INSTRUCTIONS FOR OPERATION

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1 ZAM-SERVIS s.r.o., Křišťanova 1116/14, Ostrava Přívoz, Phone: O69/ , Fax: 069/ INSTRUCTIONS FOR OPERATION (TRANSPORT, STORAGE, INSTALLATION, ASSEMBLY AND MAINTENANCE) CABLE PULL CONTROL SECURING DEVICE TYPE KTK 1 Document number: These instructions are kept at the manufacturer for the whole product life period. Any changes in engineering, functioning and use of the product will be included in these instructions! Processed by: Ing.František Ševčík, ZAM-SERVIS s.r.o. Date of issue: Pages total: Revision: p. 1/9

2 p. 2/9 CONTENTS: 1. USE. 2. SAFETY. 3. UNIT DESCRIPTION. 4. TECHNICAL PARAMETERS. 5. INSTALLATION INSTRUCTIONS. 6. OPERATING INSTRUCTIONS. 7. MAINTENANCE INSTRUCTIONS. 8. STORAGE INSTRUCTIONS. 9. TRANSPORT INSTRUCTIONS. 10. FIRE SAFETY, ECOLOGY, PRODUCT RECYCLING. 11. TESTING. 12. STANDARDS USED. 13. ORDERING. 14. SETTINGS CHART. 15. PICTURE ATTACHMENTS. 1. USE: The KTK 1 securing device (further referred to as the "KTK 1" only) serves for the control of the permitted pull of trailing cables of movable mining machinery. The maximum pull set on KTK 1 ranges from 1,125 N to 4,275 N, this setting depends on the cable type used and adjustment value in the chart. This pull enables connecting trailing cables with the core cross-section from 25 mm 2 to 95 mm 2 with various core combinations. A flat cable grip type PP 65/2/1 (permitted pull of 15,000 N) is intended for all types of cables. The device can be used in mining environment in circuits with voltage up to 250 V/50 Hz/AC/DC. The device has been designed for applications in environments with a methane explosion hazard classed M 2 with shock bumps in terms of ČSN EN This device is made as Exd I. It can be classified among intrinsically safe circuits Ex ia I. The maximum pull value adjustment is performed at the manufacturer as default settings. 2. SAFETY. The disconnecting contact of KTK 1 device must be connected into the circuit of movable mining machine in such manner to stop the machine once the maximum level of permitted pull in cable is achieved. An incorrect connection may result in cable snap with potential electric shock hazard. 3. UNIT DESCRIPTION. KTK1 consists of an enclosure with a lid made as Exd I or EXia I, pull switch, rope guide, hauling rope with a grip and a steel cable grip, as stated in the Appendix No. 1 to these instructions. The explosion proof enclosure is made of welded metal sheets. Two side walls are fitted with explosion proof bushings made by ZAM-SERVIS, type PNV 32 (2 pieces). In case either of the PNV 32 bushings remains idle, it will be plugged with the blanking insert designed for bushing PNV32. The enclosure contains a pull switch screwed into the front panel and secured by means of a retaining ring. The explosion proof characteristics of the enclosure in Exd I design are further ensured by means of tubular gap L1 of the pin passing through enclosure wall, the plane gap L2, the tubular threaded gap LZ1 and potted single-conductor bushings housing through which goes the cord guide between switch and terminal board, see drawing No Potting of 2 bushings is ensured by means of the approved potting substance TEDISTAC with ISOSTAC thickener, see Certificate No. FTZÚ 01 ATEX 0028 U. The pin of pull switch coming out of the enclosure is fitted with cord attachment, pos. 4 within assembly on Fig. 1 and 2. The rope inside attachment is secured by means of lead sealing. The rope guide is fixed onto the enclosure using four M12 screws. The hauling rope cord passes through the cord guide, pos. 3 in Fig. 1, and its opposite end is run through two loops on the steel cable grip and it is fixed by means of 2 rope brackets. The steel cable grip serves for transfer of cable pull onto the hauling rope. The cable grip is made of two parts, that is the very grip braided of steel galvanized cords into flat net shape and two steel galvanized loops for hauling cord attachment. That enables fixing anywhere on the cable for all cable types. The flat grip is wrapped around the cable at attachment point and constricted by running a wire through its loops.

