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Conductix-Wampfler 0813 Series Operating Instructions Manual

Insulated conductor rail system
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Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
Order Number:
0813xx-...
BAL0813-0007-EN
www.conductix.com
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page 1 of 108

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Summary of Contents for Conductix-Wampfler 0813 Series

  • Page 1 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Order Number: 0813xx-... BAL0813-0007-EN www.conductix.com translated document page 1 of 108...

  • Page 2: Table Of Contents

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Contents General Information ..................................5 About this document ..............................5 Limitation of liability ..............................5 Copyright ..................................6 Replacement parts ..............................6 Material defects ................................6 Technical support ................................ 6 Safety Instructions ..................................7 Explanation of symbols ..............................
  • Page 3 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Transport, Packaging and Storage ............................38 Safety ..................................38 Transport ................................... 39 Packaging .................................. 39 Storage of packaged parts ............................40 Installation ....................................41 Safety ..................................41 Provide additional protection against contact at the conductor rail end..............44 System arrangement ..............................
  • Page 4 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Safety ..................................89 Normal operation ............................... 90 Stopping the system ..............................90 Continue operation ..............................91 Maintenance and Service ................................. 92 Safety ..................................92 Tools and materials ..............................95 Maintenance plan ..............................96 Troubleshooting ..................................

  • Page 5: General Information

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 1 General Information 1.1 About this document The information provided in this document is designed to enable the Conductor Rail System 0813 to be used safely and efficiently. This document is a component of the Conductor Rail System 0813 and must be kept accessible to personnel and in close proximity to the Conductor Rail System 0813 at all times.

  • Page 6: Copyright

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 1.3 Copyright This document is protected by copyright and is exclusively intended for internal use by customers. Provision of the operating instructions to third parties, reproductions 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 the customer's internal use.

  • Page 7: Safety Instructions

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 2 Safety Instructions 2.1 Explanation of symbols Safety and hazard information is identified in these operating instructions using 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

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 2.2 Personnel requirements 2.2.1 Qualifications Inadequately trained persons are at risk of injury! Unintended use can result in serious injury to persons and property. → All activities must only be performed by qualified personnel. WARNING! Only persons who can be expected to perform their work reliably are acceptable personnel.

  • Page 9: Unauthorized Persons

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 2.2.2 Unauthorized persons Danger due to unauthorized persons! Unauthorized persons who do not meet the requirements described here are not acquainted with the dangers in the working area. WARNING! → Keep unauthorized personnel away from the working area. →...

  • Page 10: Intended Use

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 To be worn for When carrying out special work, special protective equipment is recommended. Separate special tasks reference to this is made in the individual sections. Protective eyewear For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather effects.

  • Page 11: Unintended Use

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 The conductor rail should preferably be installed horizontally with current collector insertion from below. With indoor areas, it is ◼ also possible to insert the current collector from the side (use current collector for lateral insertion). Electrical engineering operating requirements ◼...

  • Page 12: Protective Measures By The Operator/User

    ◼ ◼ The manufacturer/system engineer who installs the electrical equipment from Conductix-Wampfler must inform their self about the applicable occupational safety regulations and determine additional hazards in a risk assessment that result from the special working conditions at the place of use of the product. They must implement these in the form of operating instructions for the operation of the conductor rail system.

  • Page 13: Special Hazards

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 2.8 Special hazards The following section lists residual risks determined on the basis of a risk assessment. → Follow the safety instructions and the warnings in these operating instructions in order to reduce health hazards and avoid dangerous situations.

  • Page 14: Mechanical Hazards And Sources Of Danger

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fire hazard due to overload or sparking! Fire hazards occur due to overloaded cables, electrical arcs, short circuits or sparking. Sparking can occur with poorly serviced, contaminated conductor rails or if the installation does DANGER! not comply with the required tolerances.

  • Page 15: Danger Due To Dust And Vapors

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 2.8.3 Danger due to dust and vapors Danger of sensitization, mucous membrane irritation and respiratory disease due to dust! Abrasion from the sliding contacts collects in the conductor rails and the guideway. This dust is WARNING! very fine and is a health hazard.

  • Page 16: Dangers Related To The Operational Environment

    → Use in chemical works, galvanizing plants, electroplating plants, composting plants or in warehouses or installations where chemical substances (e.g., aromatic compounds, benzene) are stored or processed must be verified in advance by Conductix-Wampfler. DANGER! The resistance of plastic parts is critical when in contact with oils, greases or various cleaning agents.

