Vahle VKL 2 Quick guide

TRANSLATION OF THE ORIGINAL
GERMAN OPERATING INSTRUCTIONS
VKL 2
COMPACT CONDUCTOR SYSTEM
INSTALLATION MANUAL
SYSTEM MANUAL
MAINTENANCE MANUAL
EN-V 1.07

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0
TABLE OF CONTENTS
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.1 About these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ..3
1.3 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6.1 Warranty terms and conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6
2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2 Intended use / foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3 General risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3.1 Danger from electrical energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.4 Responsibilities of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.5 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.5.1 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.6 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.7 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.8 Conduct in case of danger or accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.9 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .12
3Technicaldata. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..13
4 Layout and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.1.1 Arrangement examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.2 Brief system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.3.1 Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.3.2 Connecting material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.3.3 End segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.3.4 Transfer guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.3.5 Hanger / holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.3.6 Expansion joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3.7 Line feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3.8 Fixpoint terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3.9 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3.10 Connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.1 Safety instructions for commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.2 Operation/decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.2.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.2.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..28
5.3.1 Assembly preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.3.2 Installation aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

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TABLE OF CONTENTS 1
5.3.3 Determining the system lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.3.4 End segment with feed terminal (fixpoint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.3.5 Transfer guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.3.6 Line material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.3.7 Renewing conductor rail joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.3.8 End segment with end cap (sliding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
5.3.9 Straight sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
5.3.10 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
5.3.11 Alternative fixpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.3.12 Expansion joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.3.13 Line feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.4 Condition after the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
7.2 Wear parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..52
7.3 Conductor system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
7.4 Current collector maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .55
8 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.1 Safety instructions for transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.2 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
9 Disassembly and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
9.1 Preparation for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
9.1.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
9.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .57
10 EU declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

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TABLE OF CONTENTS 2
1 GENERAL
1.1 About these instructions
These operating instructions describe the safe and efficient use of our VAHLE products. This document is part
of the system and must be kept in its immediate vicinity so that it is accessible to operating and maintenance
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 of the overall machine/system
into which our system is integrated. In addition to this document, local accident prevention regulations and
general safety regulations for the use of the system apply. Figures are included for information only and may
vary from the actual design.

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GENERAL 3
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
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 4
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 5
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 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 6
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
Compact conductor systems (type VKL2) are contact-protected 2-pin conductor rails. The 2-pin conductor sys-
tem can be combined with any number of pins and allows direct routing in track supports and support 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.
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!

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SAFETY INSTRUCTIONS 7
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 acc. to VDE 0105-100 (such work must be performed by a trained electrician;
see chapter 2, “Safety.”)
De-energize
The required isolating distances must be established.
Secure against switching on
For the duration of the work, a prohibition sign must be applied securely to switch handles or drives, to con-
trols, to pushbuttons or rocker switches, to fuse parts, to circuit breakers with which a part of the system has
been de-energized or with which it can be made live again. If this is not possible, then a clearly associated pro-
hibition sign nearby is sufficient. For manual switches, existing mechanical 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 be checked immediately before and after use.
Grounding and shorting
At the work site, the parts that are worked on must be grounded first and then shorted. The grounding and
shorting must be visible from the work site. As an exception, grounding and shorting in the vicinity of the work
site shall be permissible where required by the local situation or for safety reasons. Devices for grounding and
shorting always need to be connected to the ground first, then to the components to be grounded. Grounding
and shorting can be omitted for certain low-voltage systems (cf. VDE 0100-100)
Cover or fence off adjacent live parts
Before beginning the work, check whether it might be appropriate to establish that adjacent parts are free of
voltage.
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 8
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 9
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 10
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 11
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 12
2.9 Signage
The following symbols and information signs may be in the work area. They apply to the immediate environ-
ment of their location.
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!
Hazard from illegible signs!
Over time, labels and signs may become soiled or otherwise illegible so that hazards
may not be recognized or necessary operating instructions may not be followed.
►Always keep all safety, warning and operating instructions in easily legible condi-
tion.
NOTICE!
Observe instructions!
Use the identified device only after this documentation has been read and understood
in full.

