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Conductix-Wampfler MultiLine 0835 Mounting Instruction

Conductor rail system
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Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com
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Summary of Contents for Conductix-Wampfler MultiLine 0835

  • Page 1 Mounting Instruction Conductor rail system MultiLine 0835 MAL0835-0001c-EN www.conductix.com translated document page 1 of 81...

  • Page 2: Table Of Contents

    Mounting Instruction Conductor rail system MultiLine 0835 Contents General information ..................................5 Information about this mounting instruction ........................5 Limitation of liability ................................ 5 Copyright ..................................5 Spare parts ..................................6 Material defects ................................6 Technical support ................................6 Safety instructions ..................................7 General safety information .............................
  • Page 3 Mounting Instruction Conductor rail system MultiLine 0835 Operating conditions ..............................23 3.3.1 Unsuitable environmental conditions ..........................23 Description and mode of operation ............................24 Brief description ................................24 Description of assemblies ............................. 24 Accessories .................................. 26 Overview of the system ..............................27 4.4.1 Expansion ..................................
  • Page 4 Mounting Instruction Conductor rail system MultiLine 0835 Testing and initial commissioning ..........................58 7.2.1 Inspection list ................................58 7.2.2 Initial commissioning ..............................59 Operation ....................................60 Safety ................................... 60 8.1.1 Personnel ..................................60 8.1.2 Safety instructions ................................ 60 Normal operation ................................62 Stopping the system ..............................

  • Page 5: General Information

    Mounting Instruction Conductor rail system MultiLine 0835 1 General information 1.1 Information about this mounting instruction The information provided in this mounting instruction is designed to enable the above device to be used safely and efficiently. The mounting instruction forms part of the device and must be kept accessible to personnel at all times and stored right by the device.

  • Page 6: Spare Parts

    Mounting Instruction Conductor rail system MultiLine 0835 1.4 Spare parts Wrong spare parts are a safety hazards! Wrong or faulty spare parts can result in damage, malfunctions, complete failure and affect safety. → Always use original spare parts from the manufacturer! WARNING! Replacement parts can be ordered from your contracted dealer or directly from the manufacturer.

  • Page 7: Safety Instructions

    Mounting Instruction Conductor rail system MultiLine 0835 Safety instructions 2.1 General safety information Safety and hazard information are always marked with corresponding symbols in this mounting instruction. Safety instructions are introduced by signal words that signal the scale 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

    Mounting Instruction Conductor rail system MultiLine 0835 2.2 Personnel requirements 2.2.1 Qualifications Personnel who are not adequately trained are at risk of injury! Improper use can result in serious injury to persons and property. → Work on and with the system must only be performed by personnel with adequate training for the WARNING! relevant task.

  • Page 9: Training

    Mounting Instruction Conductor rail system MultiLine 0835 2.2.3 Training Before commissioning the equipment, personnel must be trained by the operator. This training has to be documented as shown in the template below in order to create a record of the training.

  • Page 10: Intended Use

    The operator bears sole liability for all damage that result from improper use. Intended use The conductor rail system MultiLine 0835 is an electric power supply system for track-guided mobile consumers operated in indoor spaces in the warehouse area not accessible to the public.

  • Page 11: Protective Measures To Be Taken By The Operator/User

    Mounting Instruction Conductor rail system MultiLine 0835 Using the system in clean rooms or ultra-clean rooms.  Using the system in areas that must not be contaminated with abraded materials (e.g. unpackaged food).  Use of the system with accessories that have not been certified and have not been approved by the manufacturer.

  • Page 12: Safety Rules For Working On Electrical Systems

    Mounting Instruction Conductor rail system MultiLine 0835 The operator is furthermore responsible for ensuring that the device is always in perfect working order. The following thus applies: The operator must ensure that the maintenance schedule described in this installation and operating manual is followed.
  • Page 13 Mounting Instruction Conductor rail system MultiLine 0835 Risk of injury from falling or being thrown across the room after an electrical shock! Work on the following components is dangerous: Main power supply  DANGER! Live components:  Power feeds ...

