Thermo Scientific PRO-LINE Series Service manual

Thermo Ramsey Italia S.r.l.
PROTECTION DEVICE
Series PRO-LINE
Operating and Service Manual
The manual includes ATEX safety informations for applications
in potentially esplosive atmospheres classified as Zone 22
PL-000603X-D002G

02/08/2017
G
D. Cattaneo
D. Molteni
Revised –Version G
02/05/2016
F
D. Cattaneo
D. Molteni
Upgrading - Certifications
15/04/2016
I
D. Cattaneo
D. Molteni
Revised Operating Temperature
28/10/2015
H
D. Cattaneo
D. Molteni
Revised Steel Cord Connection
14/10/2014
G
D. Cattaneo
D. Molteni
Revised Operating Temperature
10-06-2011
F
R. Cavenago
D. Molteni
Revised Technical Data Table
15-06-2010
E
D. Molteni
GTO
Upgrading - Complete
10-02-2009
D
D. Cattaneo
D.Molteni
Upgrading - ATEX Section
04-11-2003
A
D. Molteni
P.Danelli
Emission
DATE
REV.
DRAWN-UP
APPROVED
DESCRIPTION
2 / 30 Cod.: PL-000603X-D002G

GENERAL INDEX
1. GUIDE TO THE MANUAL USE. .................................................................
4
1.1
Introduction. ...........................................................................................
4
1.2
Consulting the Manual. ..........................................................................
4
1.3
Standards applied and Technical Specifications. ...............................
5
2.
SAFETY RULES. ........................................................................................
6
2.1
General Considerations. ........................................................................
6
2.2
Safety in Use...........................................................................................
6
2.3
Safety in Maintenance. ..........................................................................
6
2.4
ATEX: Safety Informations for use in Explosive Atmospheres
........ 7
3.
DEVICE DESCRIPTION. .............................................................................
8
3.1
Technical Data. .......................................................................................
8
3.2
General. ...................................................................................................
9
3.3
Belt Run-Off Switch Mod. 60-30G. ........................................................
9
3.4
Rope Emergency Switch Mod. 60-31G. ..............................................
10
3.5
Limit Switch Mod. 60-32G. ...................................................................
10
4. INSTALLATION AND ELECTRICAL CONNECTION ...............................
11
4.1
General. .................................................................................................
11
4.2
Transport and Unpacking ....................................................................
11
4.3
Positioning and Installation. ...............................................................
12
4.3.1 Belt Run-Off Switch Mod. 60-30G ....................................................
12
4.3.2 Rope Emergency Switch Mod. 60-31G. ..........................................
13
4.3.2.1. Steel Cord Installation: mechanical mounting ...........................
14
4.3.3 Limit Switch Mod. 60-32G. ...............................................................
18
4.4.
Electrical Wirings .................................................................................
18
4.5
ATEX: Safety Informations for use in Explosive Atmospheres.
..... 19
5.
USE OF PRODUCTS. ...............................................................................
21
5.1
General ..................................................................................................
21
5.2
Uses not permitted ...............................................................................
21
6.
MAINTENANCE. .......................................................................................
22
6.1
Warranty. ..............................................................................................
22
6.2
Maintenance indications. ....................................................................
22
6.2.1 Belt Run-Off Switch Mod. 60-30G. ...................................................
22
6.2.2 Rope Emergency Switch Mod. 60-31G. ..........................................
22
6.2.3 Limit Switch Mod. 60-32G. ...............................................................
23
6.3
ATEX: Additional Informations for maintenance ..............................
23
7.
DECOMMISSIONING AND DISMANTLING. ............................................
24
7.1
Decommissioning of the product. ......................................................
24
7.2
Dismantling the unit. ............................................................................
24
8.
ANNEX ......................................................................................................
25
3 / 30
Cod.: PL-000603X-D002G

1. GUIDE TO THE MANUAL USE.
1.1 Introduction.
This manual contains all the information necessary in order to guarantee a safety and
correct use of the devices.
The information contained in the manual is intended for specialised technical personnel.
Observance of the instructions in the manual will guarantee the safety of both man and
machine, operating economyand a long working life for the feeder.
The manufacturer has a policy of constantly developing and upgrading its products and
hence may make changes without prior notice
1.2 Consulting the Manual.
The consultation of the manual is facilitated by a general index that allows rapid
positionning of the subject of interest.
The indications more important are highlighted in bold type and preceded by symbols
illustrated and defined below.
DANGER
Possible dangers and important requirements for the protection of operators safety ; non
compliance or observation may involve risks to the safety of the operators and / or
demages goods and things.
WARNING
Requirements of obligations related to the behavior of operators in order to safeguard
the security of persons and property ; non compliance or observation may involve risks to
the safety of the operators and / or demages goods and things.
INFORMATIONS
Information / Prescriptions important as regards the functioning of devices and further
information regarding the current operation .
4 / 30 Cod.: PL-000603X-D002G

