Related Manuals for Vahle APOS OPTIC
Summary of Contents for Vahle APOS OPTIC
- Page 1 ORIGINAL OPERATING INSTRUCTIONS APOS OPTIC CARRYING SYSTEM AND INSTALLATION (RS #027) INSTALLATION MANUAL V 1.08 | EN MAINTENANCE MANUAL V 1.08 | EN...
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Page 2: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS ..............Document history . - Page 3 TABLE OF CONTENTS ........... . 7.3.3 Assembly - connector .
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Page 4: Document History
Information for installing the rebound strap inserted, Ident no APOS connector corrected 1.07 10/2020 List of APOS optic reding heads converted into a separate chapter and errors of the ID no. improved, general review 1.08 09/2021 Read heads removed from document (see system manual), adap- tion of designations of mounting material, review ... -
Page 5: Abbreviations
ABBREVIATIONS ABBREVIATIONS Electric monorail system Industrial Ethernet Profinet Connection or extension cable ... -
Page 6: 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 7: Symbols
GENERAL Symbols Safety instructions in this manual are identified by symbols. Each safety instruction begins with a 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 8 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 9: Copyright Protection
We reserve the right to make technical changes to improve the usability and for further development. Customer service Paul Vahle GmbH & Co. KG Westicker Str. 52 Tel: +49 (0) 2307 704-0... -
Page 10: Warranty
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 11: Safety Instructions
Failure to observe the safety instructions may result in risks to life and health! Intended use The APOS support profile is used as a supporting element for the APOS optic code strip. The profile permits a direct installation in or at an electric monorail system (EMS) profile or at appropriate carrier elements. The APOS carrier system can be combined with other VAHLE systems. -
Page 12: 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 13: Danger From Electrical Energy
SAFETY INSTRUCTIONS 4.3.1 Danger from electrical energy Perform the following safety work according to VDE 0105-100 (this work must be carried out by a qualified elec- trician, see chapter: "2 security"). Activate The required separation distances must be established. Secure against restart During work, a prohibition sign must be attached reliably on switching handles or drives of switches, control units, pressure and sensing devices, safety parts, circuit breakers that have been used to unlock a system part or that can be used to connect electricity. -
Page 14: 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 15: Personnel Requirements
SAFETY INSTRUCTIONS Personnel requirements 4.5.1 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 of severe or fatal injuries. -
Page 16: 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 for ensuring that protective equipment is worn. -
Page 17: 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 18: 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 death due to electrical current! Contact with live parts can result in life-threating injuries. ►... -
Page 19: Technical Data
TECHNICAL DATA TECHNICAL DATA Technical data carrying profile Material Aluminum Weight 0.151 kg/m Temperature range -20 ... +60°C Standard profile length 6000 mm Profile height 28 mm Suspension distance 600 mm (straight) 300 mm (curve) Bending radius (horizontal) Min. 750 mm Bending radius (vertical) Not possible ... -
Page 20: Layout And Function
LAYOUT AND FUNCTION LAYOUT AND FUNCTION System overview SMGM profile Compact hanger U10/SMGM APOS optic code strip carrier system SMGM mobile coupler HF cable SMGM base plate APOS optic reading head APOS optic universal retaining plate U10 conductor rail 10 SMGM module ... -
Page 21: Brief System Description
Carrying system The APOS optic carrying system is a bracket device to install the APOS optic code strip. The carrying profile is made of aluminum and has a dimension of (28 x 2 mm). The system consists of the carrying profile, brackets, connectors, fix points, expansion joint, code strips and the reading head. -
