„GUMOPLAST” s. c.

Wiesław Kowalski, Radosław Kowalski, Łukasz Kowalski

Puńców , ul. Cieszyńska 185
43-400 Cieszyn

WAZ -*/*/* type emergency switches

I M1 Ex ia I Ma
II 1G Ex ia IIC T6 Ga

August 2016
© Any part of this document can be reprinted nor copied by any technique without a written consent issued by “GUMOPLAST” s. c. in
Cieszyn
.
OPERATION MANUAL 15/GP-Ex-02/2
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OPERATION MANUAL 15/GP-Ex-02/1 2/18

List of contents
Page

1. List of drawings …………………………………………………………………………3

2.Compliance with standards……………………………………………………………..4
3.Purpose ……………………………………………………………………………..……5
4.Technical data……………………………………………………………..……………..5
5.Conditions of use…………………………………………………………………………6
6.Budowa…………………………………………………………………………………….7
7.Device identification…………………………………………………………….…………...13
8.Protection against corrosion…………………………………..………………………..14
9. Installation, operation and maintenance manual …………….…………………….14
10. Identification of threats caused by the product during its exploitation……………16
11.Storage conditions……………………………………………………………………...17
12.Transportation………………………………………………………..…………………17
13.List of parts………………………………………………………………………….….. 17
14.Additional equipment…………………………………………………………………....18
15.Product disposal…………………………………………………….…………………...18
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OPERATION MANUAL 15/GP-Ex-02/2 3/18

1.List of drawings.

No. Drawing description Drawing no. Number of Format

sheets

1. Internal connections diagram- 15/GP-Ex-02/E01 1 A4

WAZ-1/*/1 switch
Internal connections diagram
2. 15/GP-Ex-02/E02 1 A4
WAZ-1/*/2 switch
3. Internal connections diagram- 15/GP-Ex-02/E03 1 A4
WAZ-1/*/3 switch
4. Internal connections diagram- 15/GP-Ex-02/E04 1 A4
WAZ-1/*/4 switch
5. Internal connections diagram- 15/GP-Ex-02/E05 1 A4
WAZ-1/*/5 switch
6. Internal connections diagram- 15/GP-Ex-02/E06 1 A4
WAZ-2/*/1 and WAZ-3/*/1 switch
7. Internal connections diagram- 15/GP-Ex-02/E07 1 A4
WAZ-2/*/2 and WAZ-3/*/2 switch
8. Internal connections diagram- 15/GP-Ex-02/E08 1 A4
WAZ-2/*/3 and WAZ-3/*/3 switch
9. Internal connections diagram- 15/GP-Ex-02/E09 1 A4
WAZ-2/*/4 and WAZ-3/*/4 switch
10. Internal connections diagram- 15/GP-Ex-02/E10 1 A4
WAZ-2/*/5 and WAZ-3/*/5 switch
11. Cable glands layout 15/GP-Ex-02/M01 1 A4

General view of
12. WAZ-1/*/* switch with LED diode and 15/GP-Ex-02/M02 1 A4
PS button sealing
General view of
13. 15/GP-Ex-02/M03 1 A4
WAZ-2/*/* switch
General view of
14. 15/GP-Ex-02/M04 1 A4
WAZ-3/*/* switch
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OPERATION MANUAL 15/GP-Ex-02/2 4/18

2.Compliance with standards.

Labor protection in mining.
PN-G-50000:2002 - Mining machines and devices.
General safety and ergonomy
requirements.
PN-G-50006:1997 - Labor protection in mining.
Mining automation and
telecommunication devices.
Requirements and tests.
PN-EN-50303:2004 - Devices of group I category M1 intended
for constant operation in atmospheres
threatened with methane and/or coal dust.
PN-EN 60079-0:2013-03 - Electrical devices in gas explosive
/A11:2014-03 atmospheres. Part 0:
General requirements
PN-EN 60079-11:2012 - Explosive atmospheres – Part 11:
Protection of devices through
intrinsic safety “I”
PN-EN-60529:2003 - IP ratings guaranteed by housings.