1.3 Standards applied and Technical Specifications.
The product has been made in compliance with the set of EU standards regarding the free
circulation of industrial products in EU countries (see Machines Directive, 2006/42/CE).
The product is supplied complete with all the documentation required by these standards.
The installation, use and maintenance manual is an integral part of this documentation and
contains all the information needed to ensure the efficient operation of the unit, with
particular regard to personnel safety.
The following standards have been referred to in the design of the unit:
2006/42/CE
MACHINE SAFETY DIRECTIVE
2014/35/CE
LOW VOLTAGE (LVD) DIRECTIVE
2004/108/CE
EMC DIRECTIVE
STANDARDS
IEC 60529+A1+A2:2013
EN 60947-5-1:2005
EN 60947-5-5:1998 +A1:2006
The following standards have been referred for products with ATEX applications:
2014/34/UE ATEX DIRECTIVE
STANDARDS
EN 60079-0:2012 EN 60079-3:2009
5 / 30 Cod.: PL-000603X-D002G

2. SAFETY RULES.
2.1 General Considerations.
The manufacturer is deemed absolved of all liability in the following circumstances:
•if the products is used improperly;
•if the product has not been installed in accordance with the instructions in this
manual
•if the product has been installed in an environment that does not comply with the
conditions set by the manufacturer
•if the product has been altered by the customer in any way without the express
written authorisation of the manufacturer
•If the user has not followed the instructions given in this manual
•if the product has suffered the consequences of exceptional events such as floods,
earthquakes, etc. and has been put back into operation without the necessary
checks being made.
2.2 Safety in Use.
Once the products has been installed before starting work check:
for visible defects on the safety devices; 

for correct operation of the device; 
2.3 Safety in Maintenance.
Before carrying out any maintenance operation on the products it is mandatory:
Read this instruction manual; 

Use the correct tools for the maintenance operations that have to be done; 

Do not clean the electrical parts of the feeder with water or other fluid; 

On completing the repair work, check that all the tools have been collected up 
WARNING
•Only qualified personnel are allowed to carry out maintenance work.
•Maintenance staff must wear working clothes (with tight sleeves) and
individual protective equipment (gloves, safety glasses, etc.) in conformity
with safety legislation and binding safety standards.
•Any alteration to the product or replacement of any parts made without the
manufacturer's authorisation may cause an accident hazard and absolves
the manufacturer from all civil and criminal liability.
•If an emergency situation arises because of a fire, it is forbidden to use
water to put the fire out; always use powder-type extinguishers.
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2.4 ATEX: Safety informations for use in Esplosive Atmospheres.
The safety instruction of this manual are referred to installation, use and maintenance of
the devices for the use in a classified Area according to the 2014/34/UE ATEX directive ,
as per indication below
Zone 22, with potential explosive atmosphere for presence of combustible dust.
The fig. below shows the label affixed to certified units.
fig. 2-4
To understand the markings, see drawing: TG-0PL603X-E001D attached to chapter 8.
DANGER
For applications in explosion hazardous areas classified ATEX Zone 22,
must be strictly followed the instructions given in paragraphs 4.5 and 6.3
WARNING
THERMO RAMSEY will not be held liable for applications in explosion-risk areas
that do not conform to the specifications in the above paragraphs.
INFORMATIONS
THERMO RAMSEY may provide “ProLine” series suitable for applications in explosion
hazardous areas classified ATEX Zone 21.
7 / 30 Cod.: PL-000603X-D002G

3. DEVICE DESCRIPTION.
3.1 Technical Data.
The Table below shown the main data of the product.
GENERAL TECHNICAL DATA
Description
Value
Unit of
Notes
meas.
Overall Dimensions
High: ~105
mm
Approximate measurements
Width: ~235
of different devices without
Depth: ~155
external lever
Weight
~ 4
Kg
Degree of Protection IP
IP 65
Operating Temperature
-45° ÷ +85°
°C
Without ice formation
Stocking Temperature
-45° ÷ + 85°
°C
Relative Humidity
95
%
Without Condensing
Location
Internal / External Use
Material Housing
Cast Aluminium
Color Housing
RAL 1018
Color External Lever
RAL 3020
Impact Resistance
50g 11ms
Vibrations withstanding
10g –10 to 500Hz
according to
IEC 60068-2-27
Microswitches:
- Between open contacts in a given circuit : > 1500V
Electrical Rigidity
- Between contacts connected together and
exposed conductive parts : > 2000v
Microswitches:
- Impulse withstand voltage U imp : 4KW
Rated Insulation Voltage
- Insulation voltage Ui : 400V
Ui: 400V (IEC/EN 6947-1)
Microswitches:
Ithe:10A
Thermal Current
Low Energy load switching
Min Voltage : 10V
Min Current : 40Ma
Microswitches:
AC15 : 24V = 10A, 250V = 6A
Rated Contacts
DC13 : 24V = 8A, 48V = 6A
Microswitches:
Fuse type gG 3A
Short Circuit Protection
Rated with Field Bus
Vmax:24VCC
Options Installed
Imax:20mA
Cable Input
N° 3 with thread metric M20x1,5
Tab. 3-1
8 / 30 Cod.: PL-000603X-D002G