Page 22: Definition Of Nominal Distance (Reading Distance)
LAYOUT AND FUNCTION Definition of nominal distance (reading distance) A: Nominal distance of the reading head Desigantion Nominal distance/reading distance [A] Types of reading heads* LK-02-... 36 mm RS485, SSI, PROFINET LK-03-... 29 mm RS485, SSI ... -
Page 23: Assembly Overview
LAYOUT AND FUNCTION Assembly overview 6.4.1 Support profile Carrying profile for code strip Ident.-No: 0144483/00 Material: Aluminum Net weight: 0.151 kg/m X= 6000 mm 0144483/00 Other short lengths are available on request. ... -
Page 24: Apos Bracket
LAYOUT AND FUNCTION 6.4.2 APOS bracket Bracket TP APOS OPTIC Ident.-No: 0144409/ Material: Plastic Net weight: 0.019 kg NOTICE! ► The bracket can be latched into the existing VAH- LE compact bracket or can also be individually screw connected. -
Page 25: Apos Connector
LAYOUT AND FUNCTION 6.4.3 APOS connector Connector TP 28 MM Ident.-No: 0144411/ 1 Bridging plate 10013967 2 Connector 0144410/00 ... -
Page 26: Apos Expansion Joint
LAYOUT AND FUNCTION 6.4.4 APOS expansion joint VM-TCBDV28/AL-2-30 Ident.-No: 0144484/ (Expansion joint) Material: Aluminum/plastic Net weight: 0.193 kg Max. expansion +15 mm/ -15 mm Tightening torque 3.2 Nm ... -
Page 27: Apos Earth Conductor
LAYOUT AND FUNCTION 6.4.5 APOS earth conductor APOS earth conductor Ident.-No: 0144450/ Net weight: 0.013 kg NOTICE! ► The earth conductor is already installed in the ex- pansion joint and is part of the delivery. Individu- ally, it can be used for the required potential equalization of steel structures. -
Page 28: Apos Distance Plate
LAYOUT AND FUNCTION 6.4.6 APOS distance plate Spacer plates* including screw material A [mm] B [mm] Ident.-No. 0144522/01 *Other spacer plates on request. ... -
Page 29: Universal Retaining Plate
LAYOUT AND FUNCTION 6.4.7 Universal retaining plate Reading head bracket Ident.-No: 0144509/00 APOS-OPTIC Material: DX51D+Z Net weight: 0.341 kg Tightening torque M5*: 6 Nm Tightening torque M6: 10.5 Nm * The screw must also be secured with Loctite. The universal retaining plate guarantees a safe fixa- tion of the reading head on the mobile vehicle side. -
Page 30: 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 section “4 Safety instructions.” ► Are all acceptance reports available? (initial startup) ►... -
Page 31: Operation/Decommissioning
COMMISSIONING Operation/decommissioning 7.2.1 Operation Operation is to be understood as trouble-free, normal operation. Checking of the system that is in normal mode in accordance with the maintenance intervals (see section: “9 “). In normal operation, noticeable changes to the system must be observed. If defects occur, the system must be taken out of operation immediately in order to avoid damage. -
Page 32: Installation
7.3.1 Assembly - bracket without compact holder NOTICE! ► The bracket can be installed in this way or in a different compact hanger by VAHLE. ► Hanging distance straights: 600 mm // Hanging distance curves: 300 mm Installation instructions Prerequisites: ... -
Page 33: Assembly - Bracket With Compact Holder
7.3.2 Assembly - bracket with compact holder NOTICE! ► The bracket can be installed in this way or in a different compact hanger by VAHLE. ► Hanging distance straights: 600 mm // Hanging distance curves: 300 mm Installation instructions Prerequisites: ... -
Page 34: Assembly - Connector
COMMISSIONING 7.3.3 Assembly - connector "Klick" NOTICE! ► The interrupted flank of the plastic connector is the upper side and must be in- stalled accordingly (see C). ► The joint must have a minimum distance of 50 mm to the compact hanger. ►... - Page 35 COMMISSIONING Installation instructions Prerequisites: Clean work place Required tools:: ⚒ None Installation steps: 1. Press APOS profile at an angle of 30° into one side of the connector (A). 2. Position the profile in such a way that the profile hole is above the nose of the con- nector.
