KIEPE PRS001 Emergency Stop Switch

Brand: KIEPE Elektrik, Germany

Product Name: Bidirectional Pull-Rope Emergency Stop Switch / Conveyor Line Rope Pull Emergency Stop Switch

Order No.: 91.063293001

Product Series: PRS Pull-rope Emergency Stop Switch (Latching Pull-Rope E-Stop)

2. Model Definition

PRS = Pull Rope Switch

001: Base version, without built-in indicator lamp

Same series comparison:

PRS001: 2NC + 1SPDT (No Indicator)

PRS101: With 230 VAC indicator lamp

PRS102: With 24 VDC indicator lamp

3. Core Electrical Configuration

Contact Arrangement: 2 sets of positively opened normally closed contacts (2NC) + 1 set of changeover contact (1SPDT)

Safety Design: Positive Opening Contacts, Mechanical Latching Structure

Actuation Mode: Bidirectional rope actuation (triggered by pulling rope on either side)

Reset Method: Mechanically latched after tripping; manual reset via the blue reset lever

Tripping Force: 30 N ±10 N

Maximum permissible rope length per side: 50 m; total maximum rope length on both sides: 100 m

Cable Entries: 3 × M25×1.5 metric threaded cable glands

Acceptable conductor cross-section: Max. 2.5 mm²

4. Electrical Load Ratings

AC-15: 230 V / 1.5 A

DC-13: 24 V / 2 A

Rated insulation voltage Ui: 250 V

Mechanical service life: ≥ 200,000 operating cycles

Safety Performance Level: Up to PL d / SIL2 (subject to safety circuit architecture)

5. Mechanical & Environmental Specifications

Enclosure: Glass fibre reinforced PBT thermoplastic, yellow housing (RAL1004)

Red lever: Trip release lever

Blue lever: Manual reset lever

Ingress Protection: IP65 / IP67

Operating temperature: -25 ℃ ~ +70 ℃

Mounting: Two-point fixing with M6 bolts; maximum allowable mounting inclination ≤15°

Weight: Approx. 480 g

6. Compliant Standards

DIN EN 60947-5-5, EN ISO 13850, EN 620, BGI710, EN60204-1

Fully satisfies safety specifications for belt conveyors used in power plants, ports, metallurgy and cement industries.

7. Typical Application Scenarios

Long-distance belt conveyors, bucket elevators and bulk material handling production lines. Units are mounted along the conveyor frame, enabling operators to trigger emergency shutdown by pulling the wire rope at any position along the line.

8. Wiring Guidelines (Critical Safety Notes)
9. Route the two NC normally closed contacts in series for the emergency stop safety circuit (dual-channel safety circuit);
10. The SPDT changeover contact is generally used for fault alarm signalling;
11. The switch latches mechanically after actuation. Automatic reset is not possible. Manual reset is only permitted after hazard inspection and confirmation.
12. Wire rope installation must include tension springs, rope clamps and support hangers to prevent false tripping caused by slack wire rope.

Applicable Industries for KIEPE PRS001 Bidirectional Pull-Rope Emergency Stop Switch

PRS001 is a heavy-duty latching line-mounted emergency stop device complying with EN 620 & ISO 13850. Featuring IP67 protection and corrosion-resistant glass fibre reinforced housing, it is specially designed for safety protection on long-distance bulk material belt conveying systems, suitable for high-dust, outdoor humid and mildly corrosive environments.

1. Heavy Industry Bulk Material Conveying (Primary Application)
2. Thermal Power Plants

Coal handling belt conveyors, coal crushers, stacker-reclaimers, bucket elevators; standard safety equipment for coal conveyor galleries.

2. Cement & Building Materials Industry

Raw material conveyors, clinker production lines, limestone transport and aggregate yard belt conveyors.

3. Ports & Bulk Cargo Terminals

Belt conveyors for coal, ore and grain handling, ship loaders and yard stacker-reclaimer conveying lines; well adapted to outdoor high-humidity and salt spray environments.