3 p. 3/9 4. TECHNICAL PARAMETERS. Fixed adjustment of disconnection pull per chart, max N (800 kp) Range of cable cross-sections for ZTK 01 design 25 to 95 mm 2 Nominal voltage max. 250 V/AC/DC Nominal current Ij max. 0.2 A/AC/DC Switch function after exceeding the max. pull disconnecting Ambient temperature -20 to + 40 o C Humidity 0 to 95 % Protection IP 54 Design Exd I Weight 28 kg Dimensions 350x150x220 Protection conductor of earth terminal cross-section 6 mm 2 5. INSTALLATION INSTRUCTIONS The installation of KTK is conducted on movable machinery with trailing cable. The enclosure of KTK 1 is screwed onto the movable machine in such manner that the pull cord is directed towards the trailing cable. For an example of enclosure fixing see Fig. 4 and 5. The part of machine on which the KTK 1 is to be fixed must be capable of safe transfer of the max. permitted pull in the cable with minimum safety rating 2. The trailing cable will be fitted with the flat cable grip in such manner that it is wrapped around the cable and constricted by running a wire through its loops. The grip will be fitted onto the cable using fixing tape of width 9 and clip 9, spaced approx. 30 mm from the grip end. The loose end of hauling rope will be run through both grip loops and anchored onto the hauling rope using two brackets. The trailing cable between cable grip and machine must be run in such manner to transfer potential pull inside the cable through the cable grip directly, the hauling rope must be attached to the pull controller. The device is connected directly in series inside the safety control circuit of the machine, if the machine is powered from contactor. The second case involves the machine powered from end element controlled contactor (the end LED) and the pull switch of KTK 1 connected in series with the disconnecting circuit of end element single-conductor connection. The specific connection method must be specified in project documentation for connection of movable machinery to power supply. 6. OPERATING INSTRUCTIONS. The KTK 1 device does not require any special operator. The KTK 1 must be checked by the movable machine operator visually once per shift. Any potential failure must be removed prior to starting of machinery equipped with KTK MAINTENANCE INSTRUCTIONS. Remove dust from the enclosure surface. Protect contact surfaces from corrosion. Suitable preservation of contact surfaces of the flameproof enclosure can be achieved using a thin film of grease. Also keep all screws on the enclosure tightened properly. The manufacturer recommends overall inspection of product condition at least once a year. Any repair will be carried out by the supplying company that also supplies spare parts. 8. STORAGE INSTRUCTIONS. The KTK 1 device must be stored in areas with ambient temperature of o C and humidity up to 95 %. 9. TRANSPORT INSTRUCTIONS. The KTK 1 device can be transported on closed vehicles ensuring protection against weather effects.

4 p. 4/9 10. FIRE SAFETY, ECOLOGY AND PRODUCT RECYCLING Do not expose to open flame; harmful substances are produced by burning. The product does not contain any ecologically harmful substances. When used properly during operation it doesn t affect the environment and ecology. After expiration of the lifetime, individual components shall be disposed of as follows: plastic components shall be used for recycling at relevant plastic waste management company; appliance parts shall be disposed of as regular waste, deposited on public landfills; other parts shall be disposed of as regular waste public landfills; metals parts shall be disposed of at metallurgical plants; or the product shall be returned to its manufacturer for disposal. The relevant address is listed below. After expiration of the lifetime, the electrical and electronic equipment must not be disposed of as ordinary municipal waste. The product shall be submitted to the relevant collection grounds concerned with processing, regeneration and recycling of electric and electronic appliances. For more information about the collection point and recycling of this product, please contact the local authorities, a municipal waste management firm at your place or the shopkeeper where you purchased this product. 11. PRODUCT TESTING Every product is subject to testing at the supplying organisation prior to dispatch. 12. STANDARDS USED. EN , EN , EN , EN ORDERING Any orders submitted must specify the equipment type. The delivery includes documents listed below: - This manual - AO Certificate - The Quality Certificate issued by manufacturer - The Warranty Certificate - The Delivery Note KTK 1 is delivered packed. 14. MAX. PULL SETTINGS CHART. Cable structure 3x x4+d 3x x4+d 3x x6+d 3x x6+d 3x x6+d Nominal core crosssection Nominal insulation thickness Exterior casing thickness External Maximum axial pull mm mm 3mm 51mm 1,125 N mm mm 3.5mm 55mm 1,575 N mm mm 3.5mm 57mm 2,250 N mm mm 4.0mm 63mm 3,150 N mm mm 4.0mm 68mm 4,275 N

5 p. 5/9 15. PICTURE ATTACHMENTS. Fig. 1

6 p. 6/9 Fig. 2

7 p. 7/9 Fig. 3

8 p. 8/9 Fig. 4 EXPLOSION-PROOF ENCLOSURE WITH PULL CONTROLLER P1 DESIGN (SETTING 20,235 N) FASTENED WITH 4 M16 SCREWS HAULING ROPE FLAT CABLE GRIP TAPE CLIP TRAILING CABLE QUICK COUPLING FIXING OF THE KTK-1 ON ROADHEADER AM 50 p.9/9

9 p. 9/9 Fig. 5 FLAT CABLE GRIP HAULING ROPE, COMPLETE EXPLOSION-PROOF ENCLOSURE WITH PULL CONTROLLER P4 DESIGN (SETTING 7,845 N) FASTENED WITH 4 M6 SCREWS TAPE CLIP TRAILING CABLE QUICK COUPLING FIXING OF THE KTK-1 ON ROAD HEADING MACHINE HAUSHERR

FS1. User manual FLOAT LEVEL GAUGE. No ZAM-SERVIS s.r.o. Křišťanova 1116/14 Ostrava-Přívoz

FS1. User manual FLOAT LEVEL GAUGE. No ZAM-SERVIS s.r.o. Křišťanova 1116/14 Ostrava-Přívoz User manual FLOAT LEVEL GAUGE No. 201 29 This User manual includes: Instructions for assembly, installation, commissioning, use, operation, settings, maintenance and servicing, disassembly, disposal and