Related Manuals for Vahle VCL Series
Summary of Contents for Vahle VCL Series
- Page 1 TRANSLATION OF THE ORIGINAL GERMAN OPERATING INSTRUCTIONS COMPACT CONDUCTOR SYSTEM INSTALLATION MANUAL SYSTEM MANUAL MAINTENANCE MANUAL EN-V 1.01...
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Page 2: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS ............... . . General . - Page 3 TABLE OF CONTENTS ............4.4.3 End segment .
- Page 4 TABLE OF CONTENTS ..........Safety information about malfunctions .
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Page 5: General
GENERAL About these instructions These operating instructions enable the safe and efficient handling of our VAHLE products. This document is an integral part of the installation and must be kept accessible to operating and maintenance personnel in the immediate vicinity. The basic requirement for safe working is compliance with all specified safety instructions and instructions. -
Page 6: 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 7: 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 8: Customer Service
• If the operator independently performs repairs during the warranty period or has repairs performed by third parties. • If the product has been handled or maintained inappropriately. • If parts are used that are not original parts approved by Vahle. • If the information in this documentation is not observed. ... -
Page 9: 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 10: General Risks
SAFETY INSTRUCTIONS General risks The following section describes residual risks that arise even if the product 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 11: 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 12: 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 13: 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 14: 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 15: Signage
SAFETY INSTRUCTIONS Signage The following symbols and instruction signs are located in the work area. They relate to the immediate envi- ronment in which they are installed. DANGER! Danger of life due to electrical current! Contact with live parts can result in life-threating injuries. ►... -
Page 16: Technical Data
TECHNICAL DATA TECHNICAL DATA VCL2 Technical specifications - electrical Nominal current VCL2/100C at 35 °C [A] 100 Conductor cross section VCL2/100C [mm²] 25 Resistance VCL2/100C [Ω / 1 0 0 0 m ] 0,721 Impedance VCL2/100C [Ω / 1 0 0 0 m ] 0,723 Nominal current VCL2/40F at 35 °C [A] 40 Conductor cross section VCL2/40F... - Page 17 TECHNICAL DATA Tolerances Conductor system X-axis: [mm] ± 3 Conductor system Y-axis: [mm] ± 3 Conductor rail connectors Z-axis: [mm] 0.7 + 1 per side Current collectors X-axis: [mm] ± 15 (DEAS ± 12) Current collectors Y-axis: [mm] ± 20 Operating conditions Operating temperature [°C] - 30 to + 55...
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Page 18: Vcl3
TECHNICAL DATA VCL3 Technical specifications - electrical Nominal current VCL3/100C at 35 °C [A] 100 Conductor cross section VCL3/100C [mm²] 25 Resistance VCL3/100C [Ω / 1 0 0 0 m ] 0,721 Impedance VCL3/100C [Ω / 1 0 0 0 m ] 0,723 Nominal current VCL3/40F at 35 °C [A] 40 Conductor cross section VCL3/40F(3) -
Page 19: Vmt
TECHNICAL DATA Tolerances Conductor system X-axis: [mm] ± 3 Conductor system Y-axis: [mm] ± 3 Conductor rail connectors Z-axis: [mm] 0.7 + 1 per side Current collectors X-axis: [mm] ± 15 (DEAS ± 12) Current collectors Y-axis: [mm] ± 20 Contact pressure current collector [N] approx. -
Page 20: Layout And Function
LAYOUT AND FUNCTION LAYOUT AND FUNCTION System description VCL2/VCL3 The compact wiper line VCL was developed especially for various applications in intralogistics. With its com- pact dimensions and durability, the VCL possesses the ideal properties for potential shuttle applications in au- tomated small parts stores or for other transfer carriages. - Page 21 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, lifting stations, etc.).
