Related Manuals for Delachaux Conductix-Wampfler 0314 Series
Summary of Contents for Delachaux Conductix-Wampfler 0314 Series
- Page 1 Installation Manual Festoon Systems for I-Beams Program 0314 MAL0300-0001-EN www.conductix.com translated document page 1 of 56...
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Page 2: Table Of Contents
Installation Manual Festoon Systems for I-Beams Program 0314 Contents Page General information ................................. 5 Information about this installation manual ........................5 Limitation of liability ..............................5 Copyright ..................................6 Replacement parts ..............................6 Material defects ................................6 Technical support ................................ 6 Safety instructions .................................. - Page 3 Installation Manual Festoon Systems for I-Beams Program 0314 3.4.7 Poor vertical alignment between the crane beam and track beam ............... 20 Product description and mode of operation ........................... 21 Overview of the festoon system ..........................21 Brief description ................................. 22 Description of assemblies ............................
- Page 4 Installation Manual Festoon Systems for I-Beams Program 0314 Maintenance/inspection plan ............................. 42 8.2.1 Inspection with the system at a standstill ...................... 43 8.2.2 Inspection with the system moving ....................... 44 8.2.3 Logging ................................. 44 8.2.4 Maintenance of the festoon system ......................45 8.2.5 Wearing parts ..............................
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Page 5: General Information
Installation Manual Festoon Systems for I-Beams Program 0314 General information 1.1 Information about this installation manual These assembly instructions make it possible for you to work with the festoon system safely and efficiently. The assembly instructions are a part of the festoon system, and must be kept accessible to personnel at all times in the immediate vicinity of the festoon system. -
Page 6: Copyright
Installation Manual Festoon Systems for I-Beams Program 0314 1.3 Copyright These assembly instructions are subject to copyright, and are exclusively intended for internal use. Provision of the assembly instructions to third parties, duplications in any form – even in part – as well as the reuse and/or disclosure of their content are not permitted without the written approval of the manufacturer, except for internal use. -
Page 7: Safety Instructions
Installation Manual Festoon Systems for I-Beams Program 0314 Safety instructions 2.1 Explanation of symbols Safety and hazard information is identified in this installation manual by symbols. Safety instructions are introduced by signal words that indicate the degree of the hazard. Always observe safety and hazard instructions, and work carefully to avoid accidents, bodily injury and damage to property! ... -
Page 8: Personnel Requirements
Installation Manual Festoon Systems for I-Beams Program 0314 2.2 Personnel requirements 2.2.1 Qualifications Inadequately trained persons are at risk of injury! Improper use can result in serious injury to persons and property. Therefore: WARNING! - All activities must be carried out by qualified staff! The following qualifications have been mentioned in this installation manual for different areas of operation: ... -
Page 9: Personal Protective Equipment
Installation Manual Festoon Systems for I-Beams Program 0314 2.3 Personal protective equipment Always wear: For all work, always wear: Protective work clothing are tightly fitting working clothes with low resistance to tearing, close-fitting sleeves and no protruding parts. They serve primarily as protection against entrapment by moving machine parts. -
Page 10: Intended Use
Installation Manual Festoon Systems for I-Beams Program 0314 2.4 Intended use The festoon system is exclusively designed and built for the intended use described here. The Series 0314 festoon system and its components may only be used for the construction and operation of power supply systems for rail-mounted, mobile consumers such as cranes and lifting accessories in industrial applications. -
Page 11: Protective Measures To Be Taken By The Operator/User
Installation Manual Festoon Systems for I-Beams Program 0314 2.5 Protective measures to be taken by the operator/user The festoon system is used in an industrial setting. The operator of the festoon system is thus subject to legal requirements related to workplace safety. In addition to the safety instructions in these assembly instructions, all safety, accident protection, and environmental regulations valid in the place of operation of the festoon system must also be observed. -
Page 12: Special Hazards
Installation Manual Festoon Systems for I-Beams Program 0314 2.6 Special hazards The following section lists residual risks determined on the basis of a risk assessment. Follow the safety instructions listed here and the warnings in other sections of this installation manual in order to reduce health ... - Page 13 Installation Manual Festoon Systems for I-Beams Program 0314 Risk of fire! Risk of fire if undersized cables are used! Therefore: Warning! - The required cable cross-sections must be adhered to. Danger of tripping on projecting parts! When working on the festoon system, there is a risk of tripping. Therefore: CAUTION! - When walking in the work and danger area, be careful of projections and depressions in the floor.