  • Page 17: Conduct In The Event Of Accidents And Malfunctions

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Hazard due to energy storage! If consumers with energy storage are supplied by the conductor rail, these must be disconnected from the conductor rail or the energy storage system must be discharged according to the manufacturer's specifications before starting work and the system must be checked for the absence DANGER! of voltage.

  • Page 18: Technical Data

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 3 Technical Data System Insulated conductor rail system for use in supplying energy to crane systems, the construction of larger slip ring arrangements, transfer carriages, cable tracks or similar moving consumers mounted in non-publicly accessible areas, out of hands' reach in indoor areas and weather-protected outdoor areas (IP2x).
  • Page 19 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Current collector capacity: The current collector capacity is defined by the connected cable as well as sliding contacts used and is typically lower (see catalog)! Ambient temperatures and operating modes result in reduced current collector capacity (e.g., operating at a standstill, operating at elevated temperatures).

  • Page 20: Installation Orientation

    The conductor rail must be installed within the following tolerances. Conductix-Wampfler does not accept any responsibility for the conductor rail's correct functioning if these tolerances are not observed. In such a case, Conductix-Wampfler does not accept any liability for problems that arise if the conductor rail system is not functioning correctly.

  • Page 21: Unsuitable Ambient Conditions

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 3.3 Unsuitable ambient conditions The conductor rail must not be installed and not be operated under these environmental conditions (see also Section 2.5 , Section 2.8.4 and Section 3): Operation at excessively high or excessively low temperatures (Standard: < -10°C, > 55°C, different ambient temperatures on ◼...

  • Page 22: Product Description And Functional Principles

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 4 Product Description and Functional Principles 4.1 Brief description Single-pole insulated conductor rails consist of individual conductor rails firmly fixed on a guideway. One or more current collectors fastened to one or more mobile consumers engage with the conductor rails with their current collector heads. The mobile consumers move along the guideway in a linear, track-guided manner.
  • Page 23 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 2: System overview 0813 Pos. Name End cap Support arm Hanger clamp Anchor clamps Connector Line feed connector Towing arm Single current collector Conductor rail Examples of possible additional modules: Fig.
  • Page 24 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 The rails are straight or curved. A distinction is made between horizontal and vertical rail arrangements Fig. 5: Horizontal bend/inner and outer bend (horizontal arrangement) Pos. Name Horizontal bend Inner bend Outer bend Use the QR code ("click"...

  • Page 25: Interfaces

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 4.2 Interfaces All details are in the catalog and, when applicable, in the system-specific layout. Mechanical interfaces: The current collector must be fastened to the mobile consumer of the machine. The manufacturer/operator of the machine/system ◼...

  • Page 26: Description Of The Components

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 4.3 Description of the components The SinglePowerLine 0813 Conductor Rail System consists of: ◼ Conductor rails Hanger clamps (interface to the machine of the system engineer/operator) ◼ ◼ Connectors Line feed connectors (interface to the machine of the system engineer/operator) ◼...
  • Page 27 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 9: PH insulating profile (yellow) and PE insulating profile (with green stripes) Hanger clamp 08134 *** ◼ Hanger clamps for supporting the conductor rail. The hanger clamps are designed for mounting on a support arm or C-rail. The hanger clamps are available with hexagon nuts or square Fig.
  • Page 28 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 12: Hanger clamp 0813 with insulator Connector 081321-*** ◼ The conductor rail connections are made with compact screw connectors. Fig. 13: Connector 0813 Depending on the conductor material of the conductor bar, the connectors have either a stopper (aluminum with stainless steel strip and CopperECO) or an inspection window (copper) to be able to check the functionally necessary gap of 2 to max.
  • Page 29 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 15: The conductor rail end is in the connector's inspection window (copper) ◼ Line feed connector 081351-* The line feed takes place via line feed connectors. These are used Fig. 16: Line feed 0813 (shown with insulating caps) instead of normal connectors.
  • Page 30 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Anchor clamp 081331-2* ◼ By using two anchor clamps that are mounted around a hanger clamp, the conductor rail is fixed at one point (fixed point) and can be freely expanded from this point. The fixed point is typically attached near the line feed.
  • Page 31 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Air gap 08119*-** ◼ Air gaps are used for galvanic isolation of sections that can be fed in and disconnected from the power separately, e.g., for maintenance lines. For each isolation point, 2 air gaps are installed at a suitable distance to avoid voltage leak across the current collector.
  • Page 32 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Current Collector A current collector is a sliding electrical connection between the conductor rail and the mobile consumer. Redundancy for the PE current collector must always be included (min. 1 x double current collector). When using inverters, there must also be redundancy for the phase current collectors (protection against shutdown due to loss of phase voltage in the case of transient loss of contact).