  • Page 14: Mechanical Hazards And Sources Of Danger

    Mounting Instruction Conductor rail system MultiLine 0835 Fire hazard due to overload or spark formation! A fire hazard can occur due to overloads of the cable, electrical arcing, short-circuits or the generation of sparks. Sparks can occur due to badly maintained, dirty conductor rails or because required DANGER! tolerances are not observed during installation.
  • Page 15 Mounting Instruction Conductor rail system MultiLine 0835 Required protective equipment: Risk of injury from cuts and cutting! The ends of the power rails can have sharp edges, especially if they were cut to size at the construction site and have not been deburred.

  • Page 16: Danger From Dust And Vapours

    Mounting Instruction Conductor rail system MultiLine 0835 2.7.3 Danger from dust and vapours Required protective equipment: Risk of sensitization, irritations of the mucous membranes and disorders of the respiratory tract through dust! Dust from the carbon brushes collects in the conductor rails and the guide profile. This dust is very DANGER! fine and is categorized as a health risk.

  • Page 17: Hazards Arising From The Operating Environment

    Mounting Instruction Conductor rail system MultiLine 0835 2.7.4 Hazards arising from the operating environment The following conductor rail properties can give rise to hazards if it is installed in an operating environment where they can be dangerous: Electrical energy ...

  • Page 18: What To Do In The Event Of An Accident Or A Malfunction

    Mounting Instruction Conductor rail system MultiLine 0835 Required protective equipment: Risk of sensitization, irritations of the mucous membranes and disorders of the respiratory tract through dust! Dust from the carbon brushes collects in the conductor rails and the guide profile. This dust is very DANGER! fine and is categorized as a health risk.
  • Page 19 Secure the work area against entry  Consult qualified personnel when analysing the fault  Conductix-Wampfler must be informed immediately in the event malfunctions can cause personal injury or damage to property:  Conductix-Wampfler GmbH Tel.: +49 (0) 7621 662-0...

  • Page 20: Technical Specifications

    End segment (end section) 750 mm Longitudinally acting section of the connector* 2.5 mm + 1 mm per side * Systems that are longer than 150 m are only available in consultation with Conductix-Wampfler. MAL0835-0001c-EN www.conductix.com translated document page 20 of 81...

  • Page 21: Installation Orientation

    Mounting Instruction Conductor rail system MultiLine 0835 Insulation profile Conductor bar Connector Fig. 1: Conductor rail and connector The Annex contains a table showing the possible total system lengths when using standard components (L ), see section 13.1. 3.2.2 Installation orientation Do not fit the conductor rails vertically! →...

  • Page 22: Tolerances

    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 also not accept any liability for any problems that may arise if the conductor rail system does not function correctly.

  • Page 23: Operating Conditions

    Mounting Instruction Conductor rail system MultiLine 0835 3.3 Operating conditions Designation Value Notes Temperature range -5 °C to +60 °C In temperatures of 0 °C and below, the max. relative humidity must not exceed 30%. Max. relative humidity 85 % See above Max.

  • Page 24: Description And Mode Of Operation

    4.1 Brief description MultiLine 0835 is a conductor rail system that can be used to supply e.g. a shuttle (in a shuttle storage system) or similar mobile consumers in other kind of applications with energy. The system is variable in length.
  • Page 25 The conductor rail is designed for transmitting energy. Every conductor rail contains two conductor bars that are protected by an insulation profile. All conductor rails have a standard length of 4 m. Conductix-Wampfler can also supply shorter conductor rails of 0.5 m - 3.90 m on request.

  • Page 26: Accessories

    Fig. 8: Example: Cable bundle with strain relief Use the QR code (“click“ or “scan“), to watch our animation MultiLine 0835 System Overview. 4.3 Accessories The following accessories are included in the scope of delivery: Arrester 0835 ...

  • Page 27: Overview Of The System

    Mounting Instruction Conductor rail system MultiLine 0835 Small parts - replacement parts package comprises:  End cap bar  End cap  Crimp-type sockets 2.5 mm and 6 mm  Connector cap  Hanger clamps  Expanding rivet  Installation block 0835 ...

