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Summary of Contents for Vahle System 1
- Page 1 TRANSLATION OF THE ORIGINAL GERMAN OPERATING INSTRUCTIONS BATTERY CHARGING CONTACTS SYSTEM MANUAL INSTALLATION MANUAL MAINTENANCE MANUAL EN V 1.01...
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Page 2: Table Of Contents
4.2.1 System 1 ............ - Page 3 TABLE OF CONTENTS ............Condition after the installation .
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Page 4: General
GENERAL GENERAL About these instructions 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. - Page 5 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! ►...
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Page 6: Copyright Protection
GENERAL Copyright protection The contents of this manual are protected by copyright. Their use is permitted within the scope of the use of the installation. No further use is permitted without the written permission of the manufacturer. This manual may not be copied, given to any third party, reproduced in any form or by any means, including, but not limited to, exploitation and / or communication of the contents without the written permission of the manufacturer, except for internal purposes. -
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: General Risks
SAFETY INSTRUCTIONS General risks The following section describes residual risks that arise even if the device is used as intended. Observe the safety instructions listed here in the other sections of these instructions to reduce the risk of injuries or dam- age to property and equipment and to avoid dangerous situations. -
Page 10: Responsibilities Of The Operating Company
SAFETY INSTRUCTIONS Cover adjacent, live parts or isolate them Before starting work, check whether it is appropriate to make adjacent parts voltage-free. DANGER! Danger of life due to electrical current! Contact with live parts can result in life-threating injuries. ► Make sure that the components are not live or in tension unauthorized approxima- tion. -
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 Voltage without ground conductor [V DC / V AC] 60 / 25 Current load max. at 100 % duty cycle [A] 600 Operating temperature [°C] - 30 to + 55 Operation in humid conditions [%] 98 Raising or lowering speed [m/s] 1... -
Page 16: Layout And Function
In places where waiting times occur for operational reasons, battery charging stations can be installed (e.g. in buffer sections, reversal points, stops, etc). Optimal spatial integration of the charging station into the overall system is an important aspect. VAHLE has developed special battery charging contacts to meet these require- ments. -
Page 17: Assembly Overview
LAYOUT AND FUNCTION Assembly overview 4.2.1 System 1 AGV current collector Type SA-BLS20-2O-01 ID no. 0590207/00 Number of poles Charging current 100 % duty cycle [A] 20 Weight [kg] 0.384 for frontal contact AGV floor contact Type BLK25-2-01 ID no. -
Page 18: System 3
LAYOUT AND FUNCTION 4.2.3 System 3 AGV current collector Type SA-BLS100-2O-01 ID no. 0590541/00 Number of poles Charging current 100 % duty cycle [A] 100 Weight [kg] 0.955 for frontal contact AGV floor contact Type BLK100-2-06 ID no. 0590736/00 Number of poles Charging current 100 % duty cycle... -
Page 19: System 5
LAYOUT AND FUNCTION 4.2.5 System 5 AGV current collector Type SA-BLS200-2-01-MS ID no. 0590000/00-MS Number of poles Charging current 100 % duty cycle [A] 200 Weight [kg] 2.680 Version Milled component with cleaning brush on front side, for frontal contact AGV floor contact Type BLK200-2-01... -
Page 20: System 7
LAYOUT AND FUNCTION 4.2.7 System 7 AGV current collector Type SA-BLS50-2O/20-2-01 ID no. 0590637/00 Number of poles Number of poles, control current Charging current 100 % duty cycle [A] 100 Weight [kg] 0.614 for frontal contact, with pilot function AGV floor contact Type BLK100-2/25-2-04... -
Page 21: System 8
LAYOUT AND FUNCTION 4.2.8 System 8 AGV current collector Type SA-BLS200-2B/2O-2-01- ID no. 0590198/00-MS Number of poles Number of poles, control current Charging current 100 % duty cycle [A] 200 Weight [kg] 3.075 with cleaning brushes on front side, for frontal con- tact, with pilot function AGV floor contact Type... -
Page 22: System 9
LAYOUT AND FUNCTION 4.2.9 System 9 AGV current collector Type SA-BLS200-2-01 ID no. 0590000/01-MS Number of poles Charging current 100 % duty cycle [A] 200 Weight [kg] 1.209 with cleaning brush on front side, for frontal contact AGV current collector Type SA-BLK200-1-02 ID no. -
Page 23: System 11
LAYOUT AND FUNCTION 4.2.11 System 11 AGV current collector Type SA-BLS600-1AO-01 ID no. 0590043/00-MS Number of poles Charging current 100 % duty cycle [A] 600 Weight [kg] 4.234 for frontal contact (Illustration without cover) AGV floor contact Type BLK600-1-01 ID no. 0590044/00 Number of poles Charging current 100 %... -
Page 24: Commissioning
COMMISSIONING COMMISSIONING Safety instructions for commissioning DANGER! Installation without contact protection - Risk of fatal injuries from electrical current! Contact with electrically live components may result in fatal injuries. ► During installation, a protection against personal injury/contact in accordance with DIN EN 60204-1 must be implemented. - Page 25 COMMISSIONING WARNING! Risk of injury from falling parts! In case of improper use (faulty assembly, misuse, failure to perform maintenance, etc.), there is a risk of parts falling down. ► Wear a helmet ► Perform regular maintenance NOTICE! Transport instructions ►...
