Vahle VCL Series Quick guide

TRANSLATION OF THE ORIGINAL GERMAN
OPERATING INSTRUCTIONS
VCL
COMPACT CONDUCTOR SYSTEM
INSTALLATION MANUAL
SYSTEM MANUAL
MAINTENANCE MANUAL
EN-V 1.01

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TABLE OF CONTENTS 0
TABLE OF CONTENTS
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 About these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.6 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.6.1 Warranty terms and conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Intended use / foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 General risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8
2.3.1 Danger from electrical energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.4 Responsibilities of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.5 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.5.1 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.6 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.7 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.8 Conduct in case of danger or accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.9 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3Technicaldata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1 VCL2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.2 VCL3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.3 VMT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4 Layout and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.1 System description VCL2/VCL3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.2 System overview VCL2/VCL3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.1 Arrangement examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3 Device overview VCL2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.3.1 Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.3.2 Connecting material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.3.3 End segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.3.4 Transfer guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.3.5 Hanger/holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.3.6 Expansion joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3.7 Line feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3.8 Fixpoint terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.3.9 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.3.10 Connecting cables for collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.3.11 Connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3.12 Equipotential bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.4 Device overview VCL3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.4.1 Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.4.2 Connecting material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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TABLE OF CONTENTS 1
4.4.3 End segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4.4.4 Transfer guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4.4.5 Hanger/holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4.4.6 Expansion joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.4.7 Line feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.4.8 Fixpoint terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.4.9 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.4.10 Connecting cables for collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.4.11 Connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
4.4.12 Equipotential bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.5 System description VMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
4.6 Device overview VMT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.6.1 Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.6.2 Terminal connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.6.3 Compact hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.6.4 Adapter for fixpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.6.5 Single hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.6.6 Auxiliary supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
4.6.7 Edge protector for line feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.1 Safety instructions for commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.2 Operation/decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
5.2.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
5.2.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
5.3 Installation VCL2 / VCL3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.3.1 Assembly preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.3.2 Determining the system lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
5.3.3 End segment with feed terminal (fixpoint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.3.4 Transfer guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
5.3.5 Line material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
5.3.6 Renewing conductor rail joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
5.3.7 End segment with end cap (sliding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.3.8 Straight sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
5.3.9 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
5.3.10 Alternative fixpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
5.3.11 Expansion joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.3.12 Line feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
5.4 Installation VMT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
5.4.1 Installation aids VMT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
5.4.2 Arrangement VCL in VMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
5.4.3 Installation VMT profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
5.4.4 Creating VMT shorter lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
5.4.5 Equipotential bonding at section with VMT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.4.6 Feed terminal installation with VMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
5.4.7 Installation of VCL profile in the VMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
5.5 Condition after the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
6Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

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TABLE OF CONTENTS 2
6.1 Safety information about malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
6.2 Conduct in case of malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
7.1 Safety information about repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.2 Wear parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
7.3 Conductor system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.4 Current collector maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
8 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
8.1 Safety instructions for transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
8.2 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
9 Disassembly and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
9.1 Preparation for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
9.1.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
9.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
10 Declarations of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

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GENERAL 3
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. Diagrams serve the basic understanding and may deviate from the actual version.

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GENERAL 4
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 a potentially dangerous sit-
uation that may result in light or moderate injury unless avoided.
►The actions to prevent the hazard are identified here.
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.

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GENERAL 5
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 6
1.5 Customer service
1.6 Warranty
1.6.1 Warranty terms and conditions
The information in this document has been compiled in consideration of applicable standards and regulations,
accepted rules of engineering, as well as our accumulated years of knowledge and experience.
The warranty period and the scope of the warranty are defined in the terms of the contract and the general
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 immediately expires if one or several of the following situations arise(s):
• If the product is modified without permission from Vahle.
• If the operator independently performs repairs during the warranty period or has repairs performed by
third parties.
• If the product has been handled or maintained inappropriately.
• If parts are used that are not original parts approved by Vahle.
• If the information in this documentation is not observed.
Paul Vahle GmbH & Co. KG
Westicker Str. 52
Tel: [phone]
Fax: [phone]
59174 Kamen, GERMANY
Email: [e-mail]
Web: http://www.vahle.de
Country of origin: Germany

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SAFETY INSTRUCTIONS 7
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 / foreseeable misuse
VCL compact conductor systems (type VCL2+VCL3) are contact-protected 2- to 3-pin conductor rails. The con-
ductor systems can be combined with any number of pins and allow direct routing in track supports and sup-
port profiles. The conductor rail is only to be used for indoor installations. It can be mounted hanging or
laterally.
Appropriate use includes following all the information in these instructions.
Any use beyond 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 system for anything but the intended use.
►Never let non-instructed personnel operate the system.
►Never modify or change the system improperly.
►Never operate the system in ways that disregard the safety instructions.
►Never use the system for outdoors applications.
►Never operate the system at higher currents or voltages.
►Never operate the system with contacts made by other manufacturers.
►Never expose the system to large amounts of water.
Claims for damages resulting from improper use shall be invalid.