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Page 22: System Overview Vcl2/Vcl3
LAYOUT AND FUNCTION System overview VCL2/VCL3 System overview VCL2 (2-pin) End segment Conductor system Transfer guide with/without fixpoint Hanger Connector material ... - Page 23 LAYOUT AND FUNCTION System overview VCL3 (3-pin) End segment Conductor system Transfer guide with/without fixpoint Hanger Connector material ...
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Page 24: Arrangement Examples
LAYOUT AND FUNCTION 4.2.1 Arrangement examples Arrangement example 1 - hangers / connectors Connector Hanger Hanger Connector Hanger Hanger Connector * only applies if the connector 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... -
Page 25: Device Overview Vcl2
LAYOUT AND FUNCTION Device overview VCL2 4.3.1 Segment Segment Section Phase VCL2/100C-1000SSD 0281521/00 VCL2/100C-2000SSD 0281522/00 VCL2/100C-3000SSD 0281523/00 VCL2/100C-4000SSD 0281524/00 VCL2/40F-1000SSD 0281541/00 VCL2/40F-2000SSD 0281542/00 VCL2/40F-3000SSD 0281543/00 VCL2/40F-4000SSD 0281544/00 Weight 100C [kg] 2,406 Weight 40F [kg] 2,190 Delivery length [mm] 4000 Hanger spacing [mm] 800 Segment Section Phase + PE VCL2/100C-1000HSC... -
Page 26: End Segment
LAYOUT AND FUNCTION 4.3.3 End segment End segment Phase VCL2/100C-SSD 0281510/00 VCL2/40F-SSD 0281516/00 Weight [kg] 0,324 Delivery length [mm] 1000 Segment Section Phase + PE VCL2/100C-HSC-R 0281515/00 VCL2/100C-HSC-L 0281518/00 VCL2/40F-HSC-R 0281517/00 VCL2/40F-HSC-L 0281519/00 Weight [kg] 0,297 Delivery length [mm] 1000 Lines with PE marking require 1x end segment...- HSC-R and 1x end segment...-HSC-L... -
Page 27: Expansion Joint
LAYOUT AND FUNCTION 4.3.6 Expansion joint Expansion section Phase DT-DVCL2/100C-SSD 0281506/00 DT-DVCL2/40F-SSD 0281508/00 Weight [kg] 0,279 Delivery length [mm] 1000 Max. current [A] 50* Expansion section Phase + PE DT-DVCL2/100C-HSC 0281507/00 DT-DVCL2/40F-HSC 0281509/00 Weight [kg] 0,324 Delivery length [mm] 1000 Max. -
Page 28: Fixpoint Terminal
LAYOUT AND FUNCTION 4.3.8 Fixpoint terminal Fixpoint terminal FK-AH-VCL2 0281527/00 Weight [kg] 0,020 NOTICE! ► Permissible for voltages up to 48 V. 4.3.9 Collector Current collector DEAS SA-DEAS-2/30-2-SS-2,5-0/2-2- 2823983/00-0 PA (for control current) SA_DEAS-2-30-2-HS-2,5-0/2-2- 2823998/00-0 PA (for main power with PE) Weight [kg] 0,4 Number of poles... - Page 29 LAYOUT AND FUNCTION Current collector EASL SA-EASL-20-2-SS-0-2-PA-V.E. 2823982/00-0 (for control current) SA-EASL-20-2-HS-0-2-2-PA-V.E. 2823997/00-0 (for main current with PE) Weight [kg] 0,098 Number of poles Phase spacing [mm] 15 Max. current [A] 20 Tolerance X-direction [mm] ± 15 Tolerance Y-direction [mm] ±...
