................................................................15
2.1 Transport and packaging ............................................................................................................................15
2.2 Storage .......................................................................................................................................................15
2.3 Disposal ......................................................................................................................................................16
3 Description......................................................................................................................17
3.1 Introduction .................................................................................................................................................17
3.2 Function ......................................................................................................................................................19
4 Technical data ................................................................................................................21
4.1 General technical data................................................................................................................................21
4.2 Electrical connection...................................................................................................................................24
4.3 Tightening torques ......................................................................................................................................26

4
SEG Operating Instructions
Table of Contents
4.4 Device identification ................................................................................................................................... 26
4.5 Device variants........................................................................................................................................... 28
4.6 Dimensions ................................................................................................................................................ 29
4.7 Installation location and installation position .............................................................................................. 30
5 Mounting and dismounting ............................................................................................. 31
5.1 Scope of delivery........................................................................................................................................ 31
5.2 Important preliminary mounting instructions .............................................................................................. 32
5.2.1 General requirements ................................................................................................................................ 32
5.2.2 Substructure, installation location and installation position ........................................................................ 32
5.2.3 Mounting conditions ................................................................................................................................... 32
5.2.4 Electrical connection .................................................................................................................................. 32
5.2.5 Pull-rope system ........................................................................................................................................ 33
5.3 Tools required ............................................................................................................................................ 33
5.4 Mounting .................................................................................................................................................... 34
5.4.1 Preparatory work........................................................................................................................................ 34
5.4.2 Mechanical mounting ................................................................................................................................. 35
5.4.3 Electrical connection .................................................................................................................................. 36
5.4.4 Finishing work ............................................................................................................................................ 39
5.5 Dismounting ............................................................................................................................................... 41
5.5.1 Preparatory work........................................................................................................................................ 41
5.5.2 Detaching the electrical connections.......................................................................................................... 42
5.5.3 Mechanical dismounting............................................................................................................................. 43

5
Operating Instructions SEG
Table of Contents
6 Maintenance ...................................................................................................................44
6.1 Overview of maintenance ...........................................................................................................................44
6.2 Tools required.............................................................................................................................................44
6.3 Visual inspection.........................................................................................................................................45
6.4 Cleaning the device from the outside .........................................................................................................47
6.4.1 Removing dirt from the outside...................................................................................................................47
6.4.2 Removing ice from the outside ...................................................................................................................48
6.5 Functional test ............................................................................................................................................50
7 Repairs ...........................................................................................................................54
7.1 Tools required.............................................................................................................................................54
7.2 Replacing the cover ....................................................................................................................................54
7.3 Replacing the dummy plug .........................................................................................................................56
7.4 Replacing the screwed cable gland ............................................................................................................57
7.5 Replacing the signal lamp...........................................................................................................................59
7.6 Replacing the pressure equalization element.............................................................................................61
8 Commissioning ...............................................................................................................62
9 Defects and faults ...........................................................................................................65
10 Ordering devices, replacement parts, and accessories..................................................69
10.1 Ordering devices.........................................................................................................................................69
10.2 Ordering replacement parts and accessories .............................................................................................69

6
SEG Operating Instructions
Table of Contents

7
Operating Instructions SEG
1 Safety
1 Safety
1.1 Intended use
Pull-rope emergency stop switches, type SEG are used
as emergency stop devices actuated on both sides in
stationary conveyor systems in control circuits in accor-
dance with the safety requirements of DIN EN 620 and in
harmony with DIN EN ISO 13850. According to the BGIA
report 2/2008 "Functional safety of machine controls -
application of DIN EN ISO 13849" issued by the German
Social Accident Insurance (Deutsche Gesetzliche Unfall-
versicherung), the pull-rope emergency stop switches
can be used as emergency stop devices in safety control
circuits up to performance level PLe.
These operating instructions describe the intended use,
mechanical mounting/dismounting at the attachment
points for the pull-rope emergency stop switch SEG,
electrical connection and maintenance, repair, commis-
sioning and troubleshooting for the pull-rope emergency
stop switch SEG. These operating instructions do not
contain any information regarding the use and handling
of the pull-rope system or the control.
Improper use of the device and unauthorized changes to
the device and its components may result in injury and/or
damage, for which the manufacturer will not assume
any liability. Ensure that intended use cannot be im-
paired in any way, even by an unforeseen external influ-
ence on the device.
Die vorliegende Dokumentation ist als Teil des Produk-
tes zu betrachten und muss während der Lebensdauer
des Produktes behalten werden und dem jeweiligen Be-
sitzer/Benutzer zur Verfügung stehen. Die Dokumenta-
tion muss an jeden nachfolgenden Eigentümer des
Produktes weitergegeben werden.
Intended use includes in particular that you perform all
activities with and on the device with the aid of these op-
erating instructions.
Work on the device may be performed only by techni-
cians who have been authorized by the person respon-
sible for the safety of the system to perform the required
activities.
Qualified technicians are those who, on account of their
training, experience or instruction as well as their knowl-
edge of relevant standards, laws, provisions, accident
prevention regulations, generally acknowledged rules on
safety and operating conditions, are able to perform the
required activities and can identify and prevent potential
hazards. If the work requires specialized knowledge,
e. g. in electrical engineering, mechanics and pneumat-
ics, technicians must have the appropriate qualification.