3.2 General.
The Protection Devices Thermo Ramsey, series PRO-LINE are made with a
metallic enclosure in aluminium, common for the three models, containing the
microswitches operated through cams by an external lever.
The units may operated from any direction as the microswitches are operated both for
clockwise or countclockwise rotation of the external lever.
For electrical connection are provided N°3 cable inputs.
The cover of the housing is locked by four stainless steel shake-proof screws. Internal
spring are made with corrosion resistant material.
The enclosure is painted in RAL 1018 yellow color, while the external lever is painted in
RAL3020 red colour.
3.3 Belt Run-Off Switch Mod. 60-30G.
It ' consists of a external lever equipped with a roller which, on normal operating condition,
is not in contact with the belt and thus keeps its vertical position.
When the belt runs-off, it touches the roller, tilts it and thus operates the inside
microswitches.
Fig. 3-3-1
The position of the external lever on the shaft may be changed as required, thus allowing
the mounting of the housing on an horizontal, vertical or any inclined plate, but never
inverted.
The roller is sized for a maximum speed of 4000 R.P.M. equivalent to approximately
8 m/sec belt speed.
It contains one alarm microswitch that is activated when the external lever inclination is
15°+/- 2°, and one shut-down microswitch that is activated when the external lever
inclination is 30°+/- 2° on both side. The max lever inclination is ~65°. Each microswitch is
provide of: N°1 (NC) contact + N°1 (NO) contact.
The unit is equipped with a terminal strip for microswitches electrical wiring and with a by-
pass lever which by-passes the shut-down contact to allow the restarting of the belt.
9 / 30 Cod.: PL-000603X-D002G

3.4 Rope Emergency Switch Mod. 60-31G.
It ' consists of a external lever equipped with two pins to connect steel cords for remote
operation of the switch from both sides.
Fig. 3-4-1
When steel cords (on both sides) is pulled, the lever has a mechanical lock, manually
resettable, by the external reset lever. This feature makes remote restarting impossible,
thus eliminating the possibility of restarting the belt when people are locally working on
the conveyor.
The unit is equipped with N°2 microswitches operate at a 18° +/- 2° inclination of
the external lever.
Each microswitch is provide of: N°1 (NC) contact + N°1 (NO) contact.
This devices is used for the safety of the operators on belt conveyors.
3.5 Limit Switch Mod. 60-32G.
It ' consists of a external lever equipped with one contact wheel to be operate by
the controlled machine.
Fig. 3-5-1
The position of external lever on the shaft may be changed as required, thus allowing
the mounting of the housing on an horizontal, vertical or any inclined plate.
The unit is equipped with N°2 microswitches operate at a 18° +/- 2° inclination of
the external lever.
Each microswitch is provide of: N°1 (NC) contact + N°1 (NO) contact.
10 / 30 Cod.: PL-000603X-D002G

4. INSTALLATION AND ELECTRICAL CONNECTION
4.1 General.
The user must, at his/her expense, prepare the installation site and all necessary for the
operation of the product; this involves:
•Make available the equipment for the installation of the product;
•Make available the power supply necessary for the use of product;
•Make available the safety devices upstream on the power supply lines (such as
switches, circuit-breakers, ground connections, etc.) in accordance with binding
legislation
•Make available the auxiliary services required by the unit
•During the installation steps , never leave the enclosures of devices , without cover
or plug for input / output cables.
4.2 Transport and Unpacking.
Transport and handling devices must be made with due care in order not to damage them
and / or damage to persons or property.
Upon receipt of the device , make sure that this has not been damaged during transport
and that the packaging is intact and has not been tampered with.
If damage is detected by the transport needs to be taken, within 7 days of receipt of goods,
the steps needed to cover the damage under the provisions of supply contract.
INFORMATIONS
In the case of storage waiting for the final positioning , the product with its
packaging, should be placed in a sheltered and safe, in order to avoid damage due
to weather or impact.
The disposal of packaging must be in compliance with the requirements regulated by local
legislation regarding disposal of waste.
•Wood : natural material non-polluting , reusable, easily recyclable, disposal must be
made using the correct methods.
•Plastic: pollutant must not be burned ( toxic fumes ), Do not pollute the environment , the
disposal must be made using the correct methods in accordance with local laws.
11 / 30 Cod.: PL-000603X-D002G