WAZ-*/*/* type emergency switches meet the requirements pf harmonized standards with
The Directive of the European Union 2014/34/EU introduced by The Regulation of the
Minister of Education of 9 June 2016 (Journal of Laws of 2016 item
817) . They were designed in accordance with rules of good engineering practice in the
safety field.
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OPERATION MANUAL 15/GP-Ex-02/2 5/18

3. Purpose
WAZ-*/*/* type emergency switches are designed for emergency stopping of machines
and devices. They can also be used as limit switches, road switches, detectors of
proper run of a belt conveyor and signal transmitters in, e.g. shaft signaling systems.
Depending on the design, they are equipped in pull rods or a drive lever. The switches
are designed to work in underground excavations of mining facilities with methane
and/or coal dust explosion threat and on a surface, within areas including zones 0, 1
and 2 with explosion threats of mixtures gases and fumes of flammable liquids with air.
They are designed for work in intrinsically safe electrical circuits (ia or Ib).
4.Technical data
4.1. Below, there are technical data of safety switches designed to be used in
underground excavations of mining facilities with methane and/or coal dust explosion
threat and on a surface, within areas including zones 0, 1 and 2 with explosion threats
of mixtures gases and fumes of flammable liquids with air.

Single circuit voltage Ui1 60VDC

Current Ii 3A
Inductivity Li 0H
Capacity Ci 0F
Maximum number of contacts to be used 2 pcs. of make contacts and 2
depending on design of the switch pcs. of break contacts or 1 to 4
pcs. of change-over contacts
1 pc. of signaling button contact
Also other combination of
contacts is possible.

Voltage Ui2 (for LED signaling 30 VDC

diodes supply circuit)
Current Ii (for LED signaling diodes supply circuit) 3A

Inductivity Li (for LED signaling diodes 0H

supply circuit)
Capacity Ci (for LED signaling diodes 0F
supply circuit)
Force required to trigger
WAZ-1/1/* and WAZ-1/2/* type switches 40 ÷300 N
Diameters of the introduced cables or wires
from 4 mm to 26 mm
Cross section of conductors of cables or wires from 0,35mm2 to 2,5 mm2
Maximum number of cable fittings 4 pcs.
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OPERATION MANUAL PAGE

15/GP-Ex-02/2 6/18
Explosion proof housing label and ATEX
certificate number
l M1 Ex ia I Ma
II 1G Ex ia IIC T6 Ga
CE mark and CE notifying body no. FTZU 10 ATEX 0080

Ambient temperature 1026

Relative humidity 253 ÷ 313 K (-20ºC÷40ºC)
Weight 93±3%
IP protection class app. 4 kg
IP65

Note: In WAZ-*/*/* emergency switches intended for operation in 0, 1 and 2

atmospheres threatened with explosion of mixtures of gases and vapors of
flammable liquids with air ( II 1G Ex ia IIC T6 Ga), cable fittings made of metal only
are used.

5.Conditions of use.
1. Intrinsically safe circuits with “ia” and/or ”ib” safety levels can be connected to
terminal strip clamps of Ex ia design WAZ-*/*/* switches.

- For WAZ-1/*/1 design – equipped with two make contacts (2Z) and two break
contacts (2R), LED diode and signaling button on clamps: X1,X2 ; X3,X4 ; X5,X6 ;
X11,X12 galvanically separated circuits with parameters Ui1=60 VDC or 25 VAC can
be connected; Ii=3 A DC/AC .On clamps X7,X8 ; X9,X10 galvanically separated
circuits with parameters Ui2=30 VDC/AC ; Ii=3 A DC/AC can be connected.

- For WAZ-1/*/2 design - equipped with two make contacts (2Z) and two break
contacts (2R), LED diode on clamps: X1,X2 ; X3,X4 ; X5,X6 ; X11,X12 galvanically
separated circuits with parameters Ui1=60 VDC or 25 VAC ; Ii=3 A DC/AC can be
connected . On clamps X7,X8 ; X9,X10 galvanically separated circuits with parameters
Ui2=30 VDC/AC ; Ii=3 A DC/AC can be connected.

- For WAZ-1/*/3 design - equipped with two make contacts (2Z) and two break
contacts (2R) and signaling button on clamps: X1,X2 ; X3,X4 ; X5,X6 ;
X7,X8 ; X9,X10; X11,X12 galvanically separated circuits with parameters
Ui1=60 VDC or 25 VAC ; Ii1=3 A DC/AC can be connected.