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Page 36: Installation - Apos Carrying Profile
COMMISSIONING 7.3.4 Installation - APOS carrying profile Carrying profile in APOS holder Carrying profile in compact holder NOTICE! ► Horizontal bends are made with a U10 bending device and special bending roller set (3 x ID no: 0144407/00). ... - Page 37 COMMISSIONING Carrying profiles’ bending possibilities The following figure shows how the carrying profile can be installed (green): • Without bend • With bend in xz direction -> note min. radius! Furthermore, the figure shows an impermissible assembly (red): • Bend in xy direction (not allowed!) Fig.
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Page 38: Installation - Apos Fix Point
COMMISSIONING 7.3.5 Installation - APOS fix point The anchor point for the carrying system can be made in two different ways. This depends on whether an APOS bracket or one of our other systems’ existing compact holders is used. Variant 1 - Installation in the compact holder ... - Page 39 COMMISSIONING Variant 2 - Installation in the APOS holder/connector APOS bracket - Ident.-No.: 0144409/00 Ejot - PT screw (2.5 mm x 6 mm) Ident.-No: 10011860 Installation instructions Prerequisites: Clean work place. Required tools: ⚒ Electric drill + (drill Ø= 1.5 mm / Ø=2.5 mm) ⚒...
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Page 40: Installation - Apos Distance Plate (Potential Equalization/Fix Point)
COMMISSIONING 7.3.6 Installation - APOS distance plate (potential equalization/fix point) Depending on the system situation, the distance plate fulfills different functions. Its main task is to act as a distance bracket between carrying profile and EMS profile. It also guarantees a potential equalization to the steel structure and it is mainly used before and after lifters and switches. - Page 41 COMMISSIONING NOTICE! ► Is used as fix point, distance bracket and potential equalization to the steel struc- ture. ► Is used as distance plate at the end of systems, switch transitions or other me- chanical interruptions. ► Is used as fix point if the accompanying installation plate shows this explicitly. ►...
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Page 42: Installation - Apos Potential Equalization
COMMISSIONING 7.3.7 Installation - APOS potential equalization NOTICE! ► Earth conductor with installation material ident .-No.: 0144450/00 ► One potential equalization to the steel structure is required every 36 m. ► Please ensure easy access to the screw connection. ►... - Page 43 COMMISSIONING Installation instructions Prerequisites: Clean work place Required tools:: ⚒ Electric drill + (drill Ø=3.3mm) ⚒ Thread cutter M4 ⚒ Hex-wrench AF 3 Installation steps: 1. Drill hole with Ø=3.3 mm into the EMS profile and afterwards cut an M4 thread. 2.
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Page 44: Installation - Apos Expansion Joint
(see section: 6.4 Assembly overview). NOTICE! It is mandatory to adhere to the installation instructions and hanger intervals of the conductor rail bracket if the carrying profile is used in combination with a VAHLE con- ductor rail and SMGM data transfer. Installation instructions Prerequisites: ... -
Page 45: Installation - Apos Reading Head
LK-02-... 36 mm LK-03-... 29 mm Installation instructions Prerequisites: Clean work place and correctly installed APOS optic strip. ⚒ Hex-wrench Installation steps: 1. Select your reading head in the table below and set the associated nominal dis- tance. NOTICE! The horizontal and vertical alignment of the reading head to the code strip is import- ant for an optimal function of the absolute code reading head. - Page 46 COMMISSIONING NOTICE! For the coordination of the correct installation, please contact the VAHLE service or your contact person. WARNING! The smallest deviations of the adjustments for the reading head settings can result in the failure of the system. ► Please adhere to the specified setting values ►...
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Page 47: Installation - Apos Code Strip
COMMISSIONING 7.3.10 Installation - APOS code strip TIPS AND RECOMMENDATIONS! For positioning the code strip precisely during assembly, position markings are place every 120 mm at the lower edge of the code strip. An adhesive surface is placed on the rear side, which hardens approximately 72 hours after attachment of the code strip. - Page 48 COMMISSIONING 7.3.10.1 Guidelines for interrupting the code strip TIPS AND RECOMMENDATIONS! In general: The code strip should only be interrupted where it is absolutely necessary. The following specifications must be observed! Butt joints & code strip starts TIPS AND RECOMMENDATIONS! ►...