  • Page 28: Expansion

    Mounting Instruction Conductor rail system MultiLine 0835 End of the rail system (without end cap bar) connector Fig. 14: Overview: End section Fig. 15: Overview: Isometric view of the connection Insulation profile Connector Difference in length between the insulation profile –...

  • Page 29: Shipment, Storage And Packing

    Mounting Instruction Conductor rail system MultiLine 0835 5 Shipment, storage and packing 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 from falling parts or parts swinging out of control.

  • Page 30: Transporting The Packed Parts

    Mounting Instruction Conductor rail system MultiLine 0835 Required protective equipment: Risk of injury from punctures and cuts! The packaging material may contain sharp objects such as nails and wood splinters that can cause injury to limbs. CAUTION! → Wear protective gloves →...

  • Page 31: Removing The Packaging

    Mounting Instruction Conductor rail system MultiLine 0835 Avoid mechanical vibrations  Storage temperature: -25 °C to max. 55 °C  Relative humidity: max. 85%  When storing for more than 3 months, check the general condition of all parts and the packaging at regular intervals. If ...

  • Page 32: Installation

    Mounting Instruction Conductor rail system MultiLine 0835 Installation 6.1 Safety 6.1.1 Personnel → The system must only be installed by specialist personnel! → The system has to be installed by at least 2 people. Required protective equipment: 6.1.2 Safety instructions Risk of death due to suspended loads! Falling parts or uncontrolled swinging loads can lead to severe injury or even death.
  • Page 33 Mounting Instruction Conductor rail system MultiLine 0835 Required protective equipment: Risk of injury through crushing and impacts! There is a risk of crushing skin and limbs from: Current collector (spring force) during installation, deinstallation and maintenance  DANGER! Falling conductor rail system components if they have not been properly installed or if operated in ...
  • Page 34 Mounting Instruction Conductor rail system MultiLine 0835 Required protective equipment: Risk of injury from punctures and cuts! The packaging material can contain sharp objects such as nails and wood splinters that can cause injury to limbs. CAUTION! → Wear protective gloves →...

  • Page 35: Attaching The Contact Guard

    Mounting Instruction Conductor rail system MultiLine 0835 Before switching the system on! → Every time before the device or system is started, measure the insulation resistance according to locally applicable technical standards, directives and legal regulations. CAUTION! → Perform required country-specific electrical tests 6.1.3...

  • Page 36: Required Accessories

    Once fitted, connectors and connector caps cannot be removed again! This is why the connector caps must always be carefully aligned first before they are fitted. If they need to be changed, please get in touch with Conductix-Wampfler before doing so. See section 6.2.4 CAUTION! 6.2.4...

  • Page 37: Replace A Rail Along The Course

    Mounting Instruction Conductor rail system MultiLine 0835 To correct a connection: → Loosen conductor rails to the left and right of the connector from the hanger clamps to permit cutting → Cut the conductor rails to the left and right of the connector using a suitable cutting tool →...

  • Page 38: Adjusting The Size

    Mounting Instruction Conductor rail system MultiLine 0835 6.2.6 Adjusting the size The conductor rail system should be built using as many standard components as possible. The total length of a conductor rail system built using standard (L ) is made up of the following elements: = End segment (first section) + n (connectors + power rails) + connector + end segment (end section).
  • Page 39 Mounting Instruction Conductor rail system MultiLine 0835 Example 1: Projected length L 46030 mm Length achieved using standard components L 45530 – 45554 mm X = L 476 – 500 mm P – *the tolerance for the clearance of the conductor bars means that the system's length cannot be precisely predicted in advance.