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SAFETY INSTRUCTIONS 8
2.3 General risks
The following section describes residual risks that arise even if the product 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.
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).

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SAFETY INSTRUCTIONS 9
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.
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 10
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 11
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.

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SAFETY INSTRUCTIONS 12
2.7 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.
►Never disable or override safety devices.
In addition to locally applicable safety regulations, the following safety instructions must be observed.
The following accident prevention regulations (UVV; Germany), respectively the new Accident Prevention Reg-
ulations – Principles of Prevention (DGUV Regulation 1; Germany) must always be observed.
2.8 Conduct in case of danger or accident
Precautions:
• Have first-aid equipment (first-aid kit, blankets etc.) and fire extinguisher ready.
• Maintain free access for emergency services vehicles.
Conduct in case of accident:
• Secure site of accident and call first aid personnel.
• Alert emergency services.
• Provide first aid

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SAFETY INSTRUCTIONS 13
2.9 Signage
The following symbols and instruction signs are located in the work area. They relate to the immediate envi-
ronment in which they are installed.
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.
WARNING!
Danger from illegible signs!
Over time, labels and signs can get dirty or can become unreadable in other ways,
which means that the dangers are not identified and that operating instructions can-
not be followed.
►Always keep all safety, warning and operating instructions in a legible condition.
NOTICE!
Follow instructions!
Only use the designated product after this documentation has been completely read
and understood.

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TECHNICAL DATA 14
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3 TECHNICAL DATA
3.1 VCL2
(1) at max. 80% duty cycle
(2) At phase spacing of 15 mm and a frequency of 50Hz
(3) VCL2/40 F - max. feed length: 100 m
(4) at 100% duty cycle
Technical specifications - electrical
Nominal current VCL2/100C at 35 °C [A] 100(1)
Conductor cross section VCL2/100C [mm²] 25
Resistance VCL2/100C [Ω/1000m]0,721
Impedance(2) VCL2/100C [Ω/1000m]0,723
Nominal current VCL2/40F at 35 °C [A] 40(4)
Conductor cross section VCL2/40F(3) [mm²] 25
Resistance VCL2/40F [Ω/1000m]3,844
Impedance(2) VCL2/40F [Ω/1000m]3,846
Nominal voltage without ground conductor (PE) AC/DC [V] 48
Nominal voltage with ground conductor (PE) AC [V] Max. 500
Number of pins 2
Allocation 2 x phase / 1 x phase + PE
Cross section connection cable [mm²] 6 - 16
Conductor material Copper (CU) or steel (F)
Protection class IP2X
Dielectric strength according to DIN 53481 [kV/mm] 22,4
Volume resistivity according to IEC 60093 [Ωx cm] 2 x 1015
Surface resistance according to IEC 60093 [Ω]2 x 1013
Comparative tracking index according to IEC 60093 > 400
Technical specifications - mechanical
Max. traveling speed [m/min] 300
Travel direction Reversing operation
Distance pin [mm] 15
Max. hanging distance [mm] 800
Technical specifications - system
Max. system length without expansion section [m] 150
Standard length conductor system [mm] 4000 (shorter lengths available upon request)
Length of end segment with feed terminal [mm] 1000
Length of end segment with end cap [mm] 1000
Length of line feed [mm] 1000
Length of expansion section [mm] 1000
Length-effective portion of connectors [mm/side] 0,7

TECHNICAL DATA 15
Tolerances
Conductor system X-axis: [mm] ± 3
Conductor system Y-axis: [mm] ± 3
Conductor rail connectors Z-axis: [mm] 0.7 + 1 per side
Current collectors X-axis: [mm] ± 15 (DEAS ± 12)
Current collectors Y-axis: [mm] ± 20
Operating conditions
Operating temperature [°C] - 30 to + 55
Max. humidity at [%]
ambient temperature 10°C to 40°C
98, non-condensing
Max. deviation of operating temperature [K] 50
Flammability (insulator profile) flame-retardant, self-extinguishing,
UL 94 V0
Application Indoor installations
NOTICE!
UL certification
►For design with UL certification, please consult the manufacturer.

