Related Manuals for Vahle VKL 2
Summary of Contents for Vahle VKL 2
- Page 1 TRANSLATION OF THE ORIGINAL GERMAN OPERATING INSTRUCTIONS VKL 2 COMPACT CONDUCTOR SYSTEM INSTALLATION MANUAL SYSTEM MANUAL MAINTENANCE MANUAL EN-V 1.07...
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Page 2: Table Of Contents
TABLE OF CONTENTS ............... . . General . - Page 3 TABLE OF CONTENTS ..........5.3.3 Determining the system lengths .
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Page 4: General
About these instructions These operating instructions describe the safe and efficient use of our VAHLE products. This document is part of the system and must be kept in its immediate vicinity so that it is accessible to operating and maintenance personnel at all times. -
Page 5: Symbols
GENERAL Symbols Safety instructions in this manual are identified by symbols. Each safety instruction begins with signal word that indicates the severity of the hazard. The various types of warnings and safety instructions and their struc- ture are explained below. DANGER! The source of the hazard is described here. -
Page 6: Copyright Protection
GENERAL NOTICE! This indicates a reference to another place in this text or another document. This combination of a symbol and a signal word indicates a reference to another place in this text or in a different document. ► The places in the text or references to other documents are identified here. TIPS AND RECOMMENDATIONS! ►... -
Page 7: Customer Service
• The buyer performs the assembly or repairs himself during the warranty period or has repairs performed by third parties. • If the product has been handled or maintained inappropriately. • Use of spare parts that are not genuine Vahle parts. • Failure to observe the information in this documentation. ... -
Page 8: Safety Instructions
SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS Safety This section gives an overview of all important safety aspects relating to the protection of personnel as well as the safe use and fault-free operation. Other, task-specific safety instructions can be found in the sections on the individual phases of the product's life. -
Page 9: Danger From Electrical Energy
SAFETY INSTRUCTIONS WARNING! Risk of death from improper replacement or removal! Errors during the removal or replacement of components may cause life-threatening situations or significant property damage ► Observe the safety instructions before beginning any removal work. 2.3.1 Danger from electrical energy Perform the following safety work acc. -
Page 10: Responsibilities Of The Operating Company
SAFETY INSTRUCTIONS Responsibilities of the operating company Definition of the operating company The owner is listed in the order confirmation and has the following owner obligations: Owner obligations The system is put to commercial use. The owner of the system is therefore subject to laws and regulations on workplace health and safety. -
Page 11: Personnel Requirements
SAFETY INSTRUCTIONS Personnel requirements 2.5.1 Qualifications The tasks described in this manual present various requirements to the qualifications of the persons perform- ing them. WARNING! Hazard in case of insufficient qualification of personnel! Insufficiently qualified persons are unable to judge the risks when working on the sys- tem, which puts them and others at risk if severe or fatal injuries. -
Page 12: Personal Protective Equipment
SAFETY INSTRUCTIONS Personal protective equipment Every person who is instructed to work on the system or in the vicinity of the system (support personnel) must wear personal protective clothing/equipment for the suitable type of their work. Personal protective equipment has the purpose of protecting personnel against hazards to their health and safety at work. The owner is re- sponsible to ensure that protective equipment is worn. -
Page 13: Safety Devices
SAFETY INSTRUCTIONS Safety devices WARNING! Danger from non-functional safety devices! Non-functional or disabled safety devices cause a risk of severe injuries or even death. ► Before beginning any work, verify that all safety devices are functional and in- stalled properly. ►... -
Page 14: Signage
SAFETY INSTRUCTIONS Signage The following symbols and information signs may be in the work area. They apply to the immediate environ- ment of their location. DANGER! Danger of life due to electrical current! Contact with live parts can result in life-threating injuries. ►... -
Page 15: Technical Data
TECHNICAL DATA TECHNICAL DATA Technical specifications - electrical Nominal current VKL2/100C at 100 % active dura- tion Conductor cross section VKL2/100C [mm²] Resistance VKL2/100C [Ω / 1 0 0 0 m ] 0.721 Impedance* VKL2/100C [Ω / 1 0 0 0 m ] 0.732 Nominal current VKL2/40F at 100% active dura- tion Conductor cross section VKL2/40F**... - Page 16 TECHNICAL DATA Technical specifications - system Length of expansion joint [mm] 1000 Length-effective portion of connectors [mm/side] 0.7 Tolerances Conductor system X-axis: [mm] ± 3 Conductor system Y-axis: [mm] ± 7 Conductor rail connectors Z-axis: [mm] 0.7 + 1 per side Current collectors X-axis: [mm] ±...