  • Page 40: Installation Example

    Mounting Instruction Conductor rail system MultiLine 0835 6.2.7 Installation example 1. Fitting the end cap base of the end segment with the power feed (first section). → Determine how large (diameter) the holes for the expanding rivets need to be.
  • Page 41 Mounting Instruction Conductor rail system MultiLine 0835 Fig. 19: Holes for the end section of the conductor rail system Direction of travel End cap base Installation surface → The end cap base has to be aligned flush with the direction of travel.
  • Page 42 Mounting Instruction Conductor rail system MultiLine 0835 2. Fitting the hanger clamps The hanger clamps must be fitted with expanding rivets. The expanding rivets must be driven into the holes with a plastic hammer. Hanger clamp CAUTION! The hanger clamp clips have to point upwards! Expanding rivet →...
  • Page 43 Mounting Instruction Conductor rail system MultiLine 0835 3. Installing end segment with power feed (anchor point) Requirement: Risk of death by electrocution! Touching the connecting cable can result in death and severe injury from electric shock. → Disconnect the power supply for the conductor rail by switching it off at the...
  • Page 44 Mounting Instruction Conductor rail system MultiLine 0835 Fig. 25: Push power feed terminals with crimped connection cables onto the rail → Push the power feed terminal with connecting cable onto the rail (see Fig. 26). ATTENTION: Make sure that the clamping unit of the Fig.
  • Page 45 Mounting Instruction Conductor rail system MultiLine 0835 → Clip the rail with the mounted end caps into hanger clamps and end cap set. Fig. 30: Clip the rail with end caps into hanger clamps and end cap base (1) Hanger clamp...
  • Page 46 Mounting Instruction Conductor rail system MultiLine 0835 Use the QR code (“click“ or “scan“), to watch our animation Mounting End Segment (with Anchor Point). 4. Fitting and connecting the conductor rails Requirements and required protective equipment: Danger of death due to incorrect installation! The contact guard cannot be fitted if the connector cap has not been fitted.
  • Page 47 Mounting Instruction Conductor rail system MultiLine 0835 → Fasten the arrester in front of the end cap base with a screw clamp. Fig. 32: Fastening the arrester → Insert one connector for each conductor bar and lightly push in by hand.
  • Page 48 Mounting Instruction Conductor rail system MultiLine 0835 → Push the connector cap onto the conductor rail up to the stop. Fig. 35: Connector cap, pushed onto the conductor rail → Clip the next conductor rail into the hanger clamp (see Fig. 22).
  • Page 49 Mounting Instruction Conductor rail system MultiLine 0835 → Hold the installation block at against the open end of the conductor rail. → Drive the 2 conductor rail onto the connector up to stop with the plastic hammer. CAUTION! The conductor bars must not be seamlessly ...
  • Page 50 Mounting Instruction Conductor rail system MultiLine 0835 5. Cutting the rail sections in front of the end segment to size. The rail sections have to be at least 300 mm long! See section 6.2.5 for information on adjusting the rails' length.
  • Page 51 Mounting Instruction Conductor rail system MultiLine 0835 6. Mount end segment at rail end (without anchor point). Fig. 41: Slide the power feed terminals into conductor bar → Mount the last connector and connector cap described at page 46. → Slide the power feed terminals into the conductor bar of the already mounted conductor rail.
  • Page 52 Mounting Instruction Conductor rail system MultiLine 0835 7. Removing the arrester. → Check whether all of the components have been properly fitted. → Remove the arrester at the start of the system. Fig. 44: Removing the stop 8. Aligning the current collectors.

  • Page 53: Installation Instructions For Systems With Rail Segment And/Or End Segment Power Feeds

    Mounting Instruction Conductor rail system MultiLine 0835 Use the QR code (“click“ or “scan“), to watch our animation Current Collector Tolerances. 6.2.8 Installation instructions for systems with rail segment and/or end segment power feeds If there is a need for an intermediate power feed at the start of a lane in addition or as an alternative to the standard power feed, the lane must be divided accordingly.
  • Page 54 Mounting Instruction Conductor rail system MultiLine 0835 When replacing the end caps with intermediate power feeds, the conductor rail will become approx. 40 mm shorter. CAUTION! → The 1 section must be installed as described in section 6.2. Do not fit the end caps on the final segment. The end caps on the end cover plate are replaced with power feed connectors and caps after installation of the second section.
  • Page 55 → Tighten the clamping screws of the two power feeds with an Allen wrench. Tightening torque: 2 Nm → Clip the conductor rail into the hanger clamps. The conductor rail system Multiline 0835 is compatible with the Conductix-Wampfler Single FlexLine 0815 range. The components for the additional power feed are components from the 0815 range.
  • Page 56 Mounting Instruction Conductor rail system MultiLine 0835 Additional power feeds are used in order to reduce the voltage drop. Moving the power feed into the centre of the conductor rail system or using several power feeds will reduce the conductor rail's NOTE! effective length.