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Page 30: Connecting Cables For Collector
LAYOUT AND FUNCTION 4.3.10 Connecting cables for collector Connecting cables for DEAS current collector FLA - type Color Cable cross Outer diam- ID no. ID no. section [mm eter Ø [mm] AL-FLA2,5PH...-6,3 Phase Black 2809171/00 2809173/00 AL-FLA2,5PE...-6,3 Green/ 2809175/00 2809177/00 yellow AL-FLA4PH...-6,3... -
Page 31: Connecting Cables
LAYOUT AND FUNCTION 4.3.11 Connecting cables Connecting cable for transfer guides, double insulated, flexible M5 RKLA for M5 - type Color Cable cross Outer diam- ID no. ID no. section [mm eter Ø [mm] Al-RKLA2,5PH...-M5 Phase Black 2808971/00 2808971/00-5 Al-RKLA2,5PE...-M5 Green/ 2808958/00... - Page 32 LAYOUT AND FUNCTION Connecting cable, for line feeds, double insulated, flexible, M6 RKLA for M6 - type Color Cable cross Outer diam- ID no. ID no. section [mm eter Ø [mm] Al-RKLA2,5PH...-M6 Phase Black 2808979/00 2808979/00-5 Al-RKLA2,5PE...-M6 Green/ 2808978/00 2808978/00-5 yellow Al-RKLA4PH...-M6-HL...
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Page 33: Equipotential Bonding
LAYOUT AND FUNCTION 4.3.12 Equipotential bonding Equipotential bonding at transfer guide or line feed Equipotential bonding cable VSPA-VMT-600-VCL 0171817/00 Weight [kg] 0,142 Delivery without profile Equipotential bonding from VCL profile to VMT pro- file Equipotential bonding at rail section Rail section with PE grounding VCL2/40F-1000HSCP 0281547/00... -
Page 34: Device Overview Vcl3
LAYOUT AND FUNCTION Device overview VCL3 4.4.1 Segment Segment Section Phase VCL3/100C-4000SSD 0281584/00 VCL3/100C-3000SSD 0281583/00 VCL3/100C-2000SSD 0281582/00 VCL3/100C-1000SSD 0281581/00 VCL3/40F-1000SSD 0281601/00 VCL3/40F-2000SSD 0281602/00 VCL3/40F-3000SSD 0281603/00 VCL3/40F-4000SSD 0281604/00 Weight 100C (4m) [kg] 3,522 Weight 40F (4m) [kg] 3,300 Delivery length [mm] 4000 Hanger spacing [mm] 800 Segment Section Phase + PE... -
Page 35: End Segment
LAYOUT AND FUNCTION 4.4.3 End segment End segment Phase ESM-VCL3/100C-SSD 0281578/00 ESM-VCL3/40F-SSD 0281585/00 Weight (1m) [kg] 0,662 Delivery length [mm] 1000 Segment Section Phase + PE ESM-VCL3/100C-HSC- 0281579/00 ESM-VCL3/100C-HSC-L 0281580/00 ESM-VCL3/40F-HSC-R 0281586/00 ESM-VCL3/40F-HSC-L 0281587/00 Weight (1m) [kg] 0,662 Delivery length [mm] 1000 Lines with PE marking require 1x end segment...- HSC-R and 1x end segment...-HSC-L... -
Page 36: Expansion Joint
LAYOUT AND FUNCTION 4.4.6 Expansion joint Expansion section Phase DT-DVCL3/100C-SSD 0281599/00 DT-DVCL3/40F-SSD 0281605/00 Weight [kg] 0,953 Delivery length [mm] 1000 Max. current [A] 50* Expansion section Phase + PE DT-DVCL3/100C-HSC 0281600/00 DT-DVCL3/40F-HSC 0281606/00 Weight [kg] 0,953 Delivery length [mm] 1000 Max. -
Page 37: Fixpoint Terminal
LAYOUT AND FUNCTION 4.4.8 Fixpoint terminal Fixpoint terminal FK-AH-VCL2 0281527/00 Weight [kg] 0,020 NOTICE! ► Permissible for voltages up to 48 V. 4.4.9 Collector Current collector DEAS SA-DEAS-2/30-2-SS-3,5-0/2-2- 0281610/00 PA (for controller) SA_DEAS-2-30-2-HS-3,5-0/2-2- 0281615/00 PA (for main power with PE) Weight [kg] 0,4 Number of poles... - Page 38 LAYOUT AND FUNCTION Current collector EASL SA-EASL-20-3-SS-0-2-PA-V.E. 0281616/00 (for control current) SA-EASL-20-3-HS-0-2-2-PA-V.E. 0281617/00 (for main current with PE) Weight [kg] 0,12 Number of poles Phase spacing [mm] 15 Max. current [A] 20 Tolerance X-direction [mm] ± 15 Tolerance Y-direction [mm] ±...