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Page 17: Layout And Function
LAYOUT AND FUNCTION LAYOUT AND FUNCTION System overview End segment ESM-VKL2 Conductor line VKL2 Transfer guide with/without fix point US-VKL2 Hanger AH-VKL2 Material of connectors VM-VKL2 ... -
Page 18: Arrangement Examples
LAYOUT AND FUNCTION 4.1.1 Arrangement examples Arrangement example 1 - hangers / connectors Connector Hanger Hanger Connector Hanger Hanger Connector * only applies if the connecting cap can be supported. For exposed connectors strictly adhere to the spacing of 150 mm Arrangement example 2 - Fixed end segment / sliding end segment Fixed end segment Conductor system... -
Page 19: Brief System Description
LAYOUT AND FUNCTION Brief system description The two-pole compact wiper line VKL2 was developed especially for various applications in intralogistics. With its compact dimensions and durability, the VKL2 possesses the ideal properties for potential shuttle applica- tions in automated small parts stores or for other transfer carriages. Additional features are short installation times due to the small number of different parts (–50%) and the robust clip fastening system. - Page 20 LAYOUT AND FUNCTION Feed terminals The infeed can be realized as an end feed via the transfer guides or on the line as a line feed. Transfer guides Transfer guides are the contact-protected ends of the conductor rails at the end of the lines and mechanical line interruptions (switches, dropout sections, etc.).
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Page 21: Assembly Overview
LAYOUT AND FUNCTION Assembly overview 4.3.1 Segment Segment Section Phase VKL2/100C-4000SSD ID no.: 0281542/00 VKL2/40F-4000SSD ID no.: 0281544/00 Net weight 110C: 2.406 kg Net weight 40F: 2.190 kg Delivery length: 4000 mm Suspension spacing: 800 mm Segment Section Phase + PE VKL2/100C-4000HSC ID no.: 0281534/00 VKL2/40F-4000SHSC... -
Page 22: End Segment
LAYOUT AND FUNCTION 4.3.3 End segment End segment Phase VKL2/100C-SSD ID no.: 0281510/00 VKL2/40F-SSD ID no.: 0281516/00 Net weight: 0.324 kg Delivery length: 1000 mm Segment Section Phase + PE VKL2/100C-HSC-R ID no.: 0281515/00 VKL2/100C-HSC-L ID no.: 0281518/00 VKL2/40F-HSC-R ID no.: 0281517/00 VKL2/40F-HSC-L ID no.: 0281519/00... -
Page 23: Expansion Joint
LAYOUT AND FUNCTION Hanger for 4-poles aplications Hanger 4-poles AH-VKL2-7 ID no:0281459/00 Net weight 0,015 kg 4.3.6 Expansion joint Expansion joint Phase DT-DVKL2/100C-SSD ID no.: 0281506/00 DT-DVKL2/40F-SSD ID no.: 0281508/00 Net weight: 0.279 kg Delivery length: 1000 mm Expansion joint Phase + PE DT-DVKL2/100C-HSC ID no.: 0281507/00 DT-DVKL2/40F-HSC... -
Page 24: Fixpoint Terminal
LAYOUT AND FUNCTION 4.3.8 Fixpoint terminal Fixpoint terminal ID no.: 0281527/00 Net weight: 0.020 kg NOTICE! ► Permissible for voltages up to 48 volts. 4.3.9 Collector Current collector D-EAS SA-DEAS-2/30-2-SS-2,5-0/2-2-PA (for controller) ID no.: 2823983/00-0 Net weight: 0.302 kg Current collector D-EAS SA-DEAS-2/30-2-HS-2,5-0/2-2-PA (for main current with PE) - Page 25 LAYOUT AND FUNCTION Current collector EASL SA-EASL-20-2-SS-0-2-PA-V.E. (For control current) ID no.: 2823982/00-0 Net weight: 0.098 kg Current collector EASL SA-EASL-20-2-HS-0-2-2-PA-V.E. (For main current with PE) ID no.: 2823997/00-0 Net weight: 0.098 kg NOTICE! ► Number of poles: 2. ►...