- For WAZ-1/*/4 design - equipped with two make contacts

(2Z) and two break contacts (2R) on clamps: X1,X2 ; X3,X4 ; X5,X6 ; X7,X8 ;
X9,X10,X11,X12 galvanically separated circuits with parameters Ui1=60 VDC or 25
VAC ; I1i=3 A DC/AC can be connected.

- For WAZ-1/*/5 design - equipped with four change-over contacts on clamps: X1, X2,
X3 ; X4, X5, X6 ; X7, X8, X9 ;,X10, X11, X12 galvanically separated circuits with
parameters Ui1=60 VDC or 25 VAC ; Ii1=3 A DC/AC can be connected.
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OPERATION MANUAL 15/GP-Ex-02/2 7/18
- For WAZ-2/*/1 and WAZ-3/*/1 design – equipped with one change-over contact on
clamps X1, X2, X3 ; X4, X5, X6 ; X7, X8, X9 ;,X10, X11, X12 galvanically separated
circuits with parameters Ui1=60 VDC or 25 VAC ; Ii1=3 A DC/AC can be connected.

- For WAZ-2/*/2 and WAZ-3/*/2 design - equipped with two change-over contacts on
clamps: X1, X2, X3; X4 , X5, X6 ; X7 ; X8 ; X9 ; X10 ; X11; X12 galvanically separated
circuits with parameters Ui1=60 VDC or 25 VAC ; I1=3 A DC/AC can be connected.

- For WAZ-2/*/3 and WAZ-3/*/3 design - equipped with three change-over contacts
on clamps: X1, X2, X3 ; X4, X5 , X6 ; X7, X8, X9 ; X10 ; X11; X12 galvanically
separated circuits with parameters Ui1=60 VDC or 25 VAC ; Ii1=3 A DC/AC can be
connected.

- For WAZ-2/*/4 and WAZ-3/*/4 design - equipped with four change-over contacts on
clamps: X1, X2, X3 ; X4, X5, X6 ; X7, X8, X9 ;,X10, X11, X12 galvanically separated
circuits with parameters Ui1=60 VDC or 25 VAC ; Ii1=3 A DC/AC can be connected.

- For WAZ-2/*/5 and WAZ-3/*/5 design - equipped with two make contacts (2Z) and
two break contacts (2R), LED diode on clamps: X1,X2 ; X3,X4 ; X5,X6 ; X11,X12
galvanically separated circuits with parameters Ui1=60 VDC or 25 VAC ; Ii1=3 A DC/AC
can be connected. On clamps ; X7,X8 ;X9,X10 galvanically separated circuits with
parameters Ui2=30 VDC/AC ; Ii=3 A DC/AC can be connected.

2 . In case when the explosive atmosphere threshold is reached, the intrinsic safe circuits
with IP levels of “ib” shall be switched off in accordance to regulations in force.
3. Ambient temperature -20ºC÷40ºC,
4. Relative humidity at ambient temperature of 93±3%.

6.Design.
6.1.General description.
A case made of antistatic and inflammable plastic was used as housing for WAZ-*/*/*
switches. This housing consists of a body, cover, activating button and pull rod guides.
The cover is affixed to the body with the use of four M6 Allen screws. This cover
includes a rubber seal guaranteeing a required level of protection against dust and
water – IP65. The case includes a mechanical assembly cooperating with external pull
rods or a drive lever and a block of micro-switches with a terminal strip. The following
labels of emergency switches were accepted:
WAZ-*/*/*
where : WAZ is an Emergency Switch
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OPERATION MANUAL 15/GP-Ex-02/2 8/18

whereas */*/* is, respectively :

1/*/* design with pull rods (line)

1/1/* design with pull rods (line) with emergency line tension control
1/2/* design with pull rods (line) with emergency line tension control
1/*/1 equipped with two make contacts (2Z), two break contacts (2R), LED diode,
signaling button
1/*/2 equipped with two make contacts (2Z), two break contacts (2R),
LED signaling diode, without signaling button.
1/*/3 equipped with two make contacts (2Z), two break contacts (2R),
signaling button, without LED signaling diode.
1/*/4 equipped with two make contacts (2Z), two break contacts (2R), without
signaling button, without LED signaling diode.
1/*/5 equipped with four change-over contacts (4P), without signaling button,
without LED signaling diode.
1/*/6 special design, with different configuration of contacts and signaling
elements

