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Vahle VKS10 Translation Of The Original Instructions

Compact conductor system
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TRANSLATION OF THE ORIGINAL INSTRUCTIONS
VKS10
COMPACT CONDUCTOR SYSTEM
INSTALLATION MANUAL
SYSTEM MANUAL
MAINTENANCE MANUAL
EN-V 1.01

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  • Page 1 TRANSLATION OF THE ORIGINAL INSTRUCTIONS VKS10 COMPACT CONDUCTOR SYSTEM INSTALLATION MANUAL SYSTEM MANUAL MAINTENANCE MANUAL EN-V 1.01...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ............... . . General .
  • Page 3 TABLE OF CONTENTS ............4.3.18 Connecting cables .
  • Page 4 TABLE OF CONTENTS ............Disassembly and disposal .

  • 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: Copyright Protection

    GENERAL NOTICE! The source of the hazard is described here. This combination of a symbol and a signal word indicates a potentially dangerous sit- uation that may result in property or environmental damage unless avoided. ► The actions to prevent the hazard are identified here NOTICE! This indicates a reference to another place in this text or another document.

  • Page 7: Disclaimer

    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 8: Warranty

    • 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 9: Safety Instructions

    Failure to observe the safety instructions may result in risks to life and health! Intended use Compact conductor systems (type VKS10) are touch-safe conductor rails. The insulating housing (up to 10-pin) enables direct routing in track supports and support profiles. The conductor system must only be used for in- door systems.

  • Page 10: 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 11: Risks From Hazardous Materials

    SAFETY INSTRUCTIONS 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. 2.3.2 Risks from hazardous materials WARNING! Danger to health from hazardous materials! Improper use of hazardous materials may cause damage to health.

  • Page 12: 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 13: 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 14: 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 15: 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 16: 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 17: Technical Data

    TECHNICAL DATA TECHNICAL DATA Technical specifications - electrical Conductor cross section [mm²] 16 Resistance [Ω/1000 m] 1.102 0.723 0.595 0.510 Impedance [Ω/1000 m] 1.106 0.728 0.602 0.510 Nominal voltage with ground conductor (PE) [V] 690 (UL 600) Number of pins 4 - 10 Conductor material Copper...

  • Page 18: Layout And Function

    LAYOUT AND FUNCTION System overview The VKS10 is an easy-to-install compact conductor system with a maximum load capacity of 280 A. In combi- nation with a support profile developed in parallel, hanging distances of up to 4.5 m can be realized without the need for costly auxiliary support structures.

  • Page 19: Assembly Overview

    For the following table the types must be added: e.g. VKS10-6/63-2000HSA for 2 m ID no. 780 042. HS = with PE The 4-digit number (in bold) in the type designation indicates the length of the straight section in mm.
  • Page 20 LAYOUT AND FUNCTION   Type Weight Nominal Nominal Conductor cross section Num- ID no. cur- current ber of [kg/m] rent poles L1-L3 5-10 VKS10-8/63-..HSA 2.590 3x16 1x16 4x16 780 21• VKS10-8/100-..HSA 2.830 3x25 1x16 4x16 780 22• VKS10-8/120-..HSA 2.960 3x30 1x16 4x16 780 23•...
  • Page 21 LAYOUT AND FUNCTION   Pin allocation VKS10-4/ VKS10-5/ VKS10-6/ VKS10-7/ VKS10-8/ VKS10-9/ VKS10-9/ VKS10- VKS10- 63-140 63-140 63-140 63-140 63-140 63-140 200- 10/63- 10/200- 280a Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free...

  • Page 22: Curved Section

    LAYOUT AND FUNCTION   4.3.2 Curved section Curved section Min. Cu cross section ] 25 Curve length, max. [m] 5.3 Hanger spacing [m] ≈ 0.6 Angle, max. 180° Inner curve Inner conductor Outer curve Outer conductor (not pictured) Curved sections are supplied with straight connec- tion ends of 250 mm length on both sides.