- Page 39 LAYOUT AND FUNCTION Current collector for 3- to 6-pin application PASK current collector Ident-No. SA-PASK-50-3L-HS/3-4 0281633/00 SA-PASK-50-3R-HS/3-4 0281634/00 SA-PASK-50-4L-HS/4-4 0281624/00 SA-PASK-50-4R-HS/4-4 0281627/00 SA-PASK-50-5L-HS/5-6 0281625/00 SA-PASK-50-5R-HS/5-6 0281628/00 SA-PASK-50-6L-HS/6-6 0281626/00 SA-PASK-50-6R-HS/6-6 0281629/00 The letter (in bold) indicates the design of the current collector. The illustration shows the right version. E.G.
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Page 40: Connecting Cables For Collector
LAYOUT AND FUNCTION 4.4.10 Connecting cables for collector Connecting cables for DEAS current collector FLA - type Color Cable cross Outer diam- ID no. ID no. section [mm eter Ø [mm] AL-FLA2,5PH...-6,3 Phase Black 2809171/00 2809173/00 AL-FLA2,5PE...-6,3 Green/ 2809175/00 2809177/00 yellow AL-FLA4PH...-6,3... -
Page 41: Connecting Cables
LAYOUT AND FUNCTION Connecting cable for PASK current collector RKLA for M4 - type Color Cable cross Outer diam- ID no. ID no. section [mm eter Ø [mm] AL-RKLA6PH...-M4 Phase Black 2808737/00 2808737/00-3 AL-RKLA6PE...-M4 Green/ 2808738/00 2808738/00-3 yellow 4.4.11 Connecting cables Connecting cable for transfer guides, double insulated, flexible M5 RKLA for M5 - type... - Page 42 LAYOUT AND FUNCTION Connecting cable, for line feeds, double insulated, flexible, M6 RKLA for M6 - type Color Cable cross Outer diam- ID no. ID no. section [mm eter Ø [mm] Al-RKLA2,5PH...-M6 Phase Black 2808979/00 2808979/00-5 Al-RKLA2,5PE...-M6 Green/ 2808978/00 2808978/00-5 yellow Al-RKLA4PH...-M6-HL...
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Page 43: Equipotential Bonding
LAYOUT AND FUNCTION 4.4.12 Equipotential bonding Equipotential bonding at transfer guide or line feed Equipotential bonding cable VSPA-VMT-600-VCL 0171817/00 Weight [kg] 0,142 Delivery without profile Equipotential bonding from VCL profile to VMT pro- file Equipotential bonding at rail section Rail section with PE grounding VCL3/40F-1000HSCP 0281638/00... -
Page 44: System Description Vmt
100 amperes. With the new VAHLE multi-bearer, VAHLE has developed a product that is specially tailored to the many require- ments of floor-guided storage and conveyor systems, such as storage and retrieval systems and transfer car- riages. -
Page 45: Device Overview Vmt
LAYOUT AND FUNCTION Device overview VMT 4.6.1 Profile Profile VMT-6000 0171546/01 Weight [kg] 12,336 Delivery length [mm] 6000 4.6.2 Terminal connector Terminal connector KV-VMT 0171536/00 Weight [kg] 0,845 4.6.3 Compact hanger Compact holder Weight [kg] Ident-No. KH-VCL4-VMT 0,385 0171818/00 KH-VCL5-VMT 0,394 0171819/00... -
Page 46: Single Hangers
LAYOUT AND FUNCTION 4.6.5 Single hangers Position Type Description Tightening torque Clamping Weight Ident-No. [Nm] area [mm] [kg] VMT-HS-S Screw console (for 0,882 0171839/00 auxiliary support HSE) VMT-SPW Clamping console 1,062 0171539/00 (for auxiliary sup- port HST) VMT-S Screw console 0,902 0171547/00 VMT 55 -125... -
Page 47: Auxiliary Supports