8
SEG Operating Instructions
1 Safety
Observe the locally stipulated instructions of the plant op-
erator.
Further information on the definition of technicians can
be found e. g. in DIN VDE 0105 Part 100, EN 50110-1.
Intended use will protect you and prevent damage to
the device and its components!
1.2 Layout of safety instructions
The classification of dangers is based on ISO 3864-2
and ANSI Z535.6. It uses the key words
•“Danger”, “Warning”, and “Caution” with reference to
personal injuries,
•“Beware” for property damage, and
•“Note” to convey general information.
Dangers and instructions in this documentation have
been categorized and represented as follows:
Danger!
indicates imminent danger. Failure to avoid the danger
will result in death or extremely severe (crippling) inju-
ries.
Warning!
indicates a potentially dangerous situation. Failure to
avoid the dangerous situation may result in death or ex-
tremely severe (crippling) injuries.
!
!

9
Operating Instructions SEG
1 Safety
Note!
“Note” indicates application tips and other espe-
cially useful information.
Pictograms
The following pictograms are used to clarify the source of
the danger. The pictograms can occur at all levels of dan-
ger.
Caution!
indicates a potentially dangerous situation. Failure to
avoid the dangerous situation may result in slight or mi-
nor injuries.
Beware!
indicates a situation which may result in property dam-
age. If the situation which may result in property dam-
age is not avoided, the product or something in the area
around it may be damaged.
!
!
Pictogram Type of danger
Dangers of all type, except the danger is
identified by the following pictogram.
Injuries caused by hazardous voltages and
currents.
Injuries caused by crushing.
Injuries caused by excessively hot or cold
surfaces.
Damage caused by electrostatic dis-
charges (ESD protection).
Tab. 1-1: Pictograms for fundamental sources of danger

10
SEG Operating Instructions
1 Safety
1.3 Safety instructions
All work on the device and its components must be per-
formed by technical specialists only (for a definition of
technical specialists see Section 1.1: „Intended use“,
page 7). Always observe the safety instructions in the fol-
lowing sections.
1.3.1 Exclusion of liability and warranty
Warning of performing work improperly!
Improperly performed work will result in risks for per-
sons and damage to the device.
Vossloh Kiepe GmbH assumes no liability for risks and
damage which occur due to improperly performed work
if you perform the work on the device yourself.
We strongly recommend having all work on the device
performed by Vossloh Kiepe GmbH.
!
Warning!
The use of replacement parts which are not recom-
mended by the manufacturer may result in personal in-
jury and/or property damage.
The replacement parts must meet the technical stan-
dards specified by the manufacturer. For your own
safety and to ensure claims under the warranty, use
only original replacement parts.
!

11
Operating Instructions SEG
1 Safety
1.3.2 Safety instructions for avoiding personal in-
jury
Always observe the following safety instructions to avoid
personal injury:
Risk of death from electrical shock!
To prevent health and safety risks, always follow these
five safety rules:
1. Disconnect from power supply.
2. Secure from being switched on again.
3. Check absence of voltage.
4. Ground and short-circuit.
5. Cover or block off adjacent live parts.
Before starting working on the electrical system, apply
the five safety rules in the order mentioned above. After
work is complete, cancel the steps in reverse order.
Danger!
The lines fed into the device must not block the mecha-
nism in the device.
Use the fastening clamps available in the device to at-
tach the lines. Combine the lines meaningfully, using
cable ties if required.
The lines installed outside the device must not block the
release lever or the reset lever.
Warning!
The devices may be used in control circuits only.
Warning - risk of falling parts!
When working on the device, there is a risk of injury
from falling parts.
Wear a hard hat and safety shoes to protect your head
and feet from injury.
!
!
!

