Vahle VKL 2 Translation Of The Original Operating Instructions Download Page 1

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TRANSLATION OF THE ORIGINAL

GERMAN OPERATING INSTRUCTIONS

VKL 2

COMPACT CONDUCTOR SYSTEM

INSTALLATION MANUAL

SYSTEM MANUAL

MAINTENANCE MANUAL

EN-V 1.07

Summary of Contents for VKL 2

Page 1: ...TRANSLATION OF THE ORIGINAL GERMAN OPERATING INSTRUCTIONS VKL 2 COMPACT CONDUCTOR SYSTEM INSTALLATION MANUAL SYSTEM MANUAL MAINTENANCE MANUAL EN V 1 07...

Page 2: ...devices 11 2 8 Conduct in case of danger or accident 11 2 9 Signage 12 3 Technical data 13 4 Layout and function 15 4 1 System overview 15 4 1 1 Arrangement examples 16 4 2 Brief system description 1...

Page 3: ...46 5 4 Condition after the installation 48 6 Malfunctions 49 6 1 Safety information about malfunctions 49 6 2 Conduct in case of malfunction 49 7 Maintenance 50 7 1 Safety information about repairs 51...

Page 4: ...nance personnel at all times Following all safety instructions and other instructions in this manual is a basic prereq uisite for safe operation This document is not an instruction for the operation o...

Page 5: ...city that will result in death or serious injury unless avoided The actions to prevent the hazard are identified here WARNING The source of the hazard is described here This combination of a symbol an...

Page 6: ...n of the manufacturer except for internal purposes 1 4 Disclaimer The information in this document has been compiled in consideration of applicable standards and regulations accepted rules of engineer...

Page 7: ...delivered product require the permission of the man ufacturer Genuine spare parts and manufacturer approved accessories provide safe ty The use of non approved parts voids any liability of the manufac...

Page 8: ...yond or other than the appropriate use conversion or other modification is to be considered misuse and prohibited WARNING Danger in case of misuse Misuse may cause dangerous situations Never use the s...

Page 9: ...anical interlocks against switching on must be used Verify absence of voltage The absence of voltage must be confirmed on all pins at or as close as possible to the work site The voltage testers must...

Page 10: ...em Over the entire time the owner has to verify that the instructions drafted by him for the operation of the system conform to the current state of applicable regulations and adapt the instructions a...

Page 11: ...sk Electrically qualified person see VDE 0105 100 Due to their professional training knowledge experience and knowledge of the relevant standards and regu lations professional electricians are able to...

Page 12: ...ainst flying particles and liquid sprays Helmet Helmets protect against falling or flying parts and materials Gloves Gloves protect hands against chafing and abrasion cuts and punctures as well as aga...

Page 13: ...egulations the following safety instructions must be observed The following accident prevention regulations UVV Germany respectively the new Accident Prevention Reg ulations Principles of Prevention D...

Page 14: ...that the components are not live or in tension unauthorized approxima tion WARNING Hazard from illegible signs Over time labels and signs may become soiled or otherwise illegible so that hazards may...

Page 15: ...er of pins 2 Allocation 2 x phase 1 x phase PE Cross section connection cable mm 6 Conductor material Copper CU or steel F Protection class IP2X Dielectric strength according to DIN 53481 kV mm 22 4 V...

Page 16: ...7 Conductor rail connectors Z axis mm 0 7 1 per side Current collectors X axis mm 15 Current collectors Y axis mm 20 Contact pressure current collector N approx 8 Operating conditions Operating temper...

Page 17: ...D FUNCTION 15 4 LAYOUT AND FUNCTION 4 1 System overview 1 End segment ESM VKL2 2 Conductor line VKL2 3 Transfer guide with without fix point US VKL2 4 Hanger AH VKL2 5 Material of connectors VM VKL2 2...

Page 18: ...rted For exposed connectors strictly adhere to the spacing of 150 mm Arrangement example 2 Fixed end segment sliding end segment 1 Fixed end segment 2 Conductor system 3 Conductor system 4 Sliding end...

Page 19: ...VDE finger shows that it cannot touch live parts The insulation rail covering the conductor rail offers good insulation for maximum safety Several wiper lines can be combined with one another Only lit...

Page 20: ...system The cross section of the supplied connecting cables is designed for the stated nominal currents The reduction factors according to DIN VDE 0298 4 must be observed for the various laying proce d...