  • Page 23: Fixed Hangers/Sliding Hangers

    All sections must be fastened at least twice, with the maximum hanger spacing of 1.2 m being observed. The hanger brackets designed as sliding hangers allow three different types of fastening: 1) Installation in VAHLE support profile (clip fastening system) 2) Installation in C rail (screw fastening)
  • Page 24 LAYOUT AND FUNCTION   Fixed hanger on cast-in channel with hanger, fixed point screw Fixed hanger Type AH-VEPS10-H Weight [kg] 0.224 ID no. 780 007  ...
  • Page 25 LAYOUT AND FUNCTION   Fixed hanger for VTP10 support profile with hanger, fixed point screw Fixed hanger Type AH-VEPS10-VTP Weight [kg] 0.033 ID no. 780 009 Sliding hanger on cast-in channel with hanger and bracket profile Sliding hanger Type AH-VAS10-H Weight [kg] 0.223 ID no.

  • Page 26: End Cap

    LAYOUT AND FUNCTION   Sliding hanger for VTP10 support profile with hanger Sliding hanger Type AH-VAS10-VTP Weight [kg] 0.032 ID no. 780 010 4.3.5 End cap End caps form the contact-protected end of the conductor system. They are pushed onto the end of the con- ductor system and screwed into place.
  • Page 27 LAYOUT AND FUNCTION   End feed Separate delivery of the connection box, only in combination with line feed VLS. Type Weight [kg] ID no. ES-VEKS10-10/63-280 0.664 780 018 A = conductor system length Connection box cable glands: 2 x ST-M 40 x 1.5 for Ø = 19-28 mm 1 x ST-M 20 x 1.5 for Ø...
  • Page 28 LAYOUT AND FUNCTION Type Weight [kg] Current [A] Number of poles ID no. ES-VLS10-8/100-120 0.470 100-200 780 196 ES-VLS10-8/140 0.686 780 198 ES-VLS10-9/63 0.256 780 058 ES-VLS10-9/100-120 0.514 100-200 780 199 ES-VLS10-9/140 0.742 780 191 ES-VLS10-9/200-240(1) 0.744 200-240 780 322 ES-VLS10-9/280(1) 0.828 780 321...

  • Page 29: Rail Separation

    LAYOUT AND FUNCTION   4.3.7 Rail separation The rail separation for control pulses electrically separates the conductor system. Installation is carried out at the factory according to customer specifications. The position of the rail separations and the designations of the conductor rail sections to be separated must be specified on ordering. For designation of the conductor rail profiles, see 4.3.1 Straight sections Rail separation Weight...

  • Page 30: Transfer Funnel

    LAYOUT AND FUNCTION 4.3.8 Transfer funnel Transfer funnel only in combination with conductor system section. The funnel can be mounted on the left and right of prepared straight sections. Transfer funnel for current collector KSTU 30-63-14 Speed, max. V [m/min] 100 Funnel strips Plastic Funnel holder...

  • Page 31: Conductor System Sections For Funnel

    7.534 780 346 ET-EFTV10-10-KSTU30/63-14R 7.535 780 169 4.3.9 Conductor system sections for funnel Type (all cross sections 25 mm , length 1365 mm) ID no. VKS10-10/100-1365HS02AT 780 257 VKS10-9/100-1365HS02AT 780 250 VKS10-8/100-1365HS02AT 780 249 VKS10-7/100-1365HS02AT 780 248 VKS10-6/100-1365HS02AT 780 247...

  • Page 32: Double Line Guide

    LAYOUT AND FUNCTION   4.3.10 Double line guide The double line guide is fastened to a section in the transverse lane. It is aligned together with the current col- lectors on the storage and retrieval system. Double line guide for current collector KSTU 30-63 Speed, max.

  • Page 33: Transfer Guide Vu 10

    LAYOUT AND FUNCTION 4.3.11 Transfer guide VU 10 Transfer guide VU 10 for transitions Max. vertical and lateral offset [mm] ± 2 Max. air gap between the transfer guides [mm] 5 currentless section [mm] 30 (longer variant on request) Type Allocation from top ID no.