  • Page 33: Accessories

    Insulated Conductor Rail System SinglePowerLine Program 0813 4.4 Accessories The following accessories are specific special components and can also be ordered from Conductix-Wampfler (see KAT0813-0002): Fig. 28: Support arm (Sendzimir (hot-dip) galvanized steel) Support arm (0201860***) and support arm bracket ◼...
  • Page 34 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 31: Clamping brackets, clamping thickness 4-20 mm (galvanized steel or V4A) Clamping brackets (020180****/020181-08) ◼ Clamping brackets can also be used, for example, to attach a support arm to the customer's support structure (substructure) without drilling or welding.
  • Page 35 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Insulator (08040****) ◼ Insulators for indoor applications with high pollution and outdoor applications, up to 1000 V rated voltage. They are only used when the current collector is inserted from below. Fig.
  • Page 36 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Drilling jig for systems with a pickup guide ◼ (08-W100-0223) In order to meet the requirements of the VDE regulations, a hole must be drilled in the towing arm of systems with pickup guides with the drilling jig, which is used to accommodate the bolt on the protective conductor current collector (PE protection against interchanging).
  • Page 37 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Disassembly tool 0813 (08-V015-0493) ◼ Fig. 40: Tool 1 The disassembly tool consists of two tools and is an aid for removing a hanger clamp from the conductor rail. Tool 1 is pushed between the hanger clamp and conductor rail, while Tool 2 opens the hanger clamp.

  • Page 38: Transport, Packaging And Storage

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 5 Transport, Packaging and Storage 5.1 Safety Recommended protective equipment: Risk of death due to suspended loads! Falling parts or uncontrolled swinging loads can lead to severe injury or even death. →...

  • Page 39: Transport

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of injury due to cutting and amputation! Cuts and amputations can occur: ◼ On the packaging material (e.g.: cartons, bands, etc.). WARNING! On sharp edges of the conductor rail. ◼ →...

  • Page 40: Storage Of Packaged Parts

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Environmental damage due to improper disposal! Packaging materials are valuable raw materials and can be reused in many cases or sensibly reconditioned and recycled. CAUTION! → Dispose of packaging materials in an environmentally appropriate manner. →...

  • Page 41: Installation

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6 Installation 6.1 Safety ◼ Installation and commissioning may only be conducted by specially trained technicians! Recommended protective equipment: Risk of death due to suspended loads! Falling loads can cause serious injuries or even death. →...
  • Page 42 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of injury due to crushing of skin and limbs! There is a risk of crushing of skin and limbs due to: Spring force/gravity (stored energy). ◼ DANGER! Current collector (spring force) during preassembly, installation, disassembly and ◼...
  • Page 43 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of injury due to conductor rails sliding out! Risk of injury due to conductor rails sliding out when the packaging units are held at an angle or through carelessness with long loads. DANGER! →...

  • Page 44: Provide Additional Protection Against Contact At The Conductor Rail End

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.2 Provide additional protection against contact at the conductor rail end. An end cap is attached to the conductor rail end as protection against contact. In the case of double current collectors, a sliding contact that is under voltage can protrude from the end cap at the end of the conductor rail during operation.

  • Page 45: System Arrangement

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.3 System arrangement The following illustration provides an overview of the arrangement of the components and distances in a conductor rail system. Conductor Rail System 0813 with hanger clamps on support arms Fig.

  • Page 46: Installation Of Mechanical Components

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4 Installation of mechanical components 6.4.1 Required tools Standard tools: ◼ ◼ Measuring tape Calipers ◼ ◼ Scribe Cutting tool (e.g., precision saw, angle grinder with fine cutting disk) ◼ File for deburring cut edges after trimming ◼...
  • Page 47 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 → If the conductor bar is sawed, the cutting direction must be kept from top to bottom (see Fig. 44). Maintain the cutting direction for the conductor bar! If the cutting direction from top to bottom is not maintained, the rolled-in stainless steel strip will loosen in the conductor bar.
  • Page 48 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Pos. Name Stainless steel strip (not available with copper conductor bar) Conductor bar (aluminum or CopperECO) Inner edges Outer edges Fig. 46: Deburr the conductor rail with a smooth file Sharp edges and/or burrs can/will lead to increased wear of the sliding contacts or even to the failure of the system! A sharp edge and/or burr can quickly wear away the sliding contacts.