12
SEG Operating Instructions
1 Safety
1.3.3 Safety instructions for avoiding property
damage
When working on the pull-rope emergency stop switch
SEG, observe the following safety instructions to avoid
damage to the device:
Beware of crushing!
When the release lever or reset lever is actuated, there
is a risk of injuring your hand between the housing and
the release lever or reset lever (e. g. crushing, bruis-
ing).
Wear suitable protective gloves to protect your hands.
Before working on the device, disconnect the release
line from the release lever to prevent inadvertent actu-
ation of the release lever.
Beware of burn or frost injuries!
The device accepts the temperature of the environment
or the system and may become very hot or very cold. At
high temperatures there is a risk of burns. At negative
temperatures there is a risk of frost injuries.
Wear suitable protective gloves to protect your hands.
Beware!
Unless otherwise indicated in these operating instruc-
tions, you must make and secure the screw connec-
tions during assembly as accurately as they were origi-
nally implemented in the device delivered by Vossloh
Kiepe GmbH. Always use new screw retaining ele-
ments when assembling screw connections.
Beware!
Screw connections that were made to a specified tight-
ening torque must be restored with the appropriate
tightening torque when reinstalled. Please observe the
specifications in these operating instructions.
Electrical and mechanical screw connections may have
different tightening torques.
The order in which screw connections are made must
be observed where applicable.
!
!

13
Operating Instructions SEG
1 Safety
Penetration of dust and moisture if seals are
damaged!
If the hood seal is damaged, dust and moisture may
penetrate the device and damage the device and its
components.
Check the seal for damage before assembly. Replace
the hood if the seal is damaged.
Penetration of dust and moisture if seals are
damaged!
Seals on screwed cable glands and dummy plugs age;
as a result, the tightness of the devices can no longer
be ensured when the screwed cable glands or dummy
plugs have been opened.
Replace screwed cable glands and dummy plugs with
new screwed cable glands and dummy plugs whenever
the device has been opened.
Use only the screwed cable glands and dummy plugs
recommended by the manufacturer.
Penetration of dirt and moisture!
Only use cables with approved cable cross-sections,
otherwise dirt and moisture can penetrate the device
and damage it. The approved cable cross-sections are
specified in Chapter 4: „Technical data“, page 21.
!
!
!
Ingress of dirt and moisture!
Contact sprays, greases and oils may damage the
seals of the device.
Do not use contact sprays, greases and oils without the
consent of Vossloh Kiepe GmbH (for contact data see
Imprint).
Damage to components and lines due to in-
correct electrical connections and installa-
tion!
Ensure that the line markers are not removed from the
lines, or mark the lines appropriately so that the lines
can be assigned during installation.
Combine the lines meaningfully, using cable ties if re-
quired. Use the fastening clamps available in the device
to attach the lines.
When installing the lines, observe any bending radii
specified by the manufacturer.
!
!

14
SEG Operating Instructions
1 Safety
1.4 Personal safety equipment
The usual personal safety equipment required for work
on conveyor systems must be used for working on the
pull-rope emergency stop switch. The service and safety
requirements of the operator must be complied with.
However, the following safety equipment must be worn at
the very least (see Section 1.3.2: „Safety instructions for
avoiding personal injury", page 11):
•Appropriate work clothing for the requirements of the
relevant conveyor system
•Hard hat
•Protective gloves
•Safety shoes

15
Operating Instructions SEG
2 Transport, storage, and disposal
2 Transport, storage, and disposal
2.1 Transport and packaging
Select suitable packaging if you send the device itself or
components of the device e. g. to Vossloh Kiepe GmbH
for repair. Take special care to protect the components
against impacts, moisture, and dirt. In this way the device
components will be protected from damage in transit, for
which the manufacturer will not assume any liability.
2.2 Storage
Avoid excessive temperature fluctuations, otherwise
condensation will form which may damage the device
and its components.
Permissible storage temperature: See Chapter 4: „Tech-
nical data“, page 21
Packaging data Pull-rope emergency stop
switch SEG
Package size
(length x width x height)
240 mm x 185 mm 130 mm
Total weight of packaging,
device and operating instruc-
tions
5,23 kg
Tab. 2-1: Overview of packaging data
Damage due to improper
storage!
The ingress of dirt and moisture into a device as well as
the effects of weather (e. g. condensation formation in
the device, sunlight) will damage the device or cause
premature aging.
Protect the device by storing it in a clean and dry place
and under uniform ambient conditions.
Store the device preferably in its original packaging.
Unpackaged devices must be covered dustproof. Con-
densation must not form under the cover.
!