  • Page 34: Compact Current Collector Trolley Kesr

    LAYOUT AND FUNCTION   4.3.12 Compact current collector trolley KESR 32-55 KESR 32-55 Reversing operation Phase spacing [mm] 14 Stroke and lateral deflec- tion [mm] ± 15 Contact pressure per car- bon brush, approx. [N] 7 PE (green) on no. 4 (other configuration possible) PE moves forward when folding into the conductor system max.
  • Page 35 LAYOUT AND FUNCTION   KESR-F for connecting cable with flat plug, see technical catalog. Type Weight A [mm] B [mm] C [mm] Num- Base plate ID no. [kg] ber of poles SA-KESR32-55F-4-14HS-0-04-04 0.480 4-pin 143 170 SA-KESR32-55F-5-14HS-0-04-06-06 0.540 6-pin 143 373 (pin 6 free) SA-KESR32-55F-6-14HS-0-04-06 0.600...

  • Page 36: Compact Current Collector Trolley Kesr 63S

    LAYOUT AND FUNCTION   4.3.13 Compact current collector trolley KESR 63S KESR 63S Reversing operation Adapter plate and terminal block Phase spacing [mm] 14 Stroke and lateral deflec- tion [mm] ± 15 Contact pressure per car- bon brush, approx. [N] 7 PE (yellow) on no.
  • Page 37 LAYOUT AND FUNCTION   Left version As illustrated, PE on no. 4 Type Number of Allocation ID no. poles SA-KESR63S-4-14-HS-KBL-04-10-01-04 1 - 4 781 089 SA-KESR63S-5-14-HS-KBL-04-10-01-05 1 - 5 781 088 SA-KESR63S-6-14-HS-KBL-04-10-01-06 1 - 6 781 087 SA-KESR63S-7-14-HS-KBL-04-10-01-07 1 - 7 781 086 SA-KESR63S-8-14-HS-KBL-04-10--01-08 1 - 8...

  • Page 38: Compact Current Collector Trolley Kesl

    LAYOUT AND FUNCTION   4.3.14 Compact current collector trolley KESL 32-63 KESL 32-63 Reversing operation Phase spacing [mm] 14 Stroke and lateral deflec- tion [mm] ± 30 Contact pressure per car- bon brush, approx. [N] 7 PE (yellow) on no. 4 (other configuration possible) PE moves forward when folding into the conductor system max.
  • Page 39 LAYOUT AND FUNCTION   KESL-F for connecting cable with flat plug, see technical catalog. Type Weight A [mm] B [mm] C [mm] Num- Base plate ID no. [kg] ber of poles SA-KESL32-55F-4-14HS-0-04-04 0.536 4-pin 143 152 SA-KESL32-55F-5-14HS-0-04-06-06 0.612 6-pin 781 257 (pin 6 free) SA-KESL32-55F-6-14HS-0-04-06 0.688...

  • Page 40: Compact Current Collector Trolley Kesl 63S

    LAYOUT AND FUNCTION   4.3.15 Compact current collector trolley KESL 63S KESL 63S Reversing operation Adapter plate and terminal block Phase spacing [mm] 14 Stroke and lateral deflec- tion [mm] ± 30 Contact pressure per car- bon brush, approx. [N] 7 PE (yellow) on no.
  • Page 41 LAYOUT AND FUNCTION   Left version As illustrated, PE on no. 4 Type Number of Allocation ID no. poles SA-KESL63S-4-14-HS-KBL-04-10-01-04 1 - 4 781 075 SA-KESL63S-5-14-HS-KBL-04-10-01-05 1 - 5 781 074 SA-KESL63S-6-14-HS-KBL-04-10-01-06 1 - 6 781 073 SA-KESL63S-7-14-HS-KBL-04-10-01-07 1 - 7 781 072 SA-KESL63S-8-14-HS-KBL-04-10-01-08 1 - 8...

  • Page 42: Single Collector Assembly Kst

    LAYOUT AND FUNCTION   4.3.16 Single collector assembly KST Reversing operation Connecting cable [m] 2 Stroke and lateral deflection [mm] ± 20 Contact pressure, approx. [N] 5 Type Weight Current Connecting cable ID no. ID no. [kg] A [mm ] Ø [mm] Phase black PE yellow...