4.3 Positioning and Installation .
INFORMATIONS
The protective devices of the series PROLINE being relatively simple products , are
delivered ready for use , after proper installation. It is however advisable to carry
out the placement , installation and electrical connection to qualified personnel.
The equipment, mechanical and electrical , needed for placement and installation are as
follows :
•Spirit level
•Keys Traditional
•Common tools
•Multimeter
4.3.1 Belt Run-Off Switch Mod. 60-30G.
The Belt Run-off Switch is normally installed on both sides of the belt near the drum head
and tail. For belts of particular extension , there should be of flags even along the ribbon ,
each 200 meters about, and immediately after the loading points . The unit must be
installed at a distance from the belt such that the roller lever is angled 30 degrees when
the belt is in the position required for the block. In normal condition the belt should not
touch the roller lever.
Fig. 4-3-1
WARNING
The device should never be installed with the roller lever upside down, as
the weather and dirt can damage the bearings.
12 / 30 Cod.: PL-000603X-D002G

4.3.2 Rope Emergency Switch Mod. 60-31G.
The Rope Emergency Switch are mainly used in applications where it is necessary to
protect personnel from dangerous devices , such as machines , conveyors and so on.
They must be installed at all points accessible by the operator, usually on both sides along
the entire tape, with a maximum distance of 50 meters between two subsequent switches,
or 25 meters between a switch and a fixed point.
Fig. 4-3-2
DANGER
The Rope Emergency Switch can only be used in control circuits.
WARNING
For the correct operation of the emergency switches, use only accessories (steel
cord, springs, helicoidal nut, etc..) original THERMO RAMSEY. The use of
accessories other than releases the manufacturer from any liability.
13 / 30 Cod.: PL-000603X-D002G

4.3.2.1. Steel Cord Installation: mechanical mounting
WARNING
The correct installation of the steel cord, according to the directions set out below,"
La corretta installazione della fune, in accordo con le indicazioni specificate di
seguito, is a primary condition to ensure the proper functioning of the
protection device.
The installation of the steel rope is by using a set of accessories described and listed
below :
•Safety Spring (1): installed at the ends, are used to maintain tension in the steel rope,
in step d 'installation must be properly tensioned, to ensure that in case of breakage,
the switch is pressed by the spring installed on the opposite side.
•Redance (2): installed near the springs of security needed to create the terminal loop of
the rope, and allows the fixing of the rope by the steel cord clampe.
•Steel Cord Clamp (3): installed after the redance allow you to set the end of the
rope made up the ring back.
•Helicoidal Nut (4): installed on the fixed points has the function to end support,
installed at intervals of max. 3 mt. along the rope, serves to support the rope to avoid
that the same goes slack.
•Red Steel Cord (5): The steel cord is flexible plastic, which is the element to operate
the lever switch.
Fig. 4-3-2-1
Referring to the drawing figure 4-3-3, install the device and its accessories as described:
14 / 30 Cod.: PL-000603X-D002G

a) Fix the Rope Emergency Switch to the frame of the conveyor belt, through the
holes provided on the basis of housing.
Fig. 4-3-2-2
b) Instal the helicoidal nut (4) on a fixed support, the ends of the belt to be protected;
this support can be constituted either by the frame of the conveyor belt is still
installed by an external frame near the belt.
Fig. 4-3-2-3
c) Engage the safety springs (1), places to tie the ends of the belt.
Fig. 4-3-2-4
15 / 30 Cod.: PL-000603X-D002G

d) Instal the helicoidal nuts (4) at a maximum distance of 3 meters apart along the
entire perimeter of the belt to be protected; Fixing can be done either by using the
chassis of the belt (shoulder) or through external frame still installed at the
perimeter of the belt.
Fig. 4-3-2-5
e) Take one end of the rope (5), and wrap on the redance (2), in order to create a kind
of thin thread;
Fig. 4-3-2-6
f) Connect the two cables that were created together by clamps and tighten (3);
during this leave about 280-300 mm of rope free that will be used later to limit the
stretching of the safety spring (1)
Fig. 4-3-2-5
g) Attach the redance, one of the two safety springs (1) Attach the redance, placed at
the ends of the belt.
16 / 30 Cod.: PL-000603X-D002G