2/*/* design with drive lever

2/1/* design with drive lever with stable position
2/2/* design with drive lever without stable position
2/*/1 equipped with one change-over contact
2/*/2 equipped with two change-over contacts
2/*/3 equipped with three change-over contacts
2/*/4 equipped with four change-over contacts
2/*/5 equipped with two break contacts, two make contacts and LED diode.
2/*/6 special design, with different configuration of contacts and signaling
elements .

3/*/* design with drive lever and rotational bushing

3/1/* design with drive lever and rotational bushing with stable position
3/2/* design with drive lever and rotational bushing without stable position
3/*/1 equipped with one change-over contact
3/*/2 equipped with two change-over contacts
3/*/3 equipped with three change-over contacts
3/*/4 equipped with four change-over contacts
3/*/ 5 equipped with two break contacts, two make contacts and LED diode.
3/*/6 special design, with different configuration of contacts and signaling
elements .
Introduction of special design with other configuration of contacts on a terminal strip and
different signaling system of triggering switch on LED diodes will be presented on a
diagram included in the Operation Manual attached to each device provided to the Client.
Values of voltages Ui, currents li and also parameters L1 and Ci on clamps of
terminal strip for a given switch design will be displayed on an additional device
rating plate.
WAZ switches with “WZ” label on the end of the symbol (WAZ-*/*/*/WZ) – are
switches with pull rods made of 4H13 stainless steel.
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OPERATION MANUAL 15/GP-Ex-02/2 9/18

6.2. WAZ-1/*/* Emergency switches

In this design of switches, a mechanical assembly cooperating with pull rods was
applied. These pull rods are generally purposed for connection with an emergency
line. In WAZ-1/1/* design, mechanical assembly, due to its structure, controls level of
line tension, whereas the emergency switch in WAZ-1/2/* design does not control
tension of the emergency line. Both designs of switches can be equipped with lever
switches enabling using 2 make contacts (2Z), 2 brake contacts (2R) or 4 change-
over contacts. Optionally, WAZ-1/*/* switches can be equipped with LED diodes
(maximum 2 pieces) signaling switch triggering state and signaling button
cooperating, e.g. with an external acoustic or optical signaling system.
Terminal strip includes 12 clamps. These clamps enable to connect cables or wires to
a cross-section from mm2 to 2,5 mm2. Cable fittings or glands were applied in order to
enter the cables. They enable to gland the cables with diameters from 4 mm to 26
mm. IP protection class of fittings equals at least IP65.
Switches made in this design are used mainly as line emergency switches in control
and automation systems of belt conveyors, scraper conveyors and also on tracks of
other types of underground and surface transportation. These switches can be made
with pull rods acting with a force of 40 to 300 N. In order to identify the switch design,
value of this force will be displayed on the additional plate affixed inside the housing.
6.3. WAZ-2/*/* and WAZ-3/*/* emergency switches
Switches in this design are equipped with mechanical assembly cooperating with a
drive lever. They are purposed mainly for controlling locations of elements of
machines and devices. They can also be used in signaling systems, e.g. shaft
signaling as transmitters. Depending on the design, lever can be ended up with a
roller made of steel, plastic or hard rubber. In design WAZ-2/1/*, lever mechanical
system enables a stable position after its inclination, whereas the emergency switch in
design WAZ-2/2/*, it is equipped with unstable drive lever – after it is inclined, it
returns to its original position In design WAZ-3/1/* and WAZ-3/2/* purposed for
application of this switch in order to control the belt run, the lever is equipped with
bearing rotation bushing. WAZ-3/1/* includes a drive lever which, after being inclined,
remains in this position, whereas WAZ-3/2/* includes unstable drive lever – after it is
inclined, it returns to its original position. All designs of switches an be equipped with
blocks of lever switches enabling application of 1 to 4 change-over contacts or a set of
2 break contacts, 2 make contacts and LED diode. Terminal strip always includes 12
clamps independently on the used switches. In case of less than four switches, the
remaining clamps of the strip can be used to connect other circuits with parameters
not exceeding the values given in application conditions. The clamps enable to
connect connectors of wires or cables with cross-sections of 0,35 mm2 to 2,5 mm2.
Cables and wires are introduced through cable fittings or glands. They enable
glanding cables with diameters of 4 to 26 mm. IP protection class of fittings and
glands equals at least IP65.
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OPERATION MANUAL 15/GP-Ex-02/2 10/18