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Page 14: Actions In The Event Of Accidents And Faults
Installation Manual Festoon Systems for I-Beams Program 0314 2.7 Actions in the event of accidents and faults Measures to take in the event of accidents: Take first-aid measures. Remove persons from the danger zone. Inform responsible parties at the place of operation. ... -
Page 15: Technical Data
Installation Manual Festoon Systems for I-Beams Program 0314 Technical data 3.1 General information Designation Value Notes Max. load capacity 10 - 20 kg Depending on the number of rolls Max. travel speed 50 m/min 3.2 Interfaces Mechanical: Machine Part Load-bearing structure End clamp, towing trolley Cables Overlay, conductor holder... -
Page 16: Track Beam
Installation Manual Festoon Systems for I-Beams Program 0314 3.4 Track beam The operator is basically responsible for ensuring that the track carrier is securely fastened as well as checking it for wear, corrosion or defects. The following procedures are to be observed when installing the track beam: In general, track beams are to be protected from corrosion using appropriate measures. -
Page 17: Smoothing Of Welded Track Beams
Installation Manual Festoon Systems for I-Beams Program 0314 3.4.1 Smoothing of welded track beams Bumps and uneven areas on all sides of the welded track beams are to be sanded smooth for a length of 100 mm. Required tools and materials: NOTE! Fig. -
Page 18: Girder Joint For Non-Welded Track Beams
Installation Manual Festoon Systems for I-Beams Program 0314 3.4.3 Girder joint for non-welded track beams For non-welded girder joints, the gap between beams may be at most 8 mm. The cut is at a 45° angle. Required tools and materials: NOTE! Fig. -
Page 19: Horizontal Deviation Of Track Beams
Installation Manual Festoon Systems for I-Beams Program 0314 3.4.4 Horizontal deviation of track beams The horizontal deviation over the length of the track beam may not exceed 5 mm. For lengths shorter than 2 m, deviation may not exceed 2 mm. Required tools and materials: NOTE! Fig. -
Page 20: Poor Horizontal Alignment Between The Crane Beam And The Track Beam
Installation Manual Festoon Systems for I-Beams Program 0314 3.4.6 Poor horizontal alignment between the crane beam and the track beam The vertical alignment gap between the crane beam and track beam must not exceed 7.5 mm. This tolerance should include a possible alignment deviation of the trolley winch. -
Page 21: Product Description And Mode Of Operation
Installation Manual Festoon Systems for I-Beams Program 0314 Product description and mode of operation 4.1 Overview of the festoon system Fig. 10: Overview of the festoon system 1) End clamp 2) Festoon MAL0300-0001-EN www.conductix.com translated document page 21 of 56... -
Page 22: Brief Description
Installation Manual Festoon Systems for I-Beams Program 0314 4.2 Brief description A festoon system consists of end clamp and cable trolley. The last cable trolley is coupled via the line to the mobile consumer via which the subsequent cable trolleys are pulled. The dimensions of the festoon system can be found in the project-specific dimension sheet. - Page 23 Installation Manual Festoon Systems for I-Beams Program 0314 Cable festoon for round cables, consisting of: Side part (one or two rolls) Rail Lower part Fig. 13: Cable trolley for round cables End clamp for round cables, consisting of: Rail Lower part Fig.
- Page 24 Installation Manual Festoon Systems for I-Beams Program 0314 Cable trolley with hook consisting of: Side panel (single roll) Rail Hook Fig. 16: Cable trolley with hook Cable collar for round cables Cable collars can be used one above the other. The largest should be placed uppermost.
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Page 25: Working And Danger Areas
Installation Manual Festoon Systems for I-Beams Program 0314 4.4 Working and danger areas The following illustration shows the working area of the festoon system. There is a danger of injury from moving parts in this area. Fig. 18: Working and danger areas Working and danger areas: Between the buffer and the buffer plate ... -
Page 26: Modes Of Operation
Installation Manual Festoon Systems for I-Beams Program 0314 4.5 Modes of Operation The festoon system can be operated in one of two modes Automatic operation Manual operation. 4.5.1 Automatic operation The standard operating mode is automatic operation, in which the festoon system is operated via the consumer's controller. In this mode, no person may be in or under the working area of the festoon system. -
Page 27: Transport, Packaging And Storage
Installation Manual Festoon Systems for I-Beams Program 0314 Transport, packaging and storage 5.1 Transport 5.1.1 Safety instructions for transport Risk of death due to suspended loads! When lifting loads, there is a risk of death due to parts falling or swinging out of control. Therefore: WARNING! - Never walk under suspended loads. -
Page 28: Packaging
Installation Manual Festoon Systems for I-Beams Program 0314 5.2 Packaging The individually packaged parts have been packed in accordance with the anticipated transport conditions Only environmentally friendly materials have been used for packaging. The packaging is designed to protect the individual components from transport damage, corrosion and other harm until installation. As a result, do not destroy the packaging, remove it only shortly before installation. -