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Page 26: Connecting Cables
LAYOUT AND FUNCTION 4.3.10 Connecting cables Connecting cables, double insulated, highly flexible, AL-FLA2,5PH1-6,3 ID no.: 2809171 (Phase-black / (2.5 mm²/A=4.5mm) AL-FLA2,5PE1-6,3 ID no.: 2809175 (PE-green/yellow) / (2.5 mm²/A=4.5 mm) AL-FLA4PH2-6,3 ID no.: 2823085 (Phase-black) / (2.5 mm²/A=4.5 mm) AL-FLA4PE1-6,3 ID no.: 2823086 (PE-green/yellow) / (2.5 mm²/A=4.5 mm) Net weight:... - Page 27 LAYOUT AND FUNCTION Connecting cable, double insulated, flexible M6, 1 m Designation ID no.: Al-RKLA2,5PH1-M6 ID no.: 2808979 (2.5 mm²/A=4.5 mm) Al-RKLA2,5PE1-M6 ID no.: 2808978 (2.5 mm²/A=4.5 mm) Al-RKLA4PH1-M6-HL ID no.: 2808751 (4 mm²/A=5.3 mm) Al-RKLA4PE1-M6 ID no.: 2808752 (4 mm²/A=5.3 mm) Al-RKLA4PH1-M6 ID no.: 2808745...
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Page 28: Commissioning
COMMISSIONING COMMISSIONING Safety instructions for commissioning WARNING! Risk of injury in case of improper operation! Improper operation may result in serious injury or property damage. ► Observe the safety instructions from chapter “2 Safety instructions.” ► Are all acceptance reports available? (initial startup) ►... -
Page 29: Operation/Decommissioning
COMMISSIONING CAUTION! During installation work, there is risk of suffering crush injuries to the limbs in the ar- eas between the individual parts! During installation work, there is risk of suffering crush injuries to the limbs in the ar- eas between the individual parts. -
Page 30: Installation
COMMISSIONING Installation 5.3.1 Assembly preparation Tools and Measuring equipment The following devices, tools and measuring equipment are necessary for assembly of the conductor rails with accessories. • Suitable means of transport for bringing the conductor rail to the installation site (full-area support of the conductor rail). - Page 31 COMMISSIONING Assembly instructions Requirements: Clean and tidy workplace. Required tools: ⚒ Drill 4.5 mm Assembly instructions: 1. Determine position for the bore hole and fix in position. 2. Drill hole with 4.5 mm dia. Drill out mounting holes for holder Arrangement examples can be derived from the drilling patterns shown below.
- Page 32 COMMISSIONING End segment without fixpoint Assembly instructions Requirements: Clean and tidy workplace. Required tools: ⚒ Drill bit according to table below (4.6 mm - 4.9 Assembly instructions: 1. Determine position for the bore hole using the drilling template and fix in place. 2.
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Page 33: Installation Aids
COMMISSIONING 5.3.2 Installation aids Drilling template ID no.: 0281525 Net weight: 0.050 kg Assembly safety device ID no.: 0281526 Net weight: 0.050 kg Mounting handle ID no.: 2809348 Net weight: 0.010 kg Chop saw ID no.: 165276 Net weight: 6.500 kg Hexagon socket SW4 ID no.: 2812962... -
Page 34: Determining The System Lengths
COMMISSIONING 5.3.3 Determining the system lengths The conductor rail joints of the conductor system are manufactured with an air gap of 0.7mm +1mm. The pre- cise system length can therefore only be roughly calculated. Generally, every system should be designed with standard components. - Page 35 COMMISSIONING Possible system lengths with 0.7 mm air gap at joint Standard lengths Number of end seg- Number of straight Number of connectors [mm] ments sections 110019.60 114020.30 118021.00 122021.70 126022.40 130023.10 134023.80 138024.50 142025.20 146025.90 150026.60 ...
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Page 36: End Segment With Feed Terminal (Fixpoint)
COMMISSIONING 5.3.4 End segment with feed terminal (fixpoint) Step 1 Requirements: Clean and tidy workplace. Required tools: ⚒ ¼" reversible ratchet SW 7 Assembly instructions: 1. Mount the transfer guide to the carrier using the included screws with a tightening torque of 3 Nm. Step 2 Required tools: ⚒... - Page 37 COMMISSIONING Step 5 Assembly instructions: 1. Push the profile into the holder as illustrated 2. Check for firm seating. NOTICE! ► Make sure that the holders have properly snapped in place. CAUTION! During installation work, there is risk of suffering crush injuries to the limbs in the areas between the individual parts! During installation work, there is risk of suffering...