  • Page 57: Commissioning

    Mounting Instruction Conductor rail system MultiLine 0835 Commissioning 7.1 Safety Personnel: The conductor rail system must only be commissioned and operated for the first time after a repair by qualified electricians!  These qualified electricians have to meet the requirements described in section 2.2.1.

  • Page 58: Testing And Initial Commissioning

    Mounting Instruction Conductor rail system MultiLine 0835 Risk of fire! A fire hazard can occur due to overloads of the cable, electrical arcing, or short-circuits. → The permitted current values must be observed WARNING! → Electrical fuses must be installed according to regulations →...

  • Page 59: Initial Commissioning

    Mounting Instruction Conductor rail system MultiLine 0835 7.2.2 Initial commissioning Every time before the device or system is started, measure the insulation resistance according to locally applicable technical standards, directives and legal regulations. Carry out locally required electrical tests. → Move a loose current collector over every pole of the conductor rail system and check for freedom of motion.

  • Page 60: Operation

    Mounting Instruction Conductor rail system MultiLine 0835 Operation Installing and commissioning the conductor rail means that all of the other work required on the conductor rail will be performed as part of the system's maintenance, see section 9. The only operations required to operate the conductor rail system are switching the power supply on and off to stop/activate the system, see section 8.3.
  • Page 61 Mounting Instruction Conductor rail system MultiLine 0835 Requirement: Risk of injury due to entrapment! There is a risk of being trapped by moving parts when the system is in operation. Moving parts include, e.g. the shuttle and the current connectors fitted to it.

  • Page 62: Normal Operation

    Mounting Instruction Conductor rail system MultiLine 0835 Fire hazard due to overload or spark formation! A fire hazard can occur due to overloads of the cable, electrical arcing, short-circuits or the generation of sparks. Sparks can occur due to badly maintained, dirty conductor rails or because required DANGER! tolerances are not observed during installation.

  • Page 63: Servicing And Maintenance

    Mounting Instruction Conductor rail system MultiLine 0835 Servicing and maintenance 9.1 Safety The system must only be serviced and maintained by specialist personnel! NOTE! Requirement: Required protective equipment: Risk of sensitization, irritations of the mucous membranes and disorders of the respiratory tract through dust! Dust from the carbon brushes collects in the conductor rails and the guide profile.
  • Page 64 Mounting Instruction Conductor rail system MultiLine 0835 Risk of death by electrocution! The following hazard zone in particular also requires special care in addition to the power feed and power rail: DANGER! When using dual current collectors, one of the sliding contacts, which will be live might ...
  • Page 65 Mounting Instruction Conductor rail system MultiLine 0835 Performing maintenance work on the current collectors Risk of injury from crushing and impacts! There is a risk of crushing skin and limbs from: Current collectors (spring force) during installation, deinstallation and maintenance ...

  • Page 66: Tools And Materials

    Mounting Instruction Conductor rail system MultiLine 0835 9.2 Tools and materials The maintenance work on the conductor rail must be performed using commercially available metric tools. Maintenance work Tool Measuring the height of the carbon brushes Calliper Measuring the contact force of the carbon brushes Spring balance with a measuring range of 0 to 20 N 9.3 Cleaning...
  • Page 67 Mounting Instruction Conductor rail system MultiLine 0835 Required protective equipment: Risk of sensitization, irritations of the mucous membranes and disorders of the respiratory tract through dust! Dust from the carbon brushes collects in the conductor rails and the guide profile. This dust is very DANGER! fine and is categorized as a health risk.
  • Page 68 Mounting Instruction Conductor rail system MultiLine 0835 To be Interval Servicing task performed by Daily Visual inspection Operator Is there any coarse dirt or objects in the conductor rail?  4 weeks after Visual inspection: Technician commissioning Check whether the contact areas of the sliding contacts are worn out ...
  • Page 69 Mounting Instruction Conductor rail system MultiLine 0835 Functional inspection: Technician → Check for presence of springs → Check for correct installation height of the current collector 80 ± 10 mm (see Fig. 51) → Change the fastening position if it is not correct →...