Page 29: Installation And Commissioning
Installation Manual Festoon Systems for I-Beams Program 0314 Installation and commissioning 6.1 Safety Personnel: Installation and commissioning may only be carried out by specially trained technicians. Wear the following protective gear during all work of installation and commissioning: Protective work clothing ... -
Page 30: Preparations
Installation Manual Festoon Systems for I-Beams Program 0314 6.2 Preparations Required tools: Power drill Metal drill Crescent wrench Corrosion protection Lubricant Gauges 6.3 Installation Personnel: May only be carried out by trained technicians At least two people ... -
Page 31: Assembling The Festoon
Installation Manual Festoon Systems for I-Beams Program 0314 6.3.1 Assembling the festoon The cable trolleys can be pushed into the front end of the track beam or mounted from below on the track beam. The trolleys must be adjusted to the respective track beam (see Adjusting the trolleys). 6.3.2 Adjusting the trolleys Track beam... -
Page 32: Fitting Round Cables
Installation Manual Festoon Systems for I-Beams Program 0314 6.3.4 Fitting round cables Risk of fire! Risk of fire if undersized cables are used! Therefore: - The required cable cross-sections must be adhered to. WARNING! Danger due to improper cable installation! Incorrect arrangement of the cables in the cable bundles and the loop may result in cable damage and electric shocks. -
Page 33: Laying Flat Cables
Installation Manual Festoon Systems for I-Beams Program 0314 6.3.5 Laying flat cables Risk of fire! Risk of fire if undersized cables are used! Therefore: WARNING! - The required cable cross-sections must be adhered to. Danger due to improper cable installation! Incorrect arrangement of the cables in the cable bundles and the loop may result in cable damage and electric shocks. -
Page 34: Testing And Commissioning
Installation Manual Festoon Systems for I-Beams Program 0314 6.4 Testing and commissioning Risk of injury due to improper commissioning! Improperly performed commissioning can lead to dangerous situations for personnel. Therefore: WARNING! - Before commissioning, carry out the tests in the test list of the manufacturer. - Never start the festoon system without testing according to the manufacturer's test list. -
Page 35: Commissioning Test List
Installation Manual Festoon Systems for I-Beams Program 0314 Commissioning checklist 6.4.1 Commissioning test list This checklist should be used as a guideline to ensure the safety operation of the festoon system. The checklist is intended for qualified specialists who install the festoon systems, operate them and who are familiar with the requirements regarding work safety and accident prevention. - Page 36 Installation Manual Festoon Systems for I-Beams Program 0314 Commissioning checklist Checks with the system at a standstill Not OK The track of the carriage corresponds to the project-specific technical documentation. The storage length of the festoon system corresponds to the project-specific technical documentation. All bolts used are of sufficient length and are protected.
- Page 37 Installation Manual Festoon Systems for I-Beams Program 0314 Commissioning checklist Checks with the system at a standstill Not OK Welded joints of the track beam are ground smooth on all roller surfaces. The corrosion protection is undamaged and intact. Inspections on running systems with 10% running speed: Movement forwards from cable trolley storage/termination fitting end in direction of towing end until the cable train is fully extended.
- Page 38 Installation Manual Festoon Systems for I-Beams Program 0314 Commissioning checklist Remarks / other MAL0300-0001-EN www.conductix.com translated document page 38 of 56...
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Page 39: Operation
Installation Manual Festoon Systems for I-Beams Program 0314 Operation 7.1 Safety Risk of death due to suspended loads! When lifting loads, there is a risk of death due to parts falling or swinging out of control. Therefore: WARNING! - Never walk under suspended loads. - Block off the dangerous area under the system. -
Page 40: Functioning
Installation Manual Festoon Systems for I-Beams Program 0314 Danger of crushing! When moving the festoon system, there is a danger of crushing limbs between the buffer and buffer plate, as well as between the carriage and the track carrier. WARNING! Therefore: - When the system is moving, do not enter the traveling area of the festoon system. -
Page 41: Maintenance And Servicing
Installation Manual Festoon Systems for I-Beams Program 0314 Maintenance and servicing 8.1 Safety Danger of injury due to improperly executed maintenance tasks! Improper maintenance can result in serious injury to person and property. Therefore: WARNING! - Before starting work, make sure there is sufficient space for assembly. - Ensure the installation area is clean and tidy! Loosely stacked or scattered components and tools can cause accidents - If components have been removed, ensure their correct assembly, reinstall all fasteners and... -
Page 42: Maintenance/Inspection Plan
Installation Manual Festoon Systems for I-Beams Program 0314 8.2 Maintenance/inspection plan The following sections describe the maintenance tasks required for optimal, trouble-free operation. If regular inspections reveal increased wear, the corresponding maintenance intervals should be shortened in accordance with the actual signs of wear. Contact the manufacturer with any questions about maintenance tasks or intervals. -