  • Page 43: Connecting Cables

    LAYOUT AND FUNCTION   4.3.18 Connecting cables Connecting cable FLA highly flexible for current collector with flat plug con- nection "F" Observe assignment to current collectors Length with female spade connector 6.3 mm x 0.8 mm Longer connecting cable available Temperature range [°...

  • Page 44: Driver

    LAYOUT AND FUNCTION   4.3.19 Driver Driver For current collector KST 30-63 Type Weight [kg] A [mm] B [mm] ID no. MN-UMAA12HS-B-4-14L-80 0.33 781 444 MN-UMAA12HS-B-4-14R-80 0.33 781 443 MN-UMAA12HS-B-5-14L-94 0.36 780 186 MN-UMAA12HS-B-5-14R-94 0.36 780 185 MN-UMAA12HS-B-6-14L-108 0.39 780 184 MN-UMAA12HS-B-6-14R-108 0.39 780 183...
  • Page 45 LAYOUT AND FUNCTION   Attachment HRL support profile VTP 10 For feed terminal VNS 10, VLS 10 VTPB1050-ESAE Version in the start and end area ID no. 780 100 VTPB1050-ESST Version on the line ID no. 780 098 HRL connector only as a single part, otherwise included in combination with fastening of the supporting structure.
  • Page 46 LAYOUT AND FUNCTION   HRL auxiliary support Auxiliary support Type HRL-HSE-500 Length [mm] 500 Weight [kg] 1.894 ID no. 781 677 with attachment material  ...

  • Page 47: Attachment Of The Supporting Structure

    LAYOUT AND FUNCTION   4.3.21 Attachment of the supporting structure clamping area Clamping profile HRL upright Clamping bracket Tightening torque of the mushroom head screw M10, MA = 18 Nm Slot 9 x 30 Type Weight [kg] clamping area [mm] Figure ID no.
  • Page 48 LAYOUT AND FUNCTION   Type Weight [kg] clamping area [mm] Figure ID no. VTPB360-55-65 3.076 55-65 780 152 VTPB360-65-75 3.084 65-76 780 153 VTPB360-75-85 3.096 75-85 780 154 VTPB360-85-95 3.102 85-95 780 155 VTPB360-90-105 3.110 90-105 780 156 VTPB360-100-115 3.118 100-115 780 157 VTPB360-110-125...

  • Page 49: Path Measuring Systems

    Grounding Type PS-WCS3-EVTP10 Weight [kg] 0.026 ID no. 302 160 When installing the WCS code rail in the VKS10 system, the code rail must be connected to the system poten- tial at least every 30 m with low impedance.  ...

  • Page 50: Path Encoding

    LAYOUT AND FUNCTION   4.3.23 Path encoding Attachment spacing 0.2 m WCS 3 PS-WCS3-CS70-L2 Plastic laminate tape with special perforation (WCS 3) Weight [kg] 0.040 max path length [m] 327 ID no. 302 106 Screw PS-WCS3-FPK Screw for fixpoint Weight [kg] 0.001 ID no.

  • Page 51: Installation Plan

    4.5.1 Mechanical interfaces • Customer-side steel structure • Perfectly aligned, profile upright or (VAHLE) auxiliary support • On the vehicle side, there is a support bracket for the current collectors which is aligned to the conductor rail system. • Please refer to the installation plan for the required system dimensions and tolerances.

  • Page 52: 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 53: 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 54 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 55: Operation/Decommissioning

    COMMISSIONING   Operation/Decommissioning 6.2.1 Operation Operation is understood to be trouble-free, normal operation. Check intervals as per the maintenance sched- ule in Chapter: „8 “. If defects occur, stop using the conductor rail immediately to prevent damage. 6.2.2 Decommissioning Switch off the system and secure it against restarting. Disconnect the entire power supply from the system physically.

  • Page 56: Assembly Tools

    Type MZ-MGVS Weight [kg] 1.50 Order no. 780 090 Use only with support profile Installation comb Installation comb Type MZ-MK Weight [kg] 0.230 Order no. 781 112 Set for VKS10 For adjusting the air gap at the connecting joint  ...