h) Lay out the rope (5) to reach the switch; during this attach the rope to the helicoidal
nuts arranged as shown in d), so as to support the rope.
i) Once you reach the switch, wrap the rope (5) around one of these two pins on the
control lever.
j) Tighten the rope, and tighten with a clamp (3).
Fig. 4-3-2-6
k) Ensure that the rope is properly tensioned and visible, and limit the elongation of
the spring, as shown in figure 4-3-2-5, to a maximum length of 180 mm.
l) l) If the switch is placed in central position to the perimeter to be protected, repeat
all the steps indicated from the point e) for the second half of the perimeter.
INFORMATIONS
For installations with ropes lengths greater than 10-15 meters, in order to facilitate
the operations of tension, it is suggested to fit a stretcher as shown in Figure 4-3-2-7.
Fig. 4-3-2-7
17 / 30 Cod.: PL-000603X-D002G

DANGER
•The tension of the rope along the equipment to be protected, must
be designed so that the rope is visibile.
•In applications where the switch is installed in a central position to the
perimeter to be protected, tension must be adjusted so that in case of
breakage rope/ spring on one side the switch must be actuated by the
spring on the opposite side.
•Any spillage of material from the transport device should not affect the
operation of the emergency stop rope.
•Springs are elastic elements that allow an extension of up to 200 mm
(approximately 12 kg). Strictly follow the installation instructions, as by
lengthening the upper, are no longer guaranteed the characteristics of
elasticity, and then operating the device.
•The length of the rope should not be above 25 meters per stroke.
4.3.3 Limit Switch Mod. 60-32G.
The Limit Switch must be positioned properly in order to detect any movement (horizontal
or vertical) of the equipment that must be checked.
4.4. Electrical Wirings
DANGER
•Do not oper under voltage. !
•The work on the devices can be performed only by qualified personnelI.
•Be sure to disconnect power supply before performing any operation on the
devices.
18 / 30 Cod.: PL-000603X-D002G

The figure below shows a typical pattern of electrical wiring devices protection belt.
Electrical connections must be executed by conduit or flexible, through cable gland
installed on the device frame. To keep the original degree of protection, tha cable gland
should have the following features:
•Degree of protection IP65 minimum;
•Cable gland gasketed;
•Thread as indicated in Tab. 3-1.
For details of electrical connections, refer to Annexes who are in the back of the manual;
ensure that once installed, the cable glands are locked firmly on the housing. In
accordance with current legislation, the housing must be grounded through ground wire to
appropriate section.
4.5 ATEX: Safety informations for use in Explosive Atmospheres.
European directives (ATEX 2014/34/UE) for equipment and 1999/92/CE for the workplace
(plant), establishing the essential safety requirements against the risk of explosion in
hazardous areas; refer to these guidelines for more details on 'use and installation.
WARNING
Before installation in hazardous areas classified according to directives ATEX, you
must verify that the product is appropriate for the zone classification and
characteristics of flammable substances.
19 / 30 Cod.: PL-000603X-D002G

For the use of devices in classified areas we recommend that you carefully follow the
instructions in this chapter.
•Use cable glands with type of protection "EEx e" certified ATEX, able to guarantee
a degree or more IP protection level of the original IP (IP65) devices on which
must be installed.
•To protect the cables with rigid or flexible tubing to provide mechanical protection;
if this is not possible the cables should be installed at a height of at least 2.5 meters.
the work plan.
•Only use devices designed cable entries; is not permitted to run drilling or create
new cable entries. The Unused cable entries must be closed with caps conforming
to EN 60079-0;
•Use flame-retardant cables according to EN 60332-1-1;
•There shall be no more cables to pass within the same gland, possibly using multi-
core cables;
•It must be ensured the connection of equipotential, by loosening and rotation
devices, at the connections provided both inside and outside of the devices;
•The location of the devices must be chosen, taking into account the accessibility for
maintenance and cleaning;
•The devices must be protected from external influences (eg mechanical efforts
and / or thermal) which can be submitted, and these additional measures shall not
adversely affect the normal heat dissipation and system integrity protection
provided;
•If the devices are subjected to dust, must be given appropriate instructions to the
maintenance staff to perform periodic cleaning of the same;
•Special precautions must be taken to prevent the accumulation of electrostatic
charges on the surface of the devices;
•Maintain clean equipment by dust than 5 mm.
WARNING
THERMO RAMSEY not be responsible for installation in areas at risk of explosion
not comply with the instructions in this section (section 4.3).
20 / 30 Cod.: PL-000603X-D002G