  • Page 49: Install Conductor Rail System

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.3 Install conductor rail system Procedure for the installation: It is sensible to start the installation at one end cap and install the conductor rail along the route. Work steps: → Indicate the installation location for line feeds, customer-side fixed points, terminal boxes, expansion points, air gaps and the course of the conductor rail on the installation structure according to the layout and allocation plan on the substructure.

  • Page 50: Mount Hanger Clamps

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.3.1 6.4.3.2 Mount hanger clamps The maximum tightening torques must not be exceeded (14 Nm for a standard hanger clamp with steel nut). Too high tightening torques will damage the hanger clamp. NOTE! The hanger clamp fastening must be adapted to the respective application! The fastening elements are designed for standard fastening applications.
  • Page 51 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 50: Hanger clamps with hexagon nuts mounted with retaining Fig. 49: Hanger clamps with square nuts mounted in the support arm plate Requirements: The support structure (e.g., support arm or retaining plate) is mounted at the appropriate distance (see project-specific documents). Distance between hanger clamps: Hanger clamp to end cap: ≥...
  • Page 52 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 53: Slide the next hanger clamp onto the support arm Fig. 54: Align the hanger clamps using the mounting comb → In order to achieve an even phase offset, the next hanger clamps must be aligned with the mounting comb (see Fig. 54). The phase offset of either 80 mm (standard) or 70 mm (reduced) can be set with the mounting comb.
  • Page 53 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Work steps (for retaining plate with through holes): → Loosen the screw connection with the hexagon nut and washers from the hanger clamp (see Fig. 56). Fig. 56: Loosen the screw connection from the hanger clamp →...

  • Page 54: Mount Conductor Rail

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Use the QR code ("click" or "scan") to see our animation Mounting Hanger Clamps. 6.4.3.3 Mount conductor rail Secure components against falling! Possible falling components must be determined in the customer analysis as part of the operator's risk and hazard analysis.
  • Page 55 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Disassemble the conductor rails In the event that a conductor rail has been incorrectly installed and needs to be removed from the hanger clamp, the disassembly tool (Order No.: 08-V015-0493) should be used. Work steps: →...
  • Page 56 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 66: The hanger clamp bends up Fig. 67: Remove Tool 2 from the open side of the conductor rail → In order to remove Tool 1, the tension spring of the retaining clamp may need to be pushed away. Fig.

  • Page 57: Connect Rails

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.3.4 Connect rails The mechanical and electrical connection of the conductor rail is done by means of a connector. To allow for expansion, the distance between the hanger clamp and connector must be  400 mm! Requirements: The conductor rails are mounted into the hanger clamp.
  • Page 58 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 71: Connector with stopper (Pos. 3) (aluminum-stainless steel or Fig. 72: Connector with stopper (Pos. 3) (aluminum-stainless steel CopperECO conductor rail) - slid into the first conductor bar or CopperECO conductor rail) - slid into both conductor bar ends →...
  • Page 59 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 74: Slide the second end of the rail into the connector Fig. 75: Tighten M10 nuts → Slide the insulating cap halves of the connector over the connection point (see Fig. 76) and tighten the two fillister head tapping screws (Pos.

  • Page 60: Line Feed

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 → Mount each connection point in the same way. Avoid destroying the conductor rail! → Do not slide the conductor rails together with force. → Do not strike them with a hammer. WARNING! →...
  • Page 61 → Cut a rubber sleeve (Pos. 3) according to the cable diameter and slide the stripped ends of the connecting cable (Pos. 2) through the sleeves (one-sided or two-sided connection possible). For better sealing, Conductix-Wampfler recommends pulling a shrink tube over the cable beforehand and connecting it to the sleeve with a hot air blower after installation.
  • Page 62 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 82: Mount connector with tubular cable lug → Crimp the stripped end of the connecting cable (Pos. 2) with the tubular cable lug (Pos. 5). Fig. 83: Crimp cable end (Pos. 2) with tubular cable lug →...