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TECHNICAL DATA 13
3 TECHNICAL DATA
* At phase spacing of 15mm and a frequency of 50Hz
** VKL2/40 F - max. feed length: 100 m
Technical specifications - electrical
Nominal current VKL2/100C at 100 % active dura-
tion [A]
100
Conductor cross section VKL2/100C
[mm²]
25
Resistance VKL2/100C [Ω/1000m]0.721
Impedance* VKL2/100C [Ω/1000m]0.732
Nominal current VKL2/40F at 100% active dura-
tion [A]
40
Conductor cross section VKL2/40F**
[mm²]
25
Resistance VKL2/40F [Ω/1000m]3.844
Impedance* VKL2/40F [Ω/1000m]3.846
No m in a l vo l ta g e wi t ho u t gr o un d c on d uc t or ( P E) A C /D C
[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
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
Direction of travel Reversing operation
Distance pin [mm] 15
Max. hanging distance [mm] 800
Technical specifications - system
Max. system length without expansion joint [m] 150
Standard length conductor system [mm] 4000 (shorter lengths available upon re-
quest)
Length of end segment with feed terminal
[mm]
1000
Length of end segment with end cap [mm] 1000
Length of line feed [mm] 1000

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TECHNICAL DATA 14
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Length of expansion joint [mm] 1000
Length-effective portion of connectors [mm/side] 0.7
Technical specifications - system
Tolerances
Conductor system X-axis: [mm] ± 3
Conductor system Y-axis: [mm] ± 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 temperature [°C] - 30 to + 55
Max. humidity at [%]
ambient temperature 10°C to 40°C
98
Max. deviation of operating temperature [K] 50
Flammability flame-retardant, self-extinguishing,
UL 94 V0
Application Indoor installations

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LAYOUT AND FUNCTION 15
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4 LAYOUT AND FUNCTION
4.1 System overview
1EndsegmentESM-VKL2
2 Conductor line VKL2
3 Transfer guide with/without fix point US-VKL2
4HangerAH-VKL2
5 Material of connectors VM-VKL2
2
3
4
5
1

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LAYOUT AND FUNCTION 16
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4.1.1 Arrangement examples
Arrangement example 1 - hangers / connectors
1 Connector
2Hanger
3Hanger
4 Connector
5Hanger
6Hanger
7 Connector
* only applies if the connecting cap can be supported. 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 segment
Arrangement example 3 - Fixed end segment
1 Transfer guide used as fixpoint
2Hanger
3Hanger
4 Connector
Arrangement example 4 - Sliding end segment
1 Connector
2Hanger
3Hanger
4 Sliding transfer guide

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LAYOUT AND FUNCTION 17
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4.2 Brief system description
The two-pole compact wiper line VKL2 was developed especially for various applications in intralogistics. With
its compact dimensions and durability, the VKL2 possesses the ideal properties for potential shuttle applica-
tions in automated small parts stores or for other transfer carriages. Additional features are short installation
times due to the small number of different parts (–50%) and the robust clip fastening system.
Safety
The compact wiper line VKL2 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 current collectors are protected against contact only if the carbon brushes are fully located in the conduc-
tor rails. For conductor rail systems located at arm's length, where under normal operation the current collec-
tors 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
joint is protected against contact with a joint cap.
Linear expansions
• The connector 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 rail is 7.5 mm shorter for end segments and 15 mm
shorter for the conductor line itself. The transfer guide also serves as an end cap, feed terminal and fix-
point. Generally, the feed terminal is also the fixpoint and the end cap is the moving part.
• Expansion joints are required in special cases only. For instance to compensate for a structural expansion
joint in the building, for system lengths exceeding 150 m, or for fixpoints on both ends of the system.

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LAYOUT AND FUNCTION 18
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Feed terminals
The infeed can be realized as an end feed via the transfer guides or on the line as a line feed.
Transfer guides
Transfer guides are the contact-protected ends of the conductor rails at the end of the lines and mechanical
line interruptions (switches, dropout sections, etc.). Transfer guides are available with or without feed capabil-
ity.
Current collectors
The current collectors are manufactured from impact-resistant plastic and stainless steel parts. The current is
drawn via a carbon brush. The length of the current collector connection cable may not exceed 3 m if the down-
stream overcurrent protection device is not designed to handle the capacity of the connection cable. Refer also
to DIN VDE 0100, part 430 and DIN EN 60204-32. (Note: this is often the fact if more than one collector is
used in the 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-
dures. According to DIN EN 60204-1 and DIN EN 60204-32, the continuity of the ground conductor system via
wiper contacts must be ensured using suitable measures. As a simple and suitable measure, it is recommend-
ed to double the PE current collector.
Further remarks
• The fixpoint may only be installed in the system 1x. Normally the end of the conductor line is fixed at the
location of the feed terminal. The end cap/transfer guide on the other end may not be fixed. If both ends
need to fixed for system reasons, an expansion joint is required.
• Rail holder spacing according to chapter: „5.3.1 “.
• Connectors cannot be removed again, therefore align and install them carefully.
• The connecting caps must rest on the installation surface to prevent any incorrect deflection or warping of
the conductor line.
• The shortest permissible rail segment is 300 mm.