LAYOUT AND FUNCTION 4.6.6 Auxiliary supports Auxiliary support HSE Type Height Ident-No. [mm] HRL-HSE-300 0781697/00 HRL-HSE-350 0781758/00 HRL-HSE-400 0781710/00 HRL-HSE-450 0781694/00 HRL-HSE-500 0781677/00 Auxiliary support HST Type Height Ident-No. [mm] HRL-HST-50-250 0157172/00 HRL-HST-50-300 0152804/00 HRL-HST-50-350 0156393/00 HRL-HST-50-400 0152661/00 HRL-HST-50-450 0156492/00 HRL-HST-50-500 0152662/00... -
Page 48: 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 49: Operation/Decommissioning
COMMISSIONING CAUTION! Danger of crushing between the individual components! During assembly there is a risk of crushing of the extremities between the individual components. ► Take care of your extremities. ► Wear personal protective equipment. (see Chapter: 2 ) NOTICE! The conductor rail material is susceptible to corrosion. -
Page 50: Installation Vcl2 / Vcl3
COMMISSIONING Installation VCL2 / VCL3 5.3.1 Assembly preparation NOTICE! The following installation steps only show illustrations of the VCL2. Unless explicit ref- erence is made in the individual descriptions, the descriptions always apply to the VCL2 and VCL 3 system. Tools and Measuring equipment The following devices, tools and measuring equipment are necessary for assembly of the conductor rails with accessories. - Page 51 COMMISSIONING Drill out mounting holes for fixpoint M4 screw (mounting) Mounting plate Fixpoint / Transfer guide 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.
- Page 52 COMMISSIONING End segment with fixpoint Conductor system * only applies if the connecting cap can be supported. For exposed connectors adhere to the spacing of 150 End segment without fixpoint Assembly instructions Requirements: Clean and tidy workplace. Required tools: ⚒...
- Page 53 COMMISSIONING 5.3.1.1 Installation aids Drilling template for fixpoint terminal Ident-No. VCL2 0281525 Ident-No. VCL3 0281608 Weight [kg] 0,050 Drilling template for VCL in VMT Ident-No. 0171840/00 Weight [kg] 0,109 Assembly safety device Ident-No. 0281526 Weight [kg] 0,050 Mounting handle for feed terminal VCL MZ-MH-ES-VCL 10027863 Weight...
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Page 54: Determining The System Lengths
COMMISSIONING Screw driver PH1 Ident-No. 2812963 Weight [kg] 0,014 File FSF Ident-No. 2812964 Weight [kg] 0,085 5.3.2 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. - Page 55 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 70012.60 74013.30 78014.00 82014.70 86015.40 90016.10 94016.80 98017.50 102018.20 106018.90 110019.60 114020.30 118021.00 122021.70 126022.40 130023.10...
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Page 56: End Segment With Feed Terminal (Fixpoint)
COMMISSIONING 5.3.3 End segment with feed terminal (fixpoint) Step 1 Prerequisites: 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 57 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! Danger of crushing between the individual compo- nents! During assembly there is a risk of crushing of the ex- tremities between the individual components.