  • Page 63: Mount Anchor Clamp

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 → Mount each line feed in the same way. Do not allow any tensile stress on the line feed! → Provide the line feed with a strain relief at a suitable distance. NOTE! Avoid destroying the conductor rail! →...
  • Page 64 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Please refer to the project-specific documents for the exact position of the fixed points. Before the conductor rails are connected to each other, the anchor clamps must first be slid onto the conductor rails. Anchor clamps are positioned to the right and left of a hanger clamp.

  • Page 65: Mount Heating Wire (Optional)

    In order to increase the system availability during winter operations, conductor rail systems in outdoor systems or similar environmental conditions are additionally provided with a heating system. Conductix-Wampfler GmbH's Conductor Rail Program 0813 is suitable for outdoor use. Therefore, heating should prevent the formation of frost on the conductor rail and the resulting loss of contact with the current collector.
  • Page 66 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of death due to electrical shock! Before work on the conductor rail system can begin, the heating must also be disconnected from the power supply! The heating can be designed as a separate electrical circuit and may need to be DANGER! disconnected from the power separately from the conductor rail.

  • Page 67: Mount Expansion Unit

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.3.8 Mount expansion unit To compensate for temperature-related changes in length for systems > 200 m or sections of the route that are integrated between two fixed points, such as pickup guides at both ends of the section, expansion units are required to accommodate the change in length.
  • Page 68 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Instructions: = lowest temperature occurring in the given application highest possible ambient temperature + current max= heating* Enter the connecting cable from t to t Enter a horizontal line at the ambient temperature during installation.

  • Page 69: Mount Air Gap

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.3.9 Mount air gap Air gaps are used for galvanic isolation and segmentation of system sections and subdivide a conductor rail system into sections (e.g., maintenance lines that can be fed in and switched on separately). An air gap consists of two opposing end caps. For each isolation point, two air gaps are mounted at a suitable distance to avoid voltage leak across the double current collector.
  • Page 70 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 92: The hanger clamp, anchor clamp and end cap are mounted on both rail ends → Plate for air gap (Pos. 4) with fastening elements, consisting of hexagon screw DIN931-M6x50 (Pos. 5) (8 Nm) and lock nut DIN985 (Pos.
  • Page 71 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 94: Slide the anchor clamp to the air gap and tighten the side screws Fig. 95: Slide the hanger clamp up to the screw on the side of the anchor clamp →...

  • Page 72: Mount End Caps

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 97: Mounted air gap 0813 A potential difference in the two conductor rails in the air gap can lead to spark formation and electrical erosion in the rail during a current collector transfer. For this reason, avoid potential constructive differences! NOTE! Use the QR code ("click"...
  • Page 73 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 98: End cap on the conductor rail end Fig. 99: The end cap is mounted correctly (above) and incorrectly (below) BAL0813-0007-EN www.conductix.com translated document page 73 of 108...
  • Page 74 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 → Tighten the cylinder screw DIN912-M6x35 (Pos. 3) (see Fig. 100). Fig. 100: Tighten cylinder screw → Insert the lamellar plugs (Pos. 4) into the hole (see Fig. 101). Fig. 101: Insert the lamellar plugs over the cylinder screw →...

  • Page 75: Mount Pickup Guide

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.3.11 Mount pickup guide For areas in which it is necessary to travel in or out of the conductor rail system, pickup guides are used in combination with the current collectors provided for this purpose. It should be noted that the maximum speed at pickup guides is 80 m/min, and pickup guides are classified as wear parts.
  • Page 76 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 104: Important dimensions for systems with pickup guides Please also note the information on installing the PE current collector for systems with a pickup guide (see Section 6.4.4). NOTE! BAL0813-0007-EN www.conductix.com translated document page 76 of 108...
  • Page 77 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Hanger clamp distance for systems with pickup guides: When using multiple pole pickup guides, the distance between phases must be reduced from 80 mm (Standard) to 65 mm on the section shortly before the pickup guide. For this purpose, the 2 to 3 hanger clamps are mounted in front of the pickup guide with a distance of 65 mm (see Fig.