4. Mining Industry (Open-pit Mines Only)

Long-distance belt conveyors for open-pit coal mines, sandstone mines and metal mines.

⚠️ Explosion-proof certified KIEPE TEX series is required for underground mining; PRS001 carries no Ex certification and cannot be deployed underground.

5. Iron & Steel / Metallurgical Plants

Sintering, pelletizing and blast furnace raw material conveyors, coke plant material handling systems; resistant to high temperature and dust conditions.

1. Chemical & Salt Resource Industries
2. Chemical & Fertilizer Plants

Belt conveyors for solid raw materials including urea and phosphate chemicals;

2. Potash Mines, Rock Salt Mines & Salt Lake Operations

A prioritized application field per manufacturer documentation. The housing provides good salt spray resistance for salt mine conveying lines.

III. Grain, Agriculture & Environmental Solid Waste Sectors

1. Grain Silos & Grain Processing Facilities

Grain transfer conveyors and bulk grain handling lines at terminals;

2. Waste-to-energy Plants, Recycling & Composting Facilities

Solid waste conveyors and refuse feeding belts, capable of operating under humid, dusty conditions.

1. Other General Conveying Applications

Large automated logistics parks and ore screening lines;

Aggregate quarries and fly ash conveying systems;

Bulk cargo handling equipment at inland river terminals.

✅ Suitable Equipment Types

Belt conveyors, bucket elevators, scraper conveyors, stacker-reclaimers, shuttle belts, tripper cars and other long-distance continuous conveying machinery.

⚠️ Application Restrictions (Key Selection Guidance)

1. PRS001 has no Ex explosion-proof certification. Deployment is prohibited in underground coal mines and workshops with flammable gas atmospheres. Select KIEPE TEX explosion-proof variants for hazardous areas.
2. Additional assessment of housing chemical resistance is required for environments with persistent strong acid corrosion.
3. Primarily intended for ground/outdoor conveying equipment; compact high-speed enclosed production lines should adopt conventional emergency stop pushbuttons instead.

Official Service Life of KIEPE PRS001 (91.063293001) — Parameters from Original Datasheet

1. Mechanical Service Life (Full Operating Cycle)

≥ 200,000 operating cycles

Definition: One full cycle consists of rope pull actuation followed by manual reset; covers the durability of internal latching cams, springs and operating levers.

2. Electrical Contact Life (B10d per Safety Standard EN ISO 13849: Cycle count where maximum 10% of units develop dangerous failure)

DC-13 duty (24 V DC / 2 A, most common for conveyor control circuits): B10d = 200,000 cycles

AC-15 duty (230 V AC / 1.5 A): B10d = 840,000 cycles

⚠️ B10d is a critical parameter for safety components, used for safety circuit calculation to achieve PL d / SIL2.

3. Reference Service Life in Practical Field Operation

Pull-rope emergency stop switches are safety backup devices and rarely triggered under normal operating conditions. Most conveyor installations record fewer than 10 actuations per year:

Standard environments (power plants, cement plants, ports): Reliable service life 8 ~ 12 years is common;

Severe duty conditions (heavy dust, continuous vibration, outdoor salt spray, extreme temperature cycling): Functional assessment recommended every 6 ~ 8 years;

Frequent manual pull testing is prohibited, as repeated operation accelerates mechanical and contact wear.

4. Key Factors Affecting Service Life
5. Rope tension: Excessively taut wire rope imposes continuous lateral load on the operating mechanism and accelerates pivot wear;
6. Dust and moisture ingress: Although rated IP67, long-term dust accumulation in pivot gaps increases friction;
7. Mechanical vibration: Severe vibration from belt conveyors causes fatigue of internal moving components;
8. Contact switching duty: Do not use the switch to interrupt high-power main circuits; only connect to control signal circuits.
9. Maintenance & Replacement Recommendations

Annual inspection: Visual check, seal integrity, rope tension and functional actuation test;

Plan spare replacement when total actuations approach 150,000 cycles OR service life reaches 8 years;

Immediately decommission and replace the switch if reset jamming or intermittent contact signals occur. Do not continue operation within safety circuits.