  • Page 57: Installation

    COMMISSIONING   Installation 6.5.1 Conductor system Prerequisites:  Before installation, observe the system-specific installation plan and the applicable system documenta- tion.  Align the conductor rails in such a way that the long bar is aligned with the crane runway. ...
  • Page 58 COMMISSIONING   Mounting conductor system and adjusting connection joint Install the conductor system straight and parallel to the crane runway. The conductor system must be attached to each section with at least two hangers (support bracket or HRL support profile). Support bracket Required tools: ⚒...
  • Page 59 COMMISSIONING   Step 3 Assembly steps: 1. Screw the section to the intended fixed hanger using the screw. NOTICE! ► Each section must be equipped with a fixed hang- er. The distance between two fixed hangers must not exceed 6 m. NOTICE! Range of application - 10°...
  • Page 60 COMMISSIONING   Step 5 Assembly steps: 1. Push the connector cover cap onto one side of the section as far as it will go. Step 6 Assembly steps: 1. Insert the next section from the front into the hanger and snap it into place. Step 7 Assembly steps: 1.
  • Page 61 COMMISSIONING   Step 8 Required tools: ⚒ Plastic block ⚒ Assembly tool (mounting fork for connecting joint) Assembly steps: 1. Slide the plastic block over the copper ends. Then insert the assembly tool into the slotted holes of the HRL support profile and slide the section against the other section.
  • Page 62 COMMISSIONING   Table of plug connector assignments Conductor system types Plug connector (copper) 63-100 A 120-140 A VKS10-4/63-100 L1; L2; L3; PE VKS10-4/120-140 L1; L2; L3 VKS10-5/63-100 L1; L2; L3; PE; 1 VKS10-5/120-140 PE; 1 L1; L2; L3 VKS10-6/63-100 L1; L2; L3; PE; 1; 2 VKS10-6/120-140 PE;...
  • Page 63 COMMISSIONING   Shorter lengths We manufacture shorter lengths at our factory according to your specifications. If shorter lengths still need to be adapted on site, modify the conductor system as follows. NOTICE! ► The left side of the conductor rails has been widened at the factory to prevent it from moving inside the plastic housing.
  • Page 64 COMMISSIONING   End caps End caps form the contact-protected end of the conductor system. Step 1 Assembly steps: 1. First attach the leakage path extension to the ends. Step 2 Assembly steps: 1. Push the end caps onto the conductor rail ends. NOTICE! ►...

  • Page 65: Line Feed Vls And Vns

    COMMISSIONING   6.5.2 Line feed VLS and VNS NOTICE! ► The line feeds are preferably installed on a 1 m conductor system section. Step 1 Assembly steps: 1. Place the feed terminal as close as possible to the supply line. To access the feed, the HRL support profile is removed in this area for 600 mm.
  • Page 66 COMMISSIONING NOTICE! ► Tightening torque M6 = 7 Nm. Standard cable outlet on left, right also possible. Step 3 Assembly steps: 1. Place the cover cap on the conductor rail and pay attention to cable routing. Step 4 Assembly steps: 1.
  • Page 67 COMMISSIONING   NOTICE! Tightening torques in accordance with DIN VDE 0220 ► M10 = 44 Nm ► M5 = 5 Nm Step 2 Assembly steps: 1. Tighten the cable gland until it is sealed against the connecting cable. Step 3 Assembly steps: 1.
  • Page 68 COMMISSIONING   NOTICE! ► Observe the markings for right (R) and left (L). Step 3 Assembly steps: 1. Tighten the cable gland until it is sealed against the connecting cable. Step 4 Required tools: ⚒ Screwdriver Assembly steps: 1. Replace the cover and close the connection box. Step 5 Assembly steps: 1.

  • Page 69: Collector

    COMMISSIONING   6.5.3 Collector NOTICE! Risk of damage by polarity reversal ► Observe the correct pole configuration of the current collector. Holder for current collector For the current collectors, fastening must be parallel to the longitudinal direction of the conductor rail and at a right angle to the contact surface.
  • Page 70 COMMISSIONING   Tolerances NOTICE! ► The permissible operational tolerances "A" for the stroke and deflection apply for current collectors and conductor system together. They compen- sate for the difference that results fro m impreci- sions in the movement of the vehicle and possible installation offset at the conductor sys- tem.
  • Page 71 COMMISSIONING   Connecting the power supply DANGER! Risk of fatal injuries from electrical current! Contact with electrically live components may result in fatal injuries. ► De-energize the system before making any elec- trical connections. Assembly steps: 1. Connect the feed terminal to the power supply (see Feed terminal 4.3.6 ).