  • Page 78: Mount Current Collector

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.4 Mount current collector There are two types of current collector mounting: Single current collector 250 A ◼ ◼ Double current collector 500 A In addition, there are variants for insertion from below, from the side (see Section 6.4.4.1), variants for higher speeds and current collectors suitable for guide travel.
  • Page 79 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fig. 108: Mount the central axis of the current collector exactly on the central axis of the conductor rail BAL0813-0007-EN www.conductix.com translated document page 79 of 108...
  • Page 80 ◼ contacts or movement restrictions of the current collector (see Fig. 109 to Fig. 113). Use only highly flexible and double-insulated (for voltages > 48 V) Conductix-Wampfler connecting cables! In the event of repairs, ◼ use a cable lug with shrink tubing for the flexible connecting cables (see Connection repair set, Order No.: 08-K154-0394).
  • Page 81 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Requirements for mounting the current collectors Conductor rail is installed (see Section 6.4.3) ◼ Mobile unit (s) used in the guideway ◼ ◼ Towing arm (see Order No.: 020197-XXX) mounted on the mobile unit and aligned parallel to the poles of the conductor rail. If there are bends in the conductor rail, the towing arm is to be installed in the pivot point or in the steering axis.

  • Page 82: Current Collector Insertion From The Side

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 6.4.4.1 Current collector insertion from the side For current collector insertion from the side: The spacer ensures that the current collector remains in its neutral position. (see Pos. D in Fig. 115) When the current collector is inserted from the side, the spacer must always be seated at the bottom! Fig.

  • Page 83: Electrical Installation

    Pay attention to the selection of the connecting cable and to a correct and tension-free laying of the connecting cables (see Fig. 109 to Fig. 113). → Only use only highly flexible Conductix-Wampfler cables! In principle, connecting cables with copper wires are to be used. → Use ferrules with insulation collars for the flexible connecting cables.

  • Page 84: Commissioning

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 7 Commissioning 7.1 Safety Personnel: The conductor rail system must only be commissioned, as well as operated for the first time after a repair, by qualified ◼ electricians! The qualified electricians must meet the requirements described in Section 2.2.1. ◼...
  • Page 85 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fire hazard due to overload or sparking! Fire hazards occur due to overloaded cables, electrical arcs, short circuits or sparking. Sparking can occur with poorly serviced, contaminated conductor rails or if the installation does not comply DANGER! with the required tolerances.

  • Page 86: Testing And Initial Commissioning

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 7.2 Testing and initial commissioning 7.2.1 Test list Test Tested Has the correct installation height been observed (see Section 3)? Are all installed components clean, dry and undamaged? Are the end caps available at the beginning and end of conductor rail and mounted as described in Section 6.4.3.10? Are all hanger clamps mounted according to Section 6.4.3.1? Are the conductor rails mounted according to Section 6.4.3.3?
  • Page 87 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Test Tested Are covers and barriers in place? Is the line feed properly connected? Are all metallic components (e.g., support structure/substructure) properly grounded? Has the insulation resistance* of the conductor rail system been measured according to local technical standards, directives, and legal regulations? Have the prescribed national electrical tests been conducted (e.g., measurement of the loop impedance)?

  • Page 88: Initial Commissioning Of The Conductor Rail System

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 7.2.2 Initial commissioning of the conductor rail system → Conduct a complete run along the conductor rail (walking pace). The current collectors must not become caught, stick or scrape! Where necessary, repair any faults and conduct settings work. NOTE! After initial commissioning, a further review must be conducted to detect any damage or problems in the system.

  • Page 89: Operation

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 8 Operation Operating the conductor rail is limited to switching the voltage supply on and off when operation is interrupted, as described in Section 8.3. The safety information in Section 8.1 must be observed to ensure safety during operation. 8.1 Safety Risk of death due to electrical shock! Contact with components carrying electrical power can lead to death or severe injury due to...

  • Page 90: Normal Operation

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of injury due to falling conductor rails! The hanger clamps of the conductor rail can fail and the conductor rail can fall down. Components can be damaged if the following or similar materials are stored in the vicinity of the conductor rail: DANGER! ◼...

  • Page 91: Continue Operation

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 8.4 Continue operation Risk of injury if safety equipment and protective devices are disabled! → Before switching the system back on, ensure that all covers, safety systems and protective devices are installed and working properly. WARNING! Before switching the system back on, ensure that: The current collector heads are in contact with the conductor rail over their full length and the prescribed contact pressure is...