Page 21: ...44 00 Net weight 110C 2 406 kg Net weight 40F 2 190 kg Delivery length 4000 mm Suspension spacing 800 mm Segment Section Phase PE VKL2 100C 4000HSC ID no 0281534 00 VKL2 40F 4000SHSC ID no 0281554 00...

Page 22: ...cting cable are available upon request 4 3 5 Hanger holder NOTICE Customer specific hangers on request End segment Phase VKL2 100C SSD ID no 0281510 00 VKL2 40F SSD ID no 0281516 00 Net weight 0 324 k...

Page 23: ...SSD ID no 0281508 00 Net weight 0 279 kg Delivery length 1000 mm Expansion joint Phase PE DT DVKL2 100C HSC ID no 0281507 00 DT DVKL2 40F HSC ID no 0281509 00 Net weight 0 324 kg Delivery length 1000...

Page 24: ...0 A Tolerance X direction 12 mm Tolerance Y direction 20 mm Contact pressure approx 4 N per carbon brush Fixpoint terminal ID no 0281527 00 Net weight 0 020 kg Current collector D EAS SA DEAS 2 30 2 S...

Page 25: ...or can be combined with a custom mounting from the current collector EASL for control current 2823982 00 0 and EASL for main current with PE 2823997 00 0 Current collector EASL SA EASL 20 2 SS 0 2 PA...

Page 26: ...2 5 mm A 4 5 mm Net weight 0 035 kg WFLA AL WFLA2 5PH1 6 3 ID no 2809179 Phase black 4 mm A 5 3 mm AL WFLA2 5PE1 6 3 ID no 2809183 PE green yellow 4 mm A 5 3 mm Net weight 0 058 kg Designation ID no A...

Page 27: ...ion ID no Al RKLA2 5PH1 M6 ID no 2808979 2 5 mm A 4 5 mm Al RKLA2 5PE1 M6 ID no 2808978 2 5 mm A 4 5 mm Al RKLA4PH1 M6 HL ID no 2808751 4 mm A 5 3 mm Al RKLA4PE1 M6 ID no 2808752 4 mm A 5 3 mm Al RKLA...

Page 28: ...ersons who do not fulfill the requirements described here may not be aware of the hazards in the relevant working areas Keep unauthorized persons clear of the work area If in doubt address the relevan...

Page 29: ...he following points have to be strictly observed during assembly Appropriate handling of materials Clean and metallic bright surfaces on all contact points Smooth crossovers free of burrs of the condu...

Page 30: ...ft face hammer head about 50 mm dia Screwdriver set mounting block Mounting handle for connector Cutting tool for making shorter lengths File for deburring the rail ends when making shorter sections S...

Page 31: ...hole with 4 5 mm dia Drill out mounting holes for holder Arrangement examples can be derived from the drilling patterns shown below The X dimension describes the diameter for the bore hole which is d...

Page 32: ...kplace Required tools Drill bit according to table below 4 6 mm 4 9 mm Assembly instructions 1 Determine position for the bore hole using the drilling template and fix in place 2 Drill hole with X mm...

Page 33: ...ssembly safety device ID no 0281526 Net weight 0 050 kg Mounting handle ID no 2809348 Net weight 0 010 kg Chop saw ID no 165276 Net weight 6 500 kg Hexagon socket SW4 ID no 2812962 Net weight 0 036 kg...

Page 34: ...d 1000 Component Length mm Line feed 1000 Expansion joint 1000 Possible system lengths with 0 7 mm air gap at joint Standard lengths mm Number of end seg ments Number of straight sections Number of co...

Page 35: ...2 30 31 126022 40 2 31 32 130023 10 2 32 33 134023 80 2 33 34 138024 50 2 34 35 142025 20 2 35 36 146025 90 2 36 37 150026 60 2 37 38 Possible system lengths with 0 7 mm air gap at joint Standard len...

Page 36: ...nt the hangers to the carrier using suitable expanding rivets 2 Use the plastic hammer for fixing Step 3 Assembly instructions 1 Connect the screw terminal with the feed cable DANGER Danger of life du...

Page 37: ...uring installation work there is risk of suffering crush injuries to the limbs in the areas between the individual parts Watch out for your limbs Wear personal protective equipment see chap ter 2 Step...