  • Page 72: Special Components

    COMMISSIONING   6.5.4 Special components Transfer funnel The transfer funnels are equipped with a conductor rail section. The transfer funnel can be mounted on the left and right of prepared VKS straight sections. NOTICE! Risk of damage to the current collectors and transfer funnels. ►...
  • Page 73 COMMISSIONING   Step 4 Assembly steps: 1. Insert the three hangers into the funnel holes (1) and slide the funnel onto the conductor rail sec- tion. Step 5 Assembly steps: 1. Attach the transfer funnel to the retaining plate using the VKS hangers. Step 6 Required tools: ⚒...
  • Page 74 2. Glue in the PVC bars in the area of the line guides. NOTICE! ► Do not mount VKS10 hangers and VTP10 hangers/connectors in the area of the line guide. See the cor- responding installation plan for specific installation situations. TIPS AND RECOMMENDATIONS! It is recommended to create a reference lane using a reference device.

  • Page 75: Path Measuring Systems

    200 mm) Grounding of the code rail The laminate rail must be connected to the system potential at least every 30 m (e.g. via Vahle support profile). Bar code strip In addition to the path measuring system, the self-adhesive bar code tape (BCB) can also be attached to the bar.

  • Page 76: Condition After The Installation

    COMMISSIONING 6.5.6 Condition after the installation DANGER! An adequate grounding as per IEC 60204-1/ 60204-32 must be ensured after the installation 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 77: Malfunctions

    MALFUNCTIONS   MALFUNCTIONS Safety information about malfunctions DANGER! Electrical voltage on the system Death or serious injury from electric shock. ► 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! WARNING! Risk of injury in case of improper troubleshooting! Improper troubleshooting may cause serious injuries or property damage.

  • Page 78: Troubleshooting Table

    MALFUNCTIONS   Troubleshooting table Fault Cause Remedy Conductor system transmits no/ No supply voltage Check voltage supply on site. too little current. Conductor system burnt. Current collector position on rail in- Check current collector on site. correct NOTICE! Improper troubleshooting Non-functional system ►...

  • Page 79: Maintenance

    MAINTENANCE   MAINTENANCE This chapter primarily covers keeping the system in proper working condition. Periodic maintenance can im- prove capacity utilization by preventing malfunctions and unplanned downtime. The prerequisite is efficient planning of maintenance work and materials. For safe maintenance by appropriately trained personnel, ob- serve the following: DANGER! Risk of death due to electrical current!

  • Page 80: 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 81: Contact Line

    MAINTENANCE   Contact line For normal use, the conductor system requires only little maintenance. The following tasks should be per- formed periodically however. Interval Service/monitoring Personnel daily • Check safety equipment and operating behavior. Operator monthly • Visual inspection of general condition. Replace damaged/de- Technician/electrical- fective parts.

  • Page 82: Collector

    MAINTENANCE   Collector Interval Service/monitoring Personnel daily • Check safety equipment and operating behavior. Operator monthly Visual inspection of general condition. Replace damaged/defective Technician/electrical- parts. ly qualified person Mechanical control: • Check mobility of joints, bearings, and hinge pins. Inspection for mechanical damage of any type.
  • Page 83 MAINTENANCE Lifetime The wear of current collectors and graphite contacts depends on many different factors. These include tem- perature, humidity, current density, patination, and the amount of dirt and contamination of the application, especially the influence of foreign particles. Until an optimal layer of patina is formed on the copper conductor systems, the first set of graphite contacts (initial delivery) usually has a somewhat shorter lifetime than subsequent sets.