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Page 58: 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). 5.3.4 Transfer guides NOTICE! ► One of the two transfer guides must be mounted as a fixpoint. ►... -
Page 59: Line Material
COMMISSIONING 5.3.5 Line material Step 1 Prerequisites: 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 60: Renewing Conductor Rail Joints
COMMISSIONING Step 4 Assembly instructions: 1. Mount the next conductor system in the intended hanger as described in Chapter: "5.3.3 ". Step 5 Required tools: ⚒ Plastic hammer Assembly instructions: 1. Hammer the conductor system up to the stop us- ing the plastic hammer. -
Page 61: End Segment With End Cap (Sliding)
COMMISSIONING 5.3.7 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 62: Straight Sections
COMMISSIONING 5.3.8 Straight sections NOTICE! ► To reach the desired system length, normally only the last 1-2 profiles are adapted! It is not recommended to shorten profiles within the system! CAUTION! ► To ensure smooth and impairment-free running of the current collectors/carbon brushes, the cut surfaces must always be carefully deburred. -
Page 63: Collector
COMMISSIONING 5.3.9 Collector Single current collector assembly - EASL Assembly instructions Prerequisites: Clean and tidy workplace. Assembly steps: 1. Align the current collector with the conductor sys- tem (phase center off). NOTICE! ► Installation dimensions: 55 mm ► Suitable for funnel ►... - Page 64 COMMISSIONING Installing current collector - PASK Assembly instructions Prerequisites: Clean and tidy workplace. Assembly steps: 1. Align the current collector with the conductor sys- tem (phase center off). NOTICE! ► Installation dimension: 80 mm ► Number of poles: 3-6 ►...
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Page 65: 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 66: 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 67 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: „5.3.8 “.
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Page 68: Line Feed
COMMISSIONING 5.3.12 Line feed 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. CAUTION! Danger of crushing between the individual components! During assembly there is a risk of crushing of the extremities between the individual components. - Page 69 COMMISSIONING Step 1 Prerequisites: Clean and tidy workplace. Required tools: ⚒ Hexagon socket Assembly instructions: 1. Loosen the screws at the joint connector using a hexagon socket wrench Step 2 Assembly instructions: 1. Pull the two conductor system parts apart and re- move the connection terminals.
- Page 70 COMMISSIONING Step 5 Required tools: ⚒ Mounting handle (Siehe 5.3.1.1 Installation aids) Assembly instructions: 1. Place the mounting handle on the butt connector from behind over a joint connector . 2. Now screw the hexagon socket screws to the cor- responding connection terminal with 7 Nm.
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Page 71: Installation Vmt
COMMISSIONING Installation VMT 5.4.1 Installation aids VMT Sawing device Ident-No. 0171561/01 Weight [kg] 2,570 Installation pliers Ident-No. 0171533/00 Weight [kg] 0,700 Drilling template for fixpoint terminal MZ-BS-AH-VCL2 0281525 MZ-BS-AH-VCL3 0281608 Weight [kg] 0,050 Drilling template for VCL in VMT MZ-BS-VMT-FP-VCL 0171840/00 Weight... -
Page 72: Arrangement Vcl In Vmt
COMMISSIONING 5.4.2 Arrangement VCL in VMT KH-VCL5-VMT KH-VCL6-VMT KH-VCL4-VMT 5.4.3 Installation VMT profile Position Type Description Tightening torque Clamping Weight Ident-No. [Nm] area [mm] [kg] VMT-HS-S Screw console (for 0,882 0171839/00 auxiliary support HSE) VMT-SPW Clamping console 1,062 0171539/00 (for auxiliary sup- port HST) VMT-S... - Page 73 COMMISSIONING CAUTION! When the VMT is hanging, i.e. the opening is facing downwards, the following restric- tions apply: ► Hanging spacing: max. 3 meters ► The VMT hangers are installed in staggered arrangement. This means that the clamping springs are arranged alternately on the left or right ►...
- Page 74 COMMISSIONING Step 1 Prerequisites: Upright must be installed correctly and straight. Required tools: ⚒ Wrench/ reversible ratchet Assembly instructions: NOTICE! The installation of the clamping console AH-VMT-SPW is shown as an example. Except for the AV-VMT-BS console, all consoles are installed similarly as shown. ►...
