Vahle U35 User manual

INSTALLATION INSTRUCTIONS
U35
HEATING
EN-V 1.01

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TABLE OF CONTENTS 0
TABLE OF CONTENTS
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 About these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ..1
1.3 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.6 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4
2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.3 General risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.3.1 Danger from electrical energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4 Responsibilities of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.5 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.5.1 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.6 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.7 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.8 Conduct in case of danger or accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.9 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .10
3 Layout and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1 Schematic diagram of U35 heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.1 Safety instructions for commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.2 Heating installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.2.1 Connection & repair of heating conductors / PTC thermistor bridges . . . . . . . . . . . . . . . . . . . . . . . .17
4.2.2 Pulling in heating wire and installing feed terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.3 Drawing in heating wire through expansion section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3 Condition after the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.1 Safety instructions for transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6 Disassembly and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.1 Preparation for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.1.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .25

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GENERAL 1
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1 GENERAL
1.1 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. This documentation does not give instructions for operating the plant/machine in which our
system is integrated. In addition, the local accident prevention regulations and general safety regulations for
the use of the system apply. Illustrations serve the basic understanding and may deviate from the actual ver-
sion.
1.2 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.
This combination of a symbol and a signal word indicates an immediately dangerous
situation that will result in death or serious injury unless avoided.
►The actions to prevent the hazard are identified here
DANGER!
The source of an electrical hazard is described here.
This combination of a symbol and a signal word indicates an immediately dangerous
situation 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 combination of a symbol and a signal word indicates a potentially dangerous sit-
uation that may result in death or serious injury unless avoided.
►The actions to prevent the hazard are identified here
CAUTION!
The source of the hazard is described here.
This combination of a symbol and a signal word indicates an potentially dangerous sit-
uation that may result in light or moderate injury unless avoided.
►The actions to prevent the hazard are identified here

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GENERAL 2
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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.
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!
►Simple tips and recommendations from our long years of experience are provided
here.
1.3 Copyright protection
The contents of this manual are protected by copyright. Their use is permitted within the scope of the use of
the installation. No further use is permitted without the written permission of the manufacturer. This manual
may not be copied, given to any third party, reproduced in any form or by any means, including, but not limited
to, exploitation and / or communication of the contents without the written permission 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 engineering, 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
• Use by personnel without the required training
• Unauthorized modifications or technical changes
• Use of non-approved spare parts or accessories
The actual scope of delivery may vary from the descriptions and images in this document in case of custom
versions, the selection of additional order options, or due to latest technical changes.
The obligations agreed in the supply contract, the general terms and conditions and the terms and conditions
of delivery, and the laws and regulations applicable at the time the contract was signed all apply.
We reserve the right to make technical changes to improve the usability and for further development.

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GENERAL 3
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1.5 Customer service
1.6 Warranty
The information in this document has been compiled in consideration of applicable standards and regulations,
accepted rules of engineering, as well as our years of knowledge and experience.
The warranty period and the scope of the warranty are defined in the terms of your contract and the terms and
conditions of delivery of Vahle GmbH & Co. KG.
Our general terms of warranty and delivery are published on our website.
www.vahle.de
WARNING!
No liability in case of unauthorized changes, modifications, or accessories!
Changes or modifications to the 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 manufacturer.
►Always consult the manufacturer first!
The warranty becomes void in case of any of the events below:
• The product is changed without permission from Vahle.
• 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.
Paul Vahle GmbH & Co. KG
Westicker Str. 52
Tel: [phone]
Fax: [phone]
59174 Kamen, GERMANY
E-mail: [email protected]
Web: http://www.vahle.de
Country of origin: Germany

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SAFETY INSTRUCTIONS 4
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2 SAFETY INSTRUCTIONS
2.1 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.
DANGER!
Failure to observe the safety instructions may result in risks to life and health!
2.2 Intended use
Conductor rails can freeze in outdoor areas due to ambient temperatures near freezing point. The contact sur-
faces for the current collectors can freeze over. This layer of ice is formed by freezing condensation or white
frost (freezing humidity) and forms an insulating layer between the conductor rail and the carbon brush due to
its high electrical resistance. The conductor rail heating system provides reliable protection against freezing
over and can be used for all insulated Vahle conductor rails (except U20, U30 and U40).
2.3 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.
Do not change or modify the system inappropriately!
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 safety instructions before beginning any removal work.