Page 38: ...amp to relieve the fixpoint during connector installation 5 3 5 Transfer guides NOTICE One of the two transfer guides must be mounted as a fixpoint The transfer guides may only have an air gap of betw...

Page 39: ...stic ham mer CAUTION The connector is not reusable If assembly is unsuc cessful or the connection is faulty please proceed as described in Chapter 5 3 7 Step 3 Assembly instructions 1 Push the connect...

Page 40: ...d in Chapter 5 3 4 Step 5 Required tools Plastic hammer Assembly instructions 1 Hammer the conductor lime up to the stop using the plastic hammer NOTICE Repeat these steps until you have reached the p...

Page 41: ...g tool 1 Detach the conductor line from the rail holder so that it is possible to use the cut ting tool 2 Cut out the connection point 3 Reestablish the required overhang of the conductor rail to the...

Page 42: ...anger and connect the section 3 Insert the screw terminals in both conductor rail ends and push the transfer guide over the terminals Mount the screws with 3 Nm NOTICE Screw torque Observe 3 Nm 4 Remo...

Page 43: ...eps 1 Pull the copper profile out of the insulating housing for exactly 15 mm and make sure that the copper is flush with the insulating profile on the other side 2 Hold the tape measure to the copper...

Page 44: ...per carbon brush The current collector must be able to move freely Connecting cables may not restrict or impede the movement Double collector assembly D EASL Assembly instructions Requirements Clean...

Page 45: ...trans fer guide In special cases a fixpoint can also be realized using a hanger On the back of the conductor line each hanger has two recesses for fixing CAUTION This type of fixpoint may only be use...

Page 46: ...th help of the drilling device drill through the insulating housing and the back of the conductor line 3 Press the fixpoint clamps into the previously drilled holes and align them with the recesses of...

Page 47: ...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...

Page 48: ...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 Watch out for your limbs Wear persona...

Page 49: ...ove the connection terminals Step 3 Assembly instructions 1 Connect the connection terminals to the screw terminals At this stage only tighten the screws by hand Step 4 Assembly instructions 1 Insert...

Page 50: ...parts or situations after assembly and issue and sign an acceptance certificate Check the general functionality of the system Clearances of the line transitions and transfers Open spaces and interfer...

Page 51: ...on 6 2 Conduct in case of malfunction General principle If case of malfunctions that present an immediate hazard to persons or property immediately activate the safety devices Determine the cause of t...

Page 52: ...ned personnel the following notes must be observed 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 l...

Page 53: ...ficiently 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 All work must be performed by qualified personnel o...

Page 54: ...collector Type Description X Residual height mm Weight in kg ID no SK EK DEAS 2 30 PH 32 6 3 H Rear replacement head 0 5 0 016 2808580 SK EK DEAS 2 30 PH 32 6 3 V Front replacement head 0 5 0 016 2808...

Page 55: ...ductor rails and of burn marks Replace damaged burnt parts In particular remove accumulated car bon brush dust at separating points and transfer guides using a hand brush Remove any small burns or di...

Page 56: ...joints bearings and hinge pins Inspection for mechanical damage of any type Electrical checks Check for wear of graphite contacts firm seat of all contact screws and cable attachments Clean oxidized...

Page 57: ...0 Never blow out the mask with compressed air Use vacuum with class H filter Retrofitting a HEPA filter is required Do not eat drink or smoke during work Dust in the vacuum cleaner bag or the air filt...

Page 58: ...port 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...

Page 59: ...ve the information in chapter 2 3 1 WARNING Risk of death from improper replacement or removal Errors during the removal or replacement of components may cause life threatening situations or significa...

Page 60: ...cl accessories 2014 35 EU Low Voltage Directive This declaration is not an assurance of properties The safety hints mentioned in the product documentation must be followed The following harmonized sta...

Page 61: ...Expansions 17 F Feed terminals 18 G Grounding and shorting 7 H Hangers 17 M measuring equipment 28 O Operating company 8 Operation 27 Owner obligations 8 Q Qualifications 9 R Remarks on the system 18...

Page 62: ...EU DECLARATION OF CONFORMITY 60 V Verify absence of voltage 7...

Page 63: ...CE Technical Documentation DQS certified in accordance DIN EN ISO 9001 2008 OHSAS 18001 2007...

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Vahle VKL 2, Translation Of The Original Operating Instructions

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