GESTRA VZ 10 Manuel utilisateur

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

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.

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.

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.

Equipment specification

Pneumatic rail hook VZ 10

No.

Designation

Housing

Spring for compensating height variation

Washer

Hook (for attaching the cable)

Hexagon screws (M 8 × 20)

Ring

Tube

Cylinder

Proximity switch

Compressed air hose

No.

Designation

Protective hose

Rail of railway track

Fixing lug for slack rope (slack rope not

included in delivery)

Nose

Push rod

Compression spring

Quad ring

Split pin (4 × 32)

Rail hook VZ 20

No.

Designation

Split pin (4 × 32)

Spring

Slack rope (not included in delivery)

Spacer

This model does not have component

numbers 9 to 11, but the

other

components are identical to the VZ

10 (see

previous page).

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.

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.

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

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.



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.

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