  • Page 70: Repairing Faults

    WARNING! → Faults must only be repaired 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 together with their corresponding remedial measures. Faults must only be repaired by qualified personnel!
  • Page 71 Mounting Instruction Conductor rail system MultiLine 0835 → Protect the surroundings during cleaning works, for instance by covering or removing warehouse goods and blocking access to those areas in which dust could fall down on persons → Remove dust with a vacuum cleaner. Do not blow out dust with compressed air. Vacuum cleaners should be fitted with a class H fine filter →...

  • Page 72: Fault Remedy Table

    → Fit a contact guard that will safely cover the sliding contact if it sticks out of the conductor rail! CAUTION! 10.1 Fault remedy table Fault Cause Corrective measures Only use original Conductix-Wampfler The current collector heads' range of movement current collectors, check cable position is restricted. (make sure cables can move freely). The sliding contacts show Install current collector as specified in uneven wear.
  • Page 73 Mounting Instruction Conductor rail system MultiLine 0835 Fault Cause Corrective measures Adjust the consumer's movement Abrasive dust has collected at one of the more profile. Move over the end position to frequently used transfer points (where the direction of push the collected abrasive dust out of travel is reversed).

  • Page 74: Dismantling And Disposal

    Mounting Instruction Conductor rail system MultiLine 0835 11 Dismantling and disposal 11.1 Safety Personnel: Must only be performed by trained technicians. At least 2 people  Requirement: Required protective equipment: Risk of death by electrocution! Contact with components carrying electrical power can lead to death by electrocution or severe injury.
  • Page 75 Mounting Instruction Conductor rail system MultiLine 0835 Required protective equipment: Risk of sensitization, irritations of the mucous membranes and disorders of the respiratory tract through dust! Dust from the carbon brushes collects in the conductor rails and the guide profile. This dust is very DANGER! fine and is categorized as a health risk.

  • Page 76: Dismantling

    Mounting Instruction Conductor rail system MultiLine 0835 Danger of injury due to improper disassembly! Residual energy, sharp components, sharp points, and edges on and in the device or the required tools can cause injury. WARNING! → Make sure there is sufficient space before starting work →...

  • Page 77: Dismantling The Conductor Rail

    Mounting Instruction Conductor rail system MultiLine 0835 11.2.3 Dismantling the conductor rail Danger of injury due to improper disassembly! Residual energy, sharp components, sharp points, and edges on and in the device or the required tools can cause injury. WARNING! →...

  • Page 78: Disposal

    Mounting Instruction Conductor rail system MultiLine 0835 11.3 Disposal In the absence of a return or disposal agreement, disassembled components must be recycled as follows: Metal components must be recycled  Plastic components must be recycled  Sort other components by type of material and dispose of accordingly ...

  • Page 79: Additional Documents

    Conductor rail system MultiLine 0835 12 Additional documents 12.1 Conformity declaration The conformity declaration for this product can be obtained from Conductix-Wampfler on request. 12.2 Spare parts list The spare parts are listed in the relevant catalogues. 12.3 Other applicable documents Order Document no.

  • Page 80: Appendix

    Mounting Instruction Conductor rail system MultiLine 0835 13 Appendix 13.1 Table with standard lengths End segment Connector Power rail Number n Connector End segment Std. L Std. L (first section) [mm] [mm] (rails + [mm] minimal max. [mm] connectors) [mm]...

  • Page 81: Index

    Mounting Instruction Conductor rail system MultiLine 0835 14 Index Operator ................11 Accessories ................ 26 Other applicable documents ..........79 Accidents ................18 Packaging ................31 Commissioning ..............57 Personnel ................8 Conformity declaration ............79 Product description ............24 Copyright ................

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