6.4.Electrical equipment.
Microswitches – limit switches (S1 to S4) were used as switches in emergency switches
for switching electrical circuits. They are coupled depending on the design of a switch
with deactivating or deactivating-locking mechanism cooperating with pull rods or drive
lever. The maximum number microswitches equals four pieces.
In WAZ-1/*/* emergency switch, microswitches with curved lever were used. Whereas in
WAZ-2/*/* and WAZ-3/*/* emergency switches, a design was used with a lever
equipped with roller.

Contacts of these connectors are introduced to a terminal strip in accordance with

diagrams on fig. 15/GP-Ex-02/E01 to 15/GP-Ex-02/E10. Housings of connectors are
made of thermoplastic with CTI>175 indicator.

In order to signalize triggering state of WAZ-*/*/* switches, maximum 2 pieces of

optional LED diodes were envisaged (V), each connected with layered resistors with a
resistance of 1,8 kΩ ; 1 W (R). The diode is placed in a metal fitting and affixed to the
upper and side walls of the switch housing. Required protection class IP65 of the
diode body is executed due to the use of rubber seal. The resistor is soldered to a
wire connecting diode with a terminal strip and covered with heat shrink tubing with
insulation min. 0.4 mm or is located in the diode body.
A covered signaling button (PS) can be used as the additional equipment in WAZ-1/*/*
switches. It is located in a side wall of the switch housing and also sealed with a
rubber seal.
In WAZ-*/*/* switches, assembly of transmitters for identification of locks (coders), e.g.
of type NIB-E, NI/a or FB064.1 and FB064.2 is used. These elements have
intrinsically safe design confirmed by ATEX certificate and will be assembled in
switches according to their application conditions given in certificates

6.5.Cable fittings
Arrangement of cable fittings within the housing is shown in fig. 15/GP-Ex-02/M01.
WAZ-*/*/* switches can be equipped with a maximum of 4 pieces of fittings or glands
of protection class against penetration of dust and water not lower than IP65. Their
number, layout and type are established each time in accordance with customer’s
requirements. The example of a list with fittings and glands purpose to be used in
switches is included in Table 1.
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OPERATION MANUAL 15/GP-Ex-02/2 11/18
.

Table 1

Fitting/gland type Average cable

diameter /mm/
Manufactur
Final
er
/Supplier Plastic metal dimension
Housing /mm/
protecti with PG With metric From to
with PG With metric
on class thread thread
thread thread
MDW 9 5,5 8,7 17
MDW 16M 5,5 9,5 18
DP 11 6 9 22
MDW 11 6,5 10,5 20
MDW 20M 8,5 13
22
MDW 13 8,5 13,5
DP 13 9 12
24
IP65 MDW 16 10,5 15
DP 16 11 14
27
MDW 25M 12 17
MDW 21 13,5 19 30
DP 21 14 18 32
MDW 32M 15 22 35
ERGOM
MDW 29 38
18 25
DP 29 41
DW 9 R DW 16 RM 5 8 19
MDW 9N 5 10 18
DW 11 R 6 10 22
MDW 11N MDW 16NM 7 11,5 20
DW 13 R DW 20 RM 8 13
24
IP66 MDW 13N MDW 20NM 8 15
DW 16 R 10 15 26
DW 21 R DW 25 RM 13 19 32
MDW 21N MDW 25NM 13 20 32
DW 29 R DW 32 RM 17 25 41
MDW 29N MDW 32NM 18 25,5 38
CARBO- WKM/P11 WKM/M20 5 11 22
AUTOMATI
WKM/
ON IP66 WKM/M22 7 13 24
P13,5
TECHNOLO
GY WKM/P16 WKM/M24 9 15 30
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OPERATION MANUAL 15/GP-Ex-02/2 12/18