16
SEG Operating Instructions
2 Transport, storage, and disposal
2.3 Disposal
Our products were developed in consideration of the EU
Directive 2002/95/EC (RoHS) and do not contain any
known harmful substances.
The device components and materials can be separated
by removal and destruction of the device. The auxiliary
materials and lubricants used (< 0.1 mass percentage)
are protected from being washed out by the housing. The
auxiliary materials and lubricants must not be disposed
of in the ground water, watercourses or the sewage sys-
tem.
Our products must be disposed of according to the appli-
cable local or national and international regulations.
Aging of materials!
Materials may age due to long storage so that material
properties are impaired (e. g. seals and synthetic mate-
rials may become brittle). The properties of lubricants
may change due to long storage.
Check the device for damage before use or installation.
Do not install the device if it has visible aging damage.
Penetration of dirt and moisture!
When delivered, the cover is only screwed on finger-
tight. For transportation and storage, the screwed cable
gland is lightly sealed by a protective plug. The device
is not protected against penetration of dirt and moisture
in accordance with the protection class specified in the
technical data (see Section 4.1, page 21).
!
!

17
Operating Instructions SEG
3 Description
3 Description
3.1 Introduction
Pull-rope emergency stop switches, type SEG are used
as emergency stop devices actuated on both sides in
stationary conveyor systems in control circuits in accor-
dance with the safety requirements of DIN EN 620 and in
harmony with DIN EN ISO 13850. According to the BGIA
report 2/2008 "Functional safety of machine controls -
application of DIN EN ISO 13849" issued by the German
Social Accident Insurance (Deutsche Gesetzliche Unfall-
versicherung), the pull-rope emergency stop switches
can be used as emergency stop devices in safety control
circuits up to performance level PLe.
The pull-rope emergency stop switch SEG can be actu-
ated in two directions via a pull-rope (20). The pull-rope
is stretched under tension along the length of the convey-
or system and is guided by the pull-rope guides (21). The
pull-rope emergency stop switch SEG is mounted in the
center between the two attachment points (22).
Fig. 3-1: Function of the pull-rope emergency stop switches SEG
Reset lever (2)
Pull-rope emergency stop switch SEG
Trigger lever (1)
Pull-rope guide (21)
Pull-rope (20)
Attachment point (22)
Attachment point (22)
Direction of actuation

18
SEG Operating Instructions
3 Description
Fig. 3-2: Pull-rope emergency stop switch SEG: view of inte-
rior (reset lever to the front)
Fig. 3-3: Pull-rope emergency stop switch SEG: illustration
of switch positions (reset lever to the front)
Cam roller (16)
Switching element
N/C (safety circuit)
(5)
Switching element
N/O (control circuit)
(6)
Trigger lever (1)
Trigger lever (1)Reset lever (2)
Reset lever (2) in switch position "1"
Signal lamp (10)Cover (4)

19
Operating Instructions SEG
3 Description
3.2 Function
Pull-rope emergency stop switches, type SEG are elec-
tro-mechanical switches designed to perform safety
functions in accordance with DIN EN ISO 13849-1. The
pull-rope emergency stop switches can be actuated in
two directions.
The pull-rope emergency stop switch, type SEG is an
emergency stop device that comes with at least two
switching elements (5, 6) (see Fig. 3-2). At least one of
the switching elements (5) has a positive opening con-
tact.
•The switching element (5) N/C contact is used for
the safety circuit connection.
•The switching element (6)N/O contact is used for the
control circuit connection or for the optional signal
lamp connection (12) (see Figure 4-1, page 24).
Switching elements (5, 6) are actuated simultaneously
via the cam roller (16).
Emergency stop
In the home position (pull-rope emergency stop switch
active), reset lever (2) is in switch position "1" (see Fig. 3-
3). The switching element contacts (5) N/C contact (safe-
ty circuit) are closed, the switching element contacts (6)
N/O contact (control circuit) are open.
By actuating trigger lever (1), cam roller (16) jumps to the
shut-off position. Reset lever (2) jumps from switch posi-
tion "1" to switch position "0". Trigger lever (1) is discon-
nected and can now move freely, so preventing any sub-
sequent switching processes (locking function). The
switching element contacts (5) N/C contact (safety cir-
cuit) are open, the switching element contacts (6) N/O
contacts (control circuit) are closed.
If you are using pull-rope emergency stop switches with
signal lamp (12), the signal lamp comes on (12).
Switch position of
reset lever (2)
Switching element
N/C contact (5)
Safety circuit
N/O contact (6)
Control circuit
1 (pull-rope emer-
gency stop switch
active)
Closed Open
0 (pull-rope emer-
gency stop switch
triggered)
Open Closed
Tab. 3-1: Overview: function of the switching element

20
SEG Operating Instructions
3 Description
Manual reset
The conveyor system cannot be switched on again until
the pull-rope emergency stop switch has been unlocked
locally. To do this, reset lever (2) is switched from posi-
tion "0" to position "1" (see Fig. 3-3).
Warning!
After actuating and before resetting the emergency pull-
rope switch, inspect the conveyor along the entire
length of both release lines to establish the reason for
actuation of the emergency pull-rope switch.
!