  • Page 92: Maintenance And Service

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 9 Maintenance and Service 9.1 Safety Recommended protective equipment: Risk of injury due to electrical shock! → Switch off the power supply to the conductor rail system according to the 5 Safety Rules and secure it against switching on again.
  • Page 93 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of damage when cleaning the conductor rail! When cleaning, only loose or lightly adhering dust or foreign substances may be removed. → Do not use contact spray (formation of silicon carbide/abrasive and/or damage of plastic CAUTION! parts).
  • Page 94 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of injury due to entrapment! An ensnarement and/or impact with moving conductor rails (slip ring) or current collectors connected to the machine and other components must be prevented. DANGER! → Cordon off the work area! →...

  • Page 95: Tools And Materials

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of explosion! Airborne dust, open flames or other sources of ignition can result in explosion. DANGER! Conducting maintenance work on the current collectors Risk of injury due to crushing of skin and limbs! There is a risk of crushing of skin and limbs due to: →...

  • Page 96: Maintenance Plan

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 9.3 Maintenance plan The following tasks fall under the "Service" category: SERVICE Inspection Maintenance Repair Checks Washing Repair Measurements Cleaning Replacement Tests Resetting Readjusting The separate Maintenance Instruction WV0800-0002 contains the measures required for optimal and trouble-free operation. It also contains the required maintenance intervals.

  • Page 97: Troubleshooting

    → Allow troubleshooting to be conducted only by personnel from or authorized by the manufacturer. The faults that, to Conductix-Wampfler's best knowledge, tend to arise are listed in the following table (see Section 10.2) together with their corresponding corrective measures.
  • Page 98 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Risk of injury due to crushing of skin and limbs! There is a risk of crushing of skin and limbs due to: Current collector (spring force) during preassembly, installation, disassembly and maintenance. ◼...
  • Page 99 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Before switching the system on! → Every time before the product or system is started, measure the insulation resistance according to locally applicable technical standards, directives and legal regulations. → Conduct locally required electrical tests. CAUTION! Danger of injury due to hot surfaces Components can get hot during operation.

  • Page 100: Fault Correction Table

    SinglePowerLine Program 0813 10.2 Fault correction table Fault Cause Corrective Measures Use original current collector heads from Conductix-Wampfler (ensure freedom of movement). Range of movement of the current collector head is Mount current collector according restricted to Section 6.4.4 . Check the installation position at various points in the system.
  • Page 101 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Fault Cause Corrective Measures Check the installation position at various points in the system. Consolidate project-specific documents, fasten affected Collision with system components. components without collision, replace damaged components. Adjust the consumer's movement Abrasive dust has collected at one of the more frequently profile.

  • Page 102: Disassembly And Disposal

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 11 Disassembly and Disposal 11.1 Safety Personnel: May only be conducted by trained technicians. Recommendation: Min. 2 people ◼ Recommended protective equipment: Requirements: Prior to starting the disassembly: → Completely disconnect the conductor rail system from the power supply and secure it against switching on again.
  • Page 103 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Danger of injury due to improper disassembly! Stored residual energy, sharp components, and points and edges on and in the product or the required tools can cause injuries. WARNING! → Ensure that there is sufficient space before starting work. →...
  • Page 104 Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 Danger of injury due to dust and abrasion! Breathing difficulties and eye irritation can occur due to dust thrown up and abrasion of the sliding contacts, copper conductor bars and plastic. There is a health hazard due to airborne respirable dust.

  • Page 105: Disassembly

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 11.2 Disassembly After the end of its service life, the product must be disassembled and disposed of in an environmentally friendly manner. → Remove operating and auxiliary materials, as well as residual processing materials, and dispose of them in an environmentally appropriate manner.

  • Page 106: Further Documents

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 12 Further Documents 12.1 Applicable documents ID No. Document Number Document Name WV0800-0001 Cleaning of Conductor Rails WV0800-0002 Maintenance Schedule Conductor Rails MV0800-0018 Insulation measurement of heating wires MV0800-0019 Insulation measurement of conductor rails MV0813-0010 Grounding and short-circuit device MV0813-0015...

  • Page 107: Air Gap Diagram

    Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 12.2 Air gap diagram BAL0813-0007-EN www.conductix.com translated document page 107 of 108...

  • Page 108: Index

    Unauthorized persons ............9 Operation ................89 Unintended use ..............11 Operator ................12 Unsuitable ambient conditions ........... 21 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...

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