Fitting/gland type Average cable

diameter /mm/ Final
Plastic metal dimension
od do /mm/
with PG With metric with PG With metric
Manufactur Housing thread
er protecti thread thread thread
/Supplier on class WKM/P21 WKM/M28 15 21 36
WKM/P29 WKM/M36 18 28 41
EX1100. EX1100.
5 6,5 15
07.065 12.065
EX1100.
21
11.085
AGRO No. 5,5 8,5
E1540. 24
11.085
EX1100.
18
17.080
AGRO No. AGRO No.
E1540. E1540. 21
09.080 17.080
EX1100. EX1100.
24
13.080 20.080 6 8
AGRO No. AGRO No.
E1540. E1540.
13.080 20.080
27
AGRO No.
E1540.
16.080
EX1100. EX1100.
6,5 8 15
ASTAT IP68 07.080 12.080
EX1100. EX1100.
24
16.110 20.110
AGRO No. AGRO No.
E1540. E1540. 27
8 11
13.110 20.110
AGRO No.
E1540. 27
16.110
EX1100. EX1100.
30
21.125 25.125
9,5 12,5
AGRO No. AGRO No.
E1540. E1540 34
21.125 25.125
EX1100. EX1100.
30
21.160 25.160
AGRO No. AGRO No. 12,5 16
E1540. E1571. 34
25.160 25.160
EX1100.
14 17 36
32.170
AGRO No. AGRO No.
E1540. E1540 16 19 34
21.190 .25.190
EX1100.
16 19 38
29.190
EX1100.
17 21 36
ASTAT IP68 32.210
AGRO No. AGRO No.
E1540. E1540. 19 20,5 34
21.205 25.205
EX1100.
19 23 38
29.230
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OPERATION MANUAL 15/GP-Ex-02/2 13/18

Fitting/gland type Average cable

diameter /mm/ Final
Plastic metal dimension
with PG z gwintem z gwintem od do /mm/
Manufactur Housing thread metr. metr.
er protecti with PG thread
/Supplier on class AGRO No.
E1540. 19,5 21 41
29.210
AGRO No.
E1540. 20 21 41
32.210
EX1100.
40.240 20 24 46

AGRO No.
E1540. 21 22 41
32.220
AGRO No.
E1540.
21 23 41
29.230

EX1100.
EX1100 21,5 26 50
36.260
AGRO No.
E1540. 22 23 41
32.230
AGRO No. AGRO No.
E1540. E1540.
23 25 41
29.250 32.255

IP67 TV-M16/y 4 9 20
TV-M20/y 8 12 24
TV-M25/y 10 16 30
TV-M32/y 12 20 36
TV-M40/y 16 26 46
TV 11/y
5,5 9 22
TVM 11/y
SEZ TV 13,5/y
TVM
8 12 24
13,5/y

TV 16/y 8 12
IP68 27
TVM 16/y 12 16
TV 21/y 9 13
32
TVM 21/y 15 19
TV 29/y 15 19
41
TVM 29/y 21 25
Note: In WAZ-*/*/* emergency switches intended for operation in 0, 1 and 2
atmospheres threatened with explosion of mixtures of gases and vapors of flammable
liquids with air ( II 1G Ex ia IIC T6 Ga), cable fittings made of metal only are used
7.Device identification.
7.1.Labelling.
All the emergency switches have to include a rating plate made of brass or stainless steel
affixed to the upper wall of the housing body displaying the following data (table 2) at
minimum. In case of special design, the device has to additionally include a plate with
intrinsic safety parameters. Moreover, on the internal wall of the device there has to be a
plate or a sticker attached with designation of triggering force of the switch pull bars – it
applies only to WAZ-1/*/*.
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OPERATION MANUAL 15/GP-Ex-02/2 14/18

Table 2:

„GUMOPLAST” s. c.
Manufacturer’s name (shortened) Puńców, ul .Cieszńska 185
43-400 Cieszyn
Device type and design WAZ- */*/*
Factory number ..001….......
Year of manufacture 2015….......
Housing protection class IP65
Weight 4 kg………..
Parameters of circuits (ia)
Ui1 60V
Ui2 30 V
Ii 3A
L i: 0H
Ci 0F
Other parameters in operation manual