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Page 26: Installation
COMMISSIONING Installation 5.2.1 General assembly instructions Travel direction Current collector Brush Carbon brushes Base plate View without brush NOTICE! ► Always observe the relevant customer-specific drawings / documents during assembly. NOTICE! ► When selecting the fastening, make sure that the screw head does not protrude from the contour and that the screw connection is secured against loosening (e.g. -
Page 27: Connection Options For Current Collectors
COMMISSIONING 5.2.2 Connection options for current collectors Assembly SA-BLS200S Electrical connection Installation dimensions X [mm] 48 Torque, connection [Nm] 18 Disconnected height X [mm] approx. 58 Lift tolerance [mm] ± 5 Permissible wear [mm] 2 Assembly SA-BLS200Q Electrical connection Installation dimensions X [mm] 65 Torque, connection [Nm] 18 Disconnected height X... -
Page 28: Installing Current Collector
COMMISSIONING 5.2.3 Installing current collector NOTICE! ► Mount the current collectors with cleaning brush on the vehicle so that the cleaning brush is facing in the direction of travel. ► The current collector unit should rest on as large an area as possible around the mounting bore holes so as to ensure a secure hold. -
Page 29: Mounting Floor Contacts
COMMISSIONING 5.2.4 Mounting floor contacts CAUTION! ► Air and creepage distances according to IEC 60664-1 between phases and from phase to earth must be taken into account for operation. Regional standards must be observed! NOTICE! Charging contacts can be mounted on the side, on the floor or overhead. When mounting on the floor, observe the following: ►... -
Page 30: Floor Contact Connection Options
COMMISSIONING 5.2.5 Floor contact connection options NOTICE! The electrical connection is made to the CU connection tubes or directly to the CU contact plates. Required torque: ► M6: 8 Nm ► M8: 15 Nm ► M10: 18 Nm Option 1 BLK Connection CU connection tube The cable is connected to CU connection tubes which are connected to the CU contact plate. -
Page 31: Condition After The Installation
COMMISSIONING Condition after the installation Mechanical function test After assembly and checking for correct polarity, check the mobility of the carbon brushes when they are de- energized, the dimension when the new brush is spring-loaded and the installation dimension (distance be- tween mounting surface and upper side of CU contact surface). -
Page 32: 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 33: Troubleshooting Table
MALFUNCTIONS Troubleshooting table Malfunction Cause Remedy Periodic charging or loss of Mechanical alignment Check the mechanical alignment of charging current the charging contact. Electrical connections Check the electrical connections to the base charging contact and the carbon brush contact. Carbon brush contact Check carbon brush pressure, car- bon brushes and contact plate. -
Page 34: Maintenance
MAINTENANCE 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 due to improperly performed maintenance work! Improper maintenance can result in serious personal injury or property damage. -
Page 35: Maintenance
MAINTENANCE Maintenance This chapter primarily serves to maintain the system’s target condition and operational capability. By avoiding disturbances and unplanned shutdowns, regular maintenance can increase the efficiency. Prerequisite is an efficient planning of the maintenance work and material. In order to carry out safe maintenance by suitably trained personnel, the following instructions must be observed: DANGER! Danger of life due to electrical current! -
Page 36: Maintenance Intervals
MAINTENANCE Maintenance intervals NOTICE! Damage due to improper cleaning ► No solvents may be used for cleaning the contact surfaces and carbon brushes. Interval Maintenance/monitoring tasks Personnel Daily • Check safety equipment and operating behavior. Operator approx. every • Check the carbon brushes and carbon brush springs in accor- Technician/electri- 10.000 cycles / dance with 7.4 Carbon brush. -
Page 37: Carbon Brush
MAINTENANCE Carbon brush Carbon brush The carbon brush must not fall below the defined wear limit. The current collector must be replaced once the wear limit has been reached. The dimension can be found in the customer-specific drawing. Carbon brush springs The contact pressure of the carbon brush springs must not fall below the values in the following table. -
Page 38: 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 39: Transport Inspection
TRANSPORT AND STORAGE Transport inspection Check the delivery for completeness and transport damage upon receipt! If any external damage is found: • Refuse delivery or accept delivery only conditionally. • Note the scope of the damage in the transport documents or on the carrier's delivery note. NOTICE! The delivery may be damaged during transport! Report all defects as soon as they are found. -
Page 40: Disassembly And Disposal
All accessories must be checked for wear. Only defect-free parts may be reused. ► Use only genuine VAHLE spare parts. Disposal When the system reaches the end of its useful life, the system must be dismantled and disposed of in an en- vironmentally sound manner in accordance with the valid local regulations and laws. -
Page 41: Protective Measures
The safety hints mentioned in the product documentation must be followed. Kamen, 02.03.2018 Michael Heitmann Manager Testing & Services Paul Vahle GmbH & Co. KG · Postfach 1720 · D-59172 Kamen · Tel. 02307/704-0 · Fax 02307/704-444 · eMail: info@vahle.de ... -
Page 42: Index
PROTECTIVE MEASURES INDEX Activate 7 Current collector connection 25 Determine absence of voltage 7 Disposal 38 Electrically qualified person 9 Floor contact connection 28 Grounding and short-circuiting 7 Isolation 8 Maintenance 34 Operating company 8 Operation 29 Owner obligations 8 Qualifications 9 Requirements to personnel 9 safety aspects 6... - Page 43 Technical Documentation DQS - certified in accordance DIN EN ISO 9001:2015 OHSAS 18001:2007...
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