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