I M1 Ex ia I Ma
Designation of the explosion protection type II 1G Ex ia IIC T6 Ga
FTZU 10ATEX 0080

CE sign and number of the notified body

1026
supervising the production process
7.2.Labeling – ordering method:
Example of an order:
WAZ-1/2/3 type emergency switch.
Equipped with two fittings for ø 15 mm cable in the lower wall of the housing and
one fitting for ø10 mm cable in the right wall of the housing.
Amount -12 pieces
The orders shall be made to the following address:
„GUMOPLAST” s. c.
Wiesław Kowalski, Radosław Kowalski, Łukasz Kowalski
Puńców, Ul. Cieszyńska 185
43-400 Cieszyn
Tel/fax : (33) 8529 663
E-mail: gumoplast@gumoplast.net

8.Protection against corrosion.

All metal elements of the equipment of switches which can be corroded, are protected by
electrogalvanizing or covering with a varnish layer.
9. Installation, operation and maintenance manual.
10.1.Installation.
Emergency switches are intended for use in underground mining excavations with a
methane and/or coal dust explosion threat and on a surface, in areas including zones
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OPERATION MANUAL 15/GP-Ex-02/2 15/18

0, 1 and 2 with explosion threats of mixtures gases and fumes of flammable liquids with
air. Body of the switch shall be affixed with the use of four M8 screws to a previously
prepared structure. In a situation when there is a threat of dripping water in a place of
installation of the switch, a proper roofing shall be applied. Depending on the switch
design, it can be used as a line emergency switch in control and automation systems of
belt and scraper conveyors and also for cooperation with control and signaling systems
on tracks of another underground transportation devices (WAZ- 1/*/* ) or used to control
location of elements of machines and devices (WAZ- 2/*/* or WAZ-3/*/*).
These switches can also be used in, e.g. shaft signaling systems as signal transmitters.
Depending on the design, lever can be equipped with a roller made of steel, plastic or
hard rubber. In order to use the switch for controlling the belt run (WAZ-3/1/* or WAZ-
3/2/*), the lever is equipped with bearing rotational bushing cooperating with the
conveyor belt.
Pull rods of WAZ-1/2/* switch (design without line tension control) intended for use in
control systems of belt and scraper conveyors and other underground transportation
devices, are connected with the use of a steel line with pull rods of the cooperating
emergency switches. In order to splice the line, appropriate thimbles and clamps shall be
used.
In case of using WAZ-1/1/* switches (design with line tension control), the emergency line
shall be initially tensioned in such way that their pull rods are protruded towards medium
position. In order to regulate initial line tension, turnbuckles shall be used. For this switch
design, it is possible to anchor the second end of the line in a fixed structure – e.g.
housing element, by using a spring supplied by the manufacturer.

9.2. Operation and diagnostics.

Due to the function of emergency switches, their proper operation is highly important. It is
forbidden to carry out any rough mechanical and electronic assembly. After the switch is
installed, check whether electrical connections are made properly, emergency line are
properly spliced and tensioned, and in case of using switches equipped with a drive lever,
check a proper location of the moving element of the controlled device or machine in
relation to the drive lever. A trial start-up of the control system can be executed only after
making sure that all of the aforementioned actions were carried out properly.
9.3.Repairs and adjustments.
Maintenance of the device consists in periodic control of the condition of electrical
connections, checking operation of the mechanical system and removal of contamination.
Electrical defects shall be removed according to the supplied operation manual taking
type of interference and symptoms into account. In case of mechanical defects, the only
allowable action is to fill the grease in the switch mechanical assembly. The user can only
replace these elements and sub-assemblies which are included in the spare parts list in
the Operation Manual.
A full range of repairs and overhauls can be carried out only by the manufacturer.
9.4. Execution of surveys.
In order to guarantee the proper operation of the emergency switch, the device shall be
periodically surveyed.
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Such survey shall include visual inspection of:

- external condition of the device,
- proper fixation and stuffing of wires with consideration to their protection
against mechanical damages,
- tightening of fixing screws and nuts,
- elimination of contamination and control of connections on connectors,
- control of wires and cables with consideration to mechanical damages,
- control of insulation condition of work connectors,
- proper operation of pull rods or drive lever of the switch,
- proper splicing and tensioning of the emergency line,

9.5. Limitations of application.

Do not use the emergency switches in ambient temperature and relative humidity other
than set out in technical data!
Do not connect clamps with circuits with voltages and current values higher than values
set out in technical data and conditions of use!
Do not connect circuits of protection levels other than “Ia” or “ib” within the switch.
In case of reaching the explosive atmosphere threshold according to the regulations in
force, the intrinsically safe circuits with “ib” protection levels shall be switched off.
Non-compliance with the aforementioned notes will lower the explosion safety level!