- Page 49 COMMISSIONING Gaps TIPS AND RECOMMENDATIONS! In case of gaps and crossings, glue the code strip continuously and cut the gap out. ...
- Page 50 COMMISSIONING Cutting and reuse Cut the code strip and reuse it at a different place. Fig. 7-3 Description: Cut the code strip and reuse at a different place, dimension in [mm] 1: Code strip piece path 1 2: Code strip piece that must be removed 3: Code strip piece path 2 A: Section edge TIPS AND RECOMMENDATIONS!
- Page 51 COMMISSIONING 7.3.10.2 Incline and decline routes Inclines and declines NOTICE! ► The code strip must be cut above and below for inclines and declines! ► In order to guarantee the function on inclines and descents, a white background must be applied beforehand or afterwards. Otherwise there is a risk that, due to the shiny aluminum surface, the read head cannot determine the position ->...
- Page 52 If you want to replace the code strip at short notice due to damage or similar, you can download the APOS CodeGenerator software on our website. With the tool you can print a new preliminary code strip. Please order the correct and more durable code strip from your VAHLE contact person. ...
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Page 53: 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! After the installation, the responsible installation manager must check the system for the following parts or situations and must generate and sign an acceptance certifi- cate! ►... -
Page 54: 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 55: Maintenance
MAINTENANCE MAINTENANCE The main aim of this section is to maintain the system’s target condition and operational capability. By avoiding malfunctions and unplanned downtimes, regular maintenance can increase the utilization rate. Efficient plan- ning of maintenance work and material is a prerequisite. In order to carry out safe maintenance by appropri- ately trained personnel, the following instructions must be observed: DANGER! Danger of death due to electrical current! -
Page 56: 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 in the section “Safety”! WARNING! Risk of injury due to improperly performed maintenance work! Improper maintenance can result in serious personal injury or property damage. -
Page 57: Maintenance
Maintenance APOS optic code strip • The APOS optic code strip must be checked in specified intervals for contamination and other damages. The exact intervals can be found in section: 9.3 APOS optic - carrier system A visual inspection of the general system condition shall be carried out. This includes in particular the following points: No mechanical damages. -
Page 58: Maintenance Schedule
MAINTENANCE Maintenance schedule Interval Maintenance/monitoring tasks Personnel Daily Check the system's safety devices and driv- Operator ing behavior. Monthly Visual inspection of the general condition. Expert person- The respective parts must be exchanged in nel/electrician case of damages. Check and, if required, correctly reinstall/ exchange mechanical and electrical con- nections, especially those of the expansion joints, air separation points and the mobile... -
Page 59: Transport And Storage
TRANSPORT AND STORAGE TRANSPORT AND STORAGE 10.1 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 60: Disassembly And Disposal
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. CAUTION! All accessories must be checked for wear. Only defect-free parts may be reused. ► Use only genuine VAHLE spare parts. ... -
Page 61: 11.2 Disposal
DISASSEMBLY AND DISPOSAL 11.2 Disposal General information Current national local regulations are decisive for disposing / recovering (recycling) assemblies, machines and systems. NOTICE! Danger from incorrect disposal / operator responsibility Risk of environmental damage / loss of valuable raw materials ►... - Page 62 DISASSEMBLY AND DISPOSAL Manufacturer's obligation to provide information (according to ElektroG, Germany) Options for the return, disposal and recovery (recycling) of old devices The latest, valid guidelines, laws and regulations on site apply. • The operator, as a professional user of the products, is responsible for properly disposing or recycling of •...
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Page 63: Protective Measures
PROTECTIVE MEASURES PROTECTIVE MEASURES 12.1 EU conformity declaration ... -
Page 64: Index
INDEX INDEX Activate 11 Bracket 22 Bridging plate 23 Carrying profile 21 Connector 23 Determine absence of voltage 11 Electrically qualified person 13 Expansion joint 24 Grounding and short-circuiting 11 Information on the instructions 4 Installation 11 Intended use 9 Interior application 9 Maintenance 55 Misuse 9... - Page 65 Technical Documentation...