  • Page 84: Cleaning

    For maintenance and cleaning work where graphite contact dust may get into the ambient air, breathing protection must be used: ► Breathing protection mask acc. to EN 149, min. protection level FFP3. Vahle product ID: 10017880 ► Never blow out the mask with compressed air. ► Use vacuum with class M filter.

  • Page 85: Moving Along The Rail

    MAINTENANCE   8.4.1 Moving along the rail Vacuum the conductor system and connecting caps, as well as the reversal points. Begin at the entry point of the system to be cleaned and clean the conductor system along its entire length. Conductor system sections 1.
  • Page 86 MAINTENANCE   Connector cap, moving along the rail, before Connecting cap, moving along the rail, after  ...
  • Page 87 MAINTENANCE   Reversal points, moving along the rail, before Reversal points, moving along the rail, after  ...

  • Page 88: Mast Assembly

    MAINTENANCE   8.4.2 Mast assembly Vacuum the conductor system and connecting caps as well as the lower end cap. Begin cleaning at the top of the conductor system on the mast and clean the entire unit to the lowest part (end cap): Conductor system sections 1.
  • Page 89 MAINTENANCE   Connecting caps, mast assembly, before Connecting caps, mast assembly, after  ...
  • Page 90 MAINTENANCE   End cap 1. Remove the lower end cap. 2. Vacuum the end cap. 3. Remove the leakage path extension. 4. Knock out the leakage path extension. 5. Install the leakage path extension and the end cap.  ...

  • Page 91: Result Of Cleaning

    MAINTENANCE 8.4.3 Result of cleaning After cleaning, the conductor system should be free of loose and foreign particles. Repeat the process if nec- essary. TIPS AND RECOMMENDATIONS! Due to external soiling and influence of particles (fine dirt, liquids, wood chips, grease, abrasion dust), we recommend cleaning the floor regularly.

  • Page 92: Spare Parts

    MAINTENANCE Spare parts The spare parts are for the mechanical part of the installation exclusively. Please see the relevant sales receipt or routing diagram. For the ordering address, please see chapter 1.5, customer service. Please indicate Ident-No. Use of third-party, copied, or non-approved components voids our warranty. WARNING! No liability in case of unauthorized changes, modifications, or accessories! Changes or modifications to the delivered product require the permission of the...

  • Page 93: Wear Parts

    MAINTENANCE   Wear parts Graphite contacts PE-Kennzeichnung SK-KMK30-63-04-PH SK-KMK30-63-04-PE SK-MK55PH/PE Type for current collector Weight [kg] RH [mm] Thickness ID no. [mm] SK-KMK30-63-04-PH KST 30-KST 63 and 0.031 4.00 4.40 154 440 KSTU 30-63 SK-KMK30-63-04-PE KST 30-KST 63 and 0.031 4.00 4.40 154 453...
  • Page 94 MAINTENANCE   Current collector KESR / KESL KESR KESL Type Weight [kg] Pin allocation ID no. SA-KESR32-55F/14PH 0.006 Phase 143 111 SA-KESR32-55F/14PE 0.006 143 112 SA-KESR32-55S/14PH 0.066 Phase 143 120 SA-KESR32-55S/14PE 0.066 143 121 SA-KESL32-63S/14PH 0.084 Phase 168 395 SA-KESL32-63S/14PE 0.084 142 880 ...- 55F = flat connector...

  • Page 95: 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 96: Protective Measures

    PROTECTIVE MEASURES PROTECTIVE MEASURES 10.1 EU conformity declaration...

  • Page 97: Index

    PROTECTIVE MEASURES INDEX Activate 8 Determine absence of voltage 8 Electrically qualified person 11 Grounding and short-circuiting 8 Information to the instructions 3 Isolation 8 Operating company 10 Operation 53 Owner obligations 10 Qualifications 11 Requirements to personnel 11 safety aspects 7 Safety information 4 Storage temperature 50 Switch on again 8...

  • Page 98: Other Documents

    OTHER DOCUMENTS OTHER DOCUMENTS SAFETY DATA SHEET RIVOLTA-Cleaner (If the link does not work, see the appendix of this document.)
  • Page 99 Technical Documentation DQS - certified in accordance DIN EN ISO 9001:2015 OHSAS 18001:2007...

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