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SAFETY INSTRUCTIONS 5
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2.3.1 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, 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 clearly associated prohibition
sign must be nearby. Existing mechanical interlocking devices against restart must be used for manually op-
erated switches.
Determine absence of voltage
Absence of voltage is to be determined at or as close as possible to the work site at all poles. Absence of volt-
age must be checked with a voltage tester immediately before and after use.
Grounding and short-circuiting
Parts on which work will be performed at the work place must first be grounded and then short circuited.
Grounding and short-circuiting must be visible from the workplace. Deviating from the above, it is permitted to
ground and short-circuit near the work place if this is required due to local conditions or for safety reasons.
Devices for grounding and short-circuiting must always first be connected with the grounding system or the
ground electrode and afterwards with the parts to be grounded. Grounding and short circuiting may be waived
in certain low-voltage systems (see VDE 0100-100).
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.

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SAFETY INSTRUCTIONS 6
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2.4 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. In addition to the safety instructions in this document, the safety, accident pre-
vention, and environmental regulations for the system's field of application must be followed. The following ap-
plies in particular:
• The owner ensures protection against electric shock (contact protection).
• The owner must inform himself about applicable workplace health and safety regulations and conduct a
risk assessment for additional hazards 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 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 as necessary.
• The owner must clearly define responsibilities for the installation, operation, maintenance, and cleaning
of the system.
• The owner must ensure that all employees who handle the system have read and understood the operat-
ing instructions. The owner is also required to provide training periodically and instruct personnel about
the risks.
The owner is also responsible for ensuring that the system is always in good technical condition. The following
therefore applies:
• The owner must ensure that the maintenance intervals described in this documentation are observed.
• Control and safety devices provided by the owner for the operation of the system must be checked for com-
pleteness and functional safety.
• The owner must ensure that assembly and installation comply with EN 60204.
• The owner must ensure that all components are de-energized in the event of an emergency off. This ap-
plies in particular to the parallel busbar.

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SAFETY INSTRUCTIONS 7
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2.5 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.
►All work must be performed by qualified personnel only.
►Insufficiently qualified personnel must stay out of the work area.
Operator
The operator has been instructed by the owner about the tasks assigned to him and the risks of inappropriate
actions. An operator may perform tasks that go beyond normal operation only if this is indicated in the instruc-
tions and the owner has expressly assigned him with such a task.
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 carry out work on electrical installations and to independently rec-
ognize and avoid possible hazards. The professional electrician has been specifically trained for his/her
professional working environment and is conversant with the relevant standards and regulations.
Qualified personnel
Qualified personnel are able, based on their technical training, knowledge, experience, and familiarity with ap-
plicable regulations, to perform the assigned tasks and independently detect and avoid potential hazards.
Instructed personnel
The instructed person has been instructed by the owner about the assigned tasks and the risks of inappropri-
ate actions. Such persons must also have read and understood these safety instructions and observe them
during their work.
This may need to be confirmed by the customer/user with a signature.

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SAFETY INSTRUCTIONS 8
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2.6 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.
Personal protective equipment is described below:
Safety shoes
Safety shoes protect against falling parts as well as against slipping.
Protective goggles
Protective goggles protect against 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
against contact with hot surfaces.
Protective work clothes
Work clothing is close fitting and resistant to tearing, with close-fitting sleeves and
without any projecting parts. It is designed to protect against being caught by moving
parts of machinery. However, it must not reduce mobility. Do not wear rings, necklaces,
or other jewelry. Long hair must be covered (cap, hat, hairnet or similar). Fall-arrest
equipment, face and hearing protection acc. to DGUV Regulation 112-189.
Hearing protection
To protect against severe and permanent hearing loss.
Breathing protection
To protect against severe and chronic conditions of the airways.