TECHNICAL DATA 16
3.2 VCL3
(1) at max. 80% duty cycle
(2) At phase spacing of 15 mm and a frequency of 50Hz
(3) VCL2/40 F - max. feed length: 100 m
(4) at 100% duty cycle
Technical specifications - electrical
Nominal current VCL3/100C at 35 °C [A] 100(1)
Conductor cross section VCL3/100C [mm²] 25
Resistance VCL3/100C [Ω/1000m]0,721
Impedance(2) VCL3/100C [Ω/1000m]0,723
Nominal current VCL3/40F at 35 °C [A] 40(4)
Conductor cross section VCL3/40F(3) [mm²] 25
Resistance VCL3/40F [Ω/1000m]3,844
Impedance(2) VCL3/40F [Ω/1000m]3,845
Nominal voltage without ground conductor (PE) AC/DC [V] 48
Nominal voltage with ground conductor (PE) AC [V] Max. 500
Number of pins 3
Allocation 3 x phase / 2 x phase + PE
Cross section connection cable [mm²] 16
Conductor material Copper (CU) or steel (F)
Protection class IP2X
Dielectric strength according to DIN 53481 [kV/mm] 22,4
Volume resistivity according to IEC 60093 [Ωx cm] 2 x 1015
Surface resistance according to IEC 60093 [Ω]2 x 1013
Comparative tracking index according to IEC 60093 > 400
Technical specifications - mechanical
Max. traveling speed [m/min] 300
Distance pin [mm] 15
Max. hanging distance [mm] 800
Travel direction Reversing operation
Technical specifications - system
Max. system length without expansion section* [m] 150
Standard length conductor system [mm] 4000 (shorter lengths available upon request)
Length of end segment with feed terminal [mm] 1000
Length of end segment with end cap [mm] 1000
Length of line feed [mm] 1000
Length of expansion section [mm] 1000
Length-effective portion of connectors [mm/side] 0,7

TECHNICAL DATA 17
* When using an expansion section (max. 50A) - with a load of100 A,place feed terminals (100 A)onthe right
and left of the next rail section, and connect with a cable (bridging).
3.3 VMT
Tolerances
Conductor system X-axis: [mm] ± 3
Conductor system Y-axis: [mm] ± 3
Conductor rail connectors Z-axis: [mm] 0.7 + 1 per side
Current collectors X-axis: [mm] ± 15 (DEAS ± 12)
Current collectors Y-axis: [mm] ± 20
Contact pressure current collector [N] approx. 8
Operating conditions
Operating temperature [°C] - 30 to + 55
Max. humidity at [%]
ambient temperature 10°C to 40°C
98, non-condensing
Max. deviation of operating temperature [K] 50
Flammability (insulator profile) flame-retardant, self-extinguishing,
UL 94 V0
Application Indoor installations
Technical specifications
Support profile version Steel
Grid dimension of compact holder [mm] 100
Bearer length [mm] 6000
Max. hanger spacing (lateral/suspended) [mm] 3500/3000
Technical specifications - system dependent
Number of poles 4-6
Temperature range [°C] -30 to +55
Application area Indoor installations
NOTICE!
UL certification
►For design with UL certification, please consult the manufacturer.

LAYOUT AND FUNCTION 18
4 LAYOUT AND FUNCTION
4.1 System description VCL2/VCL3
The compact wiper line VCL was developed especially for various applications in intralogistics. With its com-
pact dimensions and durability, the VCL possesses the ideal properties for potential shuttle applications in au-
tomated small parts stores or for other transfer carriages. Additional features are short installation times due
to the small number of different components (–50%) and the robust clip fastening system.
The VCL comes in two- or multiple-pin versions.
Safety
The compact wiper line has been designed according to VDE 0100. It meets today’s requirements on the safety
of a conductor system and is contact-protected in acc. with VDE 0470, Part 1 (protection class IP 2X). The cur-
rent collectors are protected against contact only if the carbon brushes are fully located in the conductor rails.
For conductor rail systems located at arm's length, where under normal operation the current collectors leave
the conductor rails, contact protection must be provided on site, e.g. by means of barriers or by switching off.
This, however, only applies to voltages above 25 volts AC or 60 volts DC.
The 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 little space is re-
quired.
Application
Only for indoor systems with travel speeds of up to 300 m/min.
Hangers
The maximum distance between the hangers is 0.8 m.
Connectors
Joint connectors are used for the electrical and mechanical connection of the conductor rail sections. Every
connection point is protected against contact with a cover cap.
Linear expansions
• The conductor rails are permanently connected to each other by means of conductor rail connectors to
form a continuous conductor profile. The connecting caps are clamped between the two connected con-
ductor rails and travel along with the conductor rail joint.
• To compensate for changes in length, the insulation profile is 7.5 mm shorter for end segments and 15
mm shorter for the conductor system itself. The transfer guide also serves as an end cap, feed terminal
and fixpoint. Generally, the feed terminal is also the fixpoint and the end cap is the moving part.
• Expansion sections are required in special cases only. For instance to compensate for a structural expan-
sion joint in the building, for system lengths exceeding 150 m, or for fixpoints on both ends of the system.