- Page 75 COMMISSIONING CAUTION! Danger of crushing between the individual compo- nents! During assembly there is a risk of crushing of the ex- tremities between the individual components. ► Take care of your extremities. ► Wear personal protective equipment. (see Chap- ter: 2 ) Step 4 Assembly instructions:...
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Page 76: Creating Vmt Shorter Lengths
COMMISSIONING NOTICE! This interlocking (approx. 30° downwards) prevents unintentional shifting of the connector onto the VMT profile. 5.4.4 Creating VMT shorter lengths Step 6 Required tools: ⚒ Sawing device SV-VMT Assembly instructions: 1. If required, you can create shorter lengths on the construction side using the SV-VMT sawing de- vice. -
Page 77: Equipotential Bonding At Section With Vmt
COMMISSIONING 5.4.5 Equipotential bonding at section with VMT Equipotential bonding installation at section CAUTION! To guarantee the protective measures, a low imped- ance connection including protective-/equipotential bonding conductor is essential! See IEC 60364-4-41. Step 1 Required tools: ⚒ Wrench Assembly instructions: 1. -
Page 78: Feed Terminal Installation With Vmt
COMMISSIONING 5.4.6 Feed terminal installation with VMT Feed terminal installation 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 approximation. - Page 79 COMMISSIONING Step 3 Required tools: ⚒ Hexagon socket Assembly instructions: 1. Tighten the screws with a torque of 5.5 Nm (50A feed) or 9.5 Nm (100A feed). Step 4 Required tools: ⚒ Sheet punch set / pot drill / hole saw Assembly instructions: 1.
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Page 80: Installation Of Vcl Profile In The Vmt
COMMISSIONING 5.4.7 Installation of VCL profile in the VMT Step 1 Required tools: ⚒ None Assembly instructions: 1. Turn the holders into the corresponding bore- holes (as in illustration). (Grid dimension 100 mm). NOTICE! Observe the hanger distances from the supplied sys- tem or installation plan! Step 2 Required tools:... - Page 81 COMMISSIONING Step 3 Assembly instructions: 1. Click the remaining conductor rails into the pro- files. Make sure that the lugs of the holders are properly snapped in place (see figure below). 2. For other transfer guides, proceed as described in step 2.
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Page 82: 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 83: 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 84: 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 85: 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 due to improperly performed maintenance work! Improper maintenance can result in serious personal injury or property damage. -
Page 86: Wear Parts
MAINTENANCE Wear parts Wear parts for current collector for DEAS for DEAS front replacement head back replacement head for PASK for EASL Type Description X=residual height Weight [kg] Ident-No. [mm] SK-EK-DEAS-2/30-PH-36-6.3-H Rear replacement 0,016 2808580/00 head SK-EK-DEAS-2/30-PE-36-6.3-H Rear replacement 0,016 2808581/00 head... -
Page 87: 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 88: 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 89: Cleaning
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. CAUTION! For maintenance and cleaning work where graphite contact dust may get into the am- bient air, breathing protection must be used: ►... -
Page 90: 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 91: 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 92: Declarations Of Conformity
C E R T I F I C A T E O F C O M P L I A N C E E48031 Certificate Number E48031-20190301 Report Reference 2020-FEBRUARY-19 Issue Date Paul Vahle GmbH & Co. KG Issued to: Postfach 1720 59172 Kamen GERMANY CRANE AND HOIST ELECTRIFICATION SYSTEMS This certificate confirms that representative samples of... - Page 93 The safety hints mentioned in the product documentation must be followed. Kamen, 09.11.2020 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 ...
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Page 94: Index
INDEX INDEX Activate 8 Application 18 Arrangement examples 22 Connectors 18 Current collectors 19 Determine absence of voltage 8 Disposal 89 Electrically qualified person 10 Expansions 18 Feed terminals 19 Grounding and short-circuiting 8 Hangers 18 Information to the instructions 3 Isolation 9 measuring equipment 48 Operating company 9... - Page 95 INDEX Unloading 88...
- Page 96 Technical Documentation...