Vahle System 1 Operating Instructions Manual Download

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TRANSLATION OF THE ORIGINAL

GERMAN OPERATING INSTRUCTIONS

BATTERY CHARGING CONTACTS

SYSTEM MANUAL

INSTALLATION MANUAL

MAINTENANCE MANUAL

EN V 1.01

Summary of Contents for System 1

Page 1: ...TRANSLATION OF THE ORIGINAL GERMAN OPERATING INSTRUCTIONS BATTERY CHARGING CONTACTS SYSTEM MANUAL INSTALLATION MANUAL MAINTENANCE MANUAL EN V 1 01...

Page 2: ...vices 11 2 8 Conduct in case of danger or accident 11 2 9 Signage 12 3 Technical data 13 4 Layout and function 14 4 1 Brief system description 14 4 2 Assembly overview 15 4 2 1 System 1 15 4 2 2 Syste...

Page 3: ...Troubleshooting table 31 7 Maintenance 32 7 1 Safety information about repairs 32 7 2 Maintenance 33 7 3 Maintenance intervals 34 7 4 Carbon brush 35 8 Transport and storage 36 8 1 Safety instructions...

Page 4: ...n related to electricity 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 combin...

Page 5: ...bination 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 A...

Page 6: ...eering as well as our years of knowledge and experience The manufacturer shall not be liable for damages resulting from Failure to observe the technical documentation Uses other than the intended use...

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: ...transmission pilot function e g for CAN bus charging manage ment The following standards must be observed during operation with regard to personnel and property protection DIN EN 60204 1 DIN EN 60204...

Page 9: ...ches control units pressure and sensing devices safety parts circuity breakers that have been used to unlock a system part or that can be used to connect electricity If this is not possible then the c...

Page 10: ...rds that may arise from the special operating conditions at the instal lation site These must be implemented as facility instructions for the operation of the system Over the entire time the owner has...

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: ...ible with design modifications Technical specifications Voltage without ground conductor V DC V AC 60 25 1 Current load max at 100 duty cycle A 600 Operating temperature C 30 to 55 Operation in humid...

Page 16: ...customer specific requirements the charging contacts and current collectors can be installed on the floor on the vehicle or as a charging station As a standard the charging contacts are operated on c...

Page 17: ...rontal contact AGV floor contact Type BLK25 2 01 ID no 0590042 00 Number of poles 2 Charging current 100 duty cycle A 25 Weight kg 0 592 AGV current collector Type SA BLS50 2O 01 ID no 0590672 00 Numb...

Page 18: ...0590736 00 Number of poles 2 Charging current 100 duty cycle A 100 Weight kg 0 588 AGV current collector Type SA BLS200 2 01 ID no 0590000 01 MS Number of poles 2 Charging current 100 duty cycle A 20...

Page 19: ...0590001 00 Number of poles 2 Charging current 100 duty cycle A 200 Weight kg 2 542 Version Milled component AGV current collector Type SA BLS200 2QU 01 ID no 0590013 00 Number of poles 2 Charging cur...

Page 20: ...es 2 Number of poles control current 2 Charging current 100 duty cycle A 100 Weight kg 0 614 for frontal contact with pilot function AGV floor contact Type BLK100 2 25 2 04 ID no 0590624 00 Number of...

Page 21: ...poles control current 2 Charging current 100 duty cycle A 200 Weight kg 3 075 with cleaning brushes on front side for frontal con tact with pilot function AGV floor contact Type BLK200 2 25 2 01 ID no...

Page 22: ...r frontal contact AGV current collector Type SA BLK200 1 02 ID no 0590036 00 Number of poles 1 Charging current 100 duty cycle A 200 Weight kg 0 944 AGV current collector Type SA BLS400 1O 02 ID no 05...

Page 23: ...contact Type BLK600 1 01 ID no 0590044 00 Number of poles 1 Charging current 100 duty cycle A 600 Weight kg 3 241 AGV current collector Type SA BLS200 2E 01 ID no 0590065 00 Number of poles 2 Charging...

Page 24: ...als tools and auxiliary devices been cleared from the danger zones Have the electrical system powered up by an authorized electrically trained person see chapter 2 3 1 Danger from electrical energy WA...

Page 25: ...r when working on the conductor rail with tools Only tools that have not previously been used for ferritic materials may be used Use own tools for the different materials aluminum copper stainless ste...

Page 26: ...crew head does not protrude from the contour and that the screw connection is secured against loosening e g Loctite threadlocker or locknut Changes to installation dimensions by prior agreement Increa...

Page 27: ...n Nm 18 Disconnected height X mm approx 75 Lift tolerance mm 5 Permissible wear mm 2 Electrical connection X Assembly SA BLS100 InstallationdimensionsX mm 40 Torque connection Nm 5 Disconnected height...

Page 28: ...s 1 Mount the current collector unit at the correct in stallation height Use the existing mounting bore holes or threaded inserts for this purpose NOTICE Make sure not to damage the carbon brush con n...

Page 29: ...ys or buffer sections for example Mounting floor contact Prerequisites During mounting pay attention to any uneven ness of the surface The floor contact should evenly rest on as large an area as possi...

Page 30: ...Required torque M6 8 Nm M8 15 Nm M10 18 Nm Option 1 BLK Connection CU connection tube The cable is connected to CU connection tubes which are connected to the CU contact plate Option 2 BLK connection...

Page 31: ...s Check mechanical and electrical connections and re tighten if necessary Check the mobility of the carbon brushes and the free movement of the connection cable at the current collector Check the maxi...

Page 32: ...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 33: ...rdance with the instructions A fault free sequence must be verified Malfunction Cause Remedy Periodic charging or loss of charging current Mechanical alignment Check the mechanicalalignment of the cha...

Page 34: ...assembly site Before starting work follow the procedure described in paragraph Dangers due to electrical energy WARNING Danger due to insufficient qualification of persons Insufficiently qualified pe...

Page 35: ...wing instructions 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 live or in tensio...

Page 36: ...brush springs in accor dance with 7 4 Carbon brush Check all electrical connections for corrosion Ensure that all fastening elements are properly tightened Check the maximum position offset depending...

Page 37: ...rbon brush springs The contact pressure of the carbon brush springs must not fall below the values in the following table Measure the force required to push in the carbon brushes If the contact pressu...

Page 38: ...t on the facilities NOTICE Transport instructions Never hold the unit by the carbon brushes or the power cable Always transport the unit holding it by the plastic base plate or by the collector plate...

Page 39: ...e period Document and report the defects found 8 3 Storage Packaging When storing charging contacts or components care must be taken that the carbon brush contact surface and contact plate are protect...

Page 40: ...WARNING Risk of death from improper replacement or removal Errors during the removal or replacement of components may cause life threatening situations or significant property damage Observe the safet...

Page 41: ...that the products specified hereafter conform to the relevant EU regulations This declaration will be void when amendments not approved by us will be made to the products Battery changing system Paul...

Page 42: ...F Floor contact connection 28 G Grounding and short circuiting 7 I Isolation 8 M Maintenance 34 O Operating company 8 Operation 29 Owner obligations 8 Q Qualifications 9 R Requirements to personnel 9...

Page 43: ...CE Technical Documentation DQS certified in accordance DIN EN ISO 9001 2015 OHSAS 18001 2007...

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Vahle System 1, Operating Instructions Manual

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