Page 43: Inspection With The System At A Standstill
Installation Manual Festoon Systems for I-Beams Program 0314 8.2.1 Inspection with the system at a standstill - Protect the festoon system from inadvertent activation. - Any safety devices that have been removed during inspection of the system when at a standstill must be refitted immediately on completion of the work and tested. -
Page 44: Inspection With The System Moving
Installation Manual Festoon Systems for I-Beams Program 0314 8.2.2 Inspection with the system moving - Any procedures that could threaten safety are to be avoided. - The system should only be commissioned with functional protective gear and safety devices. - It is forbidden to enter the operating area of the festoon system. CAUTION! Inspection measures Interval... -
Page 45: Maintenance Of The Festoon System
Installation Manual Festoon Systems for I-Beams Program 0314 8.2.4 Maintenance of the festoon system - Turn off the power supply and ensure that no inadvertent activation is possible. - When installation tasks are carried out above eye level, use proper climbing aids and working platforms. -
Page 46: Wearing Parts
Installation Manual Festoon Systems for I-Beams Program 0314 Service measures Interval Components Measure Description Roller mounting Tighten all fasteners. Cable attachment Tighten all fasteners on clamping bars and cable clamps. Surface/ corrosion protection Refinish hot-dip galvanized surfaces with zinc coating. Corrosion coating Refinish lacquered surfaces. -
Page 47: Wear Limits
Installation Manual Festoon Systems for I-Beams Program 0314 8.2.6 Wear limits Components Wear limit has been reached if - the diameter of the roller has been reduced from the nominal diameter by 2 mm Rollers - Sharp impressions can be seen - Increased bearing play occurs due to worn ball bearings - significant lubrication leakage is seen - The rollers do not run smoothly... -
Page 48: Troubleshooting
Installation Manual Festoon Systems for I-Beams Program 0314 Troubleshooting Danger of injury due to improper troubleshooting! Improper troubleshooting can result in serious injury to person and property. Therefore: WARNING! - Contact the manufacturer in case of malfunction. - Allow troubleshooting to be carried out only by personnel from or authorized by the manufacturer Improper use can result in serious injury to persons and property. -
Page 49: Dismantling And Disposal
Installation Manual Festoon Systems for I-Beams Program 0314 10 Dismantling and disposal 10.1 Safety Danger of injury due to improper disassembly! Stored energy, sharp components, points, and edges on and in the festoon system or the tools needed can cause injury. WARNING! Therefore: - Make sure there is sufficient space before starting work... -
Page 50: Dismantling
Installation Manual Festoon Systems for I-Beams Program 0314 10.2 Dismantling After the system is no longer in use, the festoon system must be disassembled and environmentally friendly disposal carried out. Before starting disassembly: Remove operating and auxiliary materials, as well as residual processing materials, and dispose of them in an environmentally ... -
Page 51: Additional Documents
Installation Manual Festoon Systems for I-Beams Program 0314 11 Additional Documents 11.1 Declaration of incorporation The declaration of incorporation is available as a separate document. MAL0300-0001-EN www.conductix.com translated document page 51 of 56... -
Page 52: Documentation For Electrical Equipment
Installation Manual Festoon Systems for I-Beams Program 0314 11.2 Documentation for electrical equipment See separate electrical documentation. 11.3 Spare parts list Keeping a stock of the most essential spare and wear parts at the place of installation ensures constant operational readiness of the system. NOTE! Incorrect replacement parts are a safety hazard! Wrong or faulty spare parts can result in damage, malfunctions or complete failure as well as impair... -
Page 53: Product Observations
Installation Manual Festoon Systems for I-Beams Program 0314 11.4 Product observations We strive to observe our products after delivery in order to further improve them and better meet your needs. Please use the form on the following pages to communicate your experiences and issues with us that could be of interest for our improvement process. - Page 54 Installation Manual Festoon Systems for I-Beams Program 0314 MAL0300-0001-EN www.conductix.com translated document page 54 of 56...
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Page 55: Final Inspection Protocol
Installation Manual Festoon Systems for I-Beams Program 0314 11.5 Final inspection protocol Customer: Customer number.: Order no.: Contractor: Order acceptance no.: Construction Project name: location: Address Postal code: City: Contact person / phone number: Meeting place: Start of installation (on site) End of installation (on site) Installation time required (in hours): Travel time required (in hours):... - Page 56 Installation Manual Festoon Systems for I-Beams Program 0314 Conductix-Wampfler GmbH Phone: +49 (0) 7621 662-0 Rheinstrasse 27 + 33 Fax: +49 ( 0) 7621 662-144 79576 Weil am Rhein – Märkt info.de@conductix.com Germany www.conductix.com MAL0300-0001-EN www.conductix.com translated document page 56 of 56...