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Page 38: Transfer Guides
COMMISSIONING Step 7 Required tools: ⚒ Assembly safety device Assembly instructions: 1. Attach the assembly safety device to the transfer guide using a screw clamp (to relieve the fixpoint during connector installation). 5.3.5 Transfer guides NOTICE! ► One of the two transfer guides must be mounted as a fixpoint. -
Page 39: Line Material
COMMISSIONING 5.3.6 Line material Step 1 Requirements: Clean and tidy workplace. Required tools: ⚒ Mounting handle Assembly instructions: 1. Push the conductor rail connector into the open- ing of the mounting handle. Step 2 Required tools: ⚒ Mounting handle ⚒... - Page 40 COMMISSIONING Step 4 Assembly instructions: 1. Mount the next conductor line in the intended hanger as described in Chapter: „5.3.4 “. Step 5 Required tools: ⚒ Plastic hammer Assembly instructions: 1. Hammer the conductor lime up to the stop using the plastic hammer.
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Page 41: Renewing Conductor Rail Joints
COMMISSIONING 5.3.7 Renewing conductor rail joints Assembly/disassembly steps ⚒ Cutting tool ⚒ Deburring tool 1. Detach the conductor line from the rail holder so that it is possible to use the cut- ting tool. 2. Cut out the connection point. 3. -
Page 42: End Segment With End Cap (Sliding)
COMMISSIONING 5.3.8 End segment with end cap (sliding) Assembly instructions Requirements: Clean and tidy workplace. Required tools: ⚒ Screw driver PH1 Assembly steps: 1. Mount the connectors and connecting cap on the last section. 2. Clip the end segment into the hanger and connect the section. 3. - Page 43 COMMISSIONING CAUTION! ► To ensure smooth and impairment-free running of the current collectors/carbon brushes, the cut surfaces must always be carefully deburred. ► Shorter lengths may not be below 300 mm! Assembly instructions Requirements: Clean and tidy workplace. Required tools: ⚒...
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Page 44: Collector
COMMISSIONING 5.3.10 Collector Single collector assembly - EASL Assembly instructions Requirements: Clean and tidy workplace. Assembly steps: 1. Align the collector with the conductor line (phase center). NOTICE! ► Installation dimensions: 55 mm ► Suitable for funnel ► Number of poles: 2 ►... -
Page 45: Alternative Fixpoint
CAUTION! ► This type of fixpoint may only be used for systems with up to 48V AC/DC. ► For systems with higher voltages please contact Vahle in advance! Recess for fixpoint ... -
Page 46: Expansion Joints
COMMISSIONING Assembly instructions Requirements: Clean and tidy workplace. Required tools: ⚒ Tape measure ⚒ Drill Assembly steps: 1. Position the drilling device on the point of the conductor line where you intend to mount the fixpoint. NOTICE! ► Do not drill through the contact surface of the conductor rail! ►... - Page 47 COMMISSIONING Assembly instructions Requirements: Clean and tidy workplace. Assembly steps: 1. Before installing the expansion joint in the line, press the mounting clip into the expansion gap. 2. Mount the expansion joint in the intended line section as described in chapter: „5.3.9 “.
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Page 48: Line Feed
COMMISSIONING 5.3.13 Line feed NOTICE! ► Line feeds are always delivers pre-assembled and without connecting cable. ► Observe hanging distances. CAUTION! During installation work, there is risk of suffering crush injuries to the limbs in the ar- eas between the individual parts! During installation work, there is risk of suffering crush injuries to the limbs in the ar- eas between the individual parts. - Page 49 COMMISSIONING Step 1 Requirements: Clean and tidy workplace. Required tools: ⚒ Hexagon socket Assembly instructions: 1. Loosen the screws using a hexagon socket wrench Step 2 Assembly instructions: 1. Pull the two conductor line parts apart and re- move the connection terminals.