10. Identification of threats caused by the product during its

exploitation.
10.1.Introduction.
In order to meet the requirements and technical conditions set out by the customer, the
emergency switches can be equipped with pull rods or drive lever, LED signaling diode,
signaling button and various number of microswitches and cable fittings. As a result of
this, switches of various designs will be exploited. Due to relatively simple structure of
the device, all designs are included in a common operation manual. As the switches can
operate in various control and automation systems, one shall read the operation manual
of the whole system before commencing any repair.

! WARNING

Prior to executing any repair or maintenance of switches, read the

Operation Manual thoroughly. Also read the operation manual of the
system in which the switches operate.

Information contained in the Operation Manual are fully sufficient to execute a proper
repair or maintenance. However, the User shall guarantee that the persons carrying out
these actions are trained within the scope of explosion and intrinsically safe devices.
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10.2.Safety measures.
In case of maintenance and repair of the emergency switches, prior to execution of
works, one should read documentation of all the system and follow the regulations in
force.
During a repair, only elements which are included in the spare parts list of the Operation
Manual can be replaced.

! WARNING

Modification of the device or using spare parts which does

not meet technical conditions of the manufacturer can lead to
serious danger or loss of warranty.

10.3.Threats during exploitation.

Do not start the device or machine directly after installing emergency switches
without prior verification of circuits in which these switches were included.

! WARNING
After installation of emergency switches in the particular system, check whether
connections and mechanical assembly are made properly.

11.Storage conditions.
WAZ-*/*/* type emergency switches shall be stored in closed warehouse
compartments in an atmosphere free of aggressive fumes and dust in temperatures 278
÷ 313K (+5ºC ÷ +40ºC) and relative humidity of up to 75%. The device shall be packed
in a bubble wrap or corrugated cardboard.
12.Transportation.
The switches shall be transported by covered means of transportation in a factory
package within temperatures 253 ÷ 313K (-20ºC ÷ +40ºC). During transportation, the
load shall be protected against shifting.

13. List of parts

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OPERATION MANUAL 15/GP-Ex-02/2 18/18

Manufacturer/
No. Part name Remarks
Distributor
1 Assembly of microswitches GUMOPLAST
Number of
microswitches
depending on the
switch design
WAZ-*/*/*
(from 1pcs 4 pcs.).
According to
ASTAT(AGRO),SEZ, List in the
2 Cable fittings or glands Carboautomatyka description
Signaling diode assembly
LED with metal fitting
(nickeled brass) and layered
resistor 1.8 kΩ According to
3 ;1 W GUMOPLAST documentation
Terminal strip - Material:
12-rail threaded connector, type polyamide
TLZ-4 or PLZ-4 SE ”Pokój” or PA 6, PA
4 LTA 12-4.0 or LTV 12-4 „Simet” 66,CTI=600
5 Housing seal GUMOPLAST
6 Signaling button GUMOPLAST
14.Additional equipment.

Manufacturer/
No. Part name Remarks
supplier
1. Tensioning spring GUMOPLAST Amount depending on installation
conditions
2 Thimbles GUMOPLAST
1 piece per each line fixing
2.
Line clamp GUMOPLAST 1 piece per each line fixing (double)
or 2 pieces (single)
3. Turnbuckle GUMOPLAST 1 piece per one line section
4. Number depending on
Zinc coated steel line or GUMOPLAST Installation conditions
covered with red PVC
5. Spring connector GUMOPLAST 1 piece per one tensioning spring

15.Product disposal.
Packages and used devices shall be stored or disposed in accordance with valid
guidelines and requirements set out in The Waste Act of 27.04.2001 (Journal of Laws
2001, no. 62, item 628) as amended.