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Page 50: Condition After The Installation
COMMISSIONING Condition after the installation DANGER! An adequate grounding as per IEC 60204-1/ 60204-32 must be ensured after the in- stallation of the profile! WARNING! The responsible assembly manager must check the system for the following parts or situations after assembly and issue and sign an acceptance certificate! ►... -
Page 51: Malfunctions
MALFUNCTIONS MALFUNCTIONS Safety information about malfunctions WARNING! Risk of injury in case of improper troubleshooting! Improper troubleshooting may cause serious injuries or property damage. ► Ensure sufficient installation space before beginning any work. ► Switch off power supply, verify that the system is free of voltage, and secure against switching back on. -
Page 52: Maintenance
MAINTENANCE MAINTENANCE The purpose of these chapter is primarily to maintain the desired condition and to maintain the capacity of the system. By avoiding disturbances and unplanned downtimes, regular maintenance can increase the utilization rate. The prerequisite is an efficient planning of the maintenance work and the maintenance material. In order to be able to carry out a safe maintenance by suitably trained personnel, the following notes must be observed: DANGER! Danger of life due to electrical current! -
Page 53: Safety Information About Repairs
MAINTENANCE Safety information about repairs DANGER! Before beginning any work, ensure that the system is free of voltage and remains so for the duration of the work. Observe the safety instructions from chapter “Safety”! WARNING! Risk of injury in case of improperly executed maintenance! Improper maintenance may cause serious injuries or property damage. -
Page 54: Wear Parts
MAINTENANCE Wear parts Wear parts for current collector Type Description X=Residual height/ Weight in ID no. SK-EK-DEAS-2/30-PH-32-6.3-H Rear replacement 0.016 2808580 head SK-EK-DEAS-2/30-PH-32-6.3-V Front replacement 0.016 2808575 head SK-EK-EAS-20-PH-36-6.3-PA 0.014 2820750/00-PA ... -
Page 55: Conductor System Maintenance
MAINTENANCE Conductor system maintenance On transfer guides for track switches, the lifting station etc., the max. vertical and lateral offset of 3 mm must not be exceeded. The maximum air gap between the opposing transfer guides is 5 mm. Interval Service/monitoring tasks Personnel... -
Page 56: Current Collector Maintenance
MAINTENANCE Current collector maintenance Interval Service/monitoring tasks Personnel Daily • Check safety equipment and operating Operator behavior of the system. Monthly Mechanical checks Technician/elec- trically qualified • Check mobility of joints, bearings, and person hinge pins. Inspection for mechanical damage of any type. -
Page 57: Cleaning
After having been de-energized, the profiles can be cleaned with an industrial vacuum cleaner to remove loose dust or graphite deposits. Please consult VAHLE for information and intervals for intensive cleaning or wet cleaning. In this regard particularly observe the connector joints as well as the lane end position of the SRM/ carriage. -
Page 58: Transport And Storage
TRANSPORT AND STORAGE TRANSPORT AND STORAGE Safety instructions for transport and storage NOTICE! Damage due to improper transport or storage. Improper transport or storage may cause significant property damage! ► Storage temperature: 0 °C to +45 °C ► Storage location: Indoors, dry, no exposure to chemicals. ►... -
Page 59: Disassembly And Disposal
All accessories must be checked for wear. Only defect-free parts may be reused. ► Use only genuine VAHLE spare parts. Disposal At the end of the system's service life, the system must be disassembled and disposed of in an environmentally friendly manner according to local laws and regulations. -
Page 60: Eu Declaration Of Conformity
The safety hints mentioned in the product documentation must be followed. Kamen, 26.10.2017 Michael Heitmann Manager Mechanical Engineering Paul Vahle GmbH & Co. KG · Postfach 1720 · D-59172 Kamen · Tel. 02307/704-0 · Fax 02307/704-444 · eMail: info@vahle.de ... -
Page 61: Index
EU DECLARATION OF CONFORMITY INDEX About this manual 2 Application 17 Arrangement examples 16 barriers 7 Connectors 17 Current collectors 18 De-energize 7 Electrically qualified person 9 Expansions 17 Feed terminals 18 Grounding and shorting 7 Hangers 17 measuring equipment 28 Operating company 8 Operation 27 Owner obligations 8... - Page 62 EU DECLARATION OF CONFORMITY Verify absence of voltage 7 ...
- Page 63 Technical Documentation DQS - certified in accordance DIN EN ISO 9001:2008 OHSAS 18001:2007...