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Conductix-Wampfler ChargeLine 0865 Operating Instructions Manual

Conductor rail system
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Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com
Translated from: BAL0865-0001-DE
page 1 of 51

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  • Page 1 Operating Instructions Conductor Rail System ChargeLine 0865 BAL0865-0001-EN www.conductix.com Translated from: BAL0865-0001-DE page 1 of 51...

  • Page 2: Table Of Contents

    Operating Instructions Conductor Rail System ChargeLine 0865 Contents General Information ..................................4 Information about these operating instructions ....................... 4 Limitation of liability ................................ 4 Copyright ..................................5 Replacement parts ................................. 5 Material defects ................................5 Technical support ................................5 Safety Information ..................................6 Explanation of symbols ..............................
  • Page 3 Operating Instructions Conductor Rail System ChargeLine 0865 Safety ................................... 40 Maintenance and Service ................................. 41 Safety ................................... 41 Tools and materials ..............................42 Cleaning ..................................42 Maintenance plan ................................. 42 Troubleshooting Table ................................45 Disassembly and Disposal ................................ 47 11.1 Safety ...................................

  • Page 4: General Information

    Operating Instructions Conductor Rail System ChargeLine 0865 1 General Information 1.1 Information about these operating instructions The information provided in this document is designed to enable the equipment to be used safely and efficiently. This document is a component of the system and must be kept accessible to personnel and in its immediate vicinity. Prior to commencing any work, personnel must have carefully read through and understood these operating instructions.

  • Page 5: Copyright

    Operating Instructions Conductor Rail System ChargeLine 0865 1.3 Copyright These operating instructions are protected by copyright and exclusively intended for internal use by the customer. 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 6: Safety Information

    Operating Instructions Conductor Rail System ChargeLine 0865 Safety Information 2.1 Explanation of symbols Safety and hazard information is identified in these operating instructions using symbols. Safety and hazard information is introduced by signal words that indicate the degree of the hazard. Always observe safety and hazard information and work carefully to avoid accidents, bodily injury and material damage! ...

  • Page 7: Personnel Requirements

    Operating Instructions Conductor Rail System ChargeLine 0865 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 material damage. → All activities may only be conducted by personnel who are qualified for the respective activity!

  • Page 8: Personal Protective Equipment

    Operating Instructions Conductor Rail System ChargeLine 0865 2.3 Personal protective equipment Always wear For all work, always wear: Protective clothing Primarily for protection against ensnarement by moving machine parts. Work clothing must be close fitting with a low resistance to tearing; it must have close-fitting sleeves and no protruding parts.

  • Page 9: Intended Use

    Operating Instructions Conductor Rail System ChargeLine 0865 2.4 Intended use The product is exclusively designed and built for the intended use described herein. Claims of any kind due to damages from unintended use are excluded. The operator bears sole liability for all damage that results from unintended use.
  • Page 10 Operating Instructions Conductor Rail System ChargeLine 0865 2.6.1 Electrical hazards and sources of danger Requirements: Risk of death due to electric shock! Contact with energized components can lead to death or severe injury due to electric shock. There is also a risk of injury from shock reactions, falling or being thrown across the room as a result of an DANGER! electric shock.
  • Page 11 Operating Instructions Conductor Rail System ChargeLine 0865 Fire hazard due to overload or sparking! Fire hazards occur due to overload of the cables, electrical arcs, short circuits, or the formation of sparks. Sparks can form in poorly serviced, contaminated conductor rails or if the installation does not DANGER! comply with required tolerances.
  • Page 12 Operating Instructions Conductor Rail System ChargeLine 0865 Required protective equipment: Risk of injury due to cutting and severing! The ends of the conductor bars can have sharp edges, particularly if they were cut to size at the installation site and have not been deburred.
  • Page 13 Operating Instructions Conductor Rail System ChargeLine 0865 2.6.3 Danger due to dust and vapors Required protective equipment: Danger of sensitization, mucous membrane irritation and respiratory diseases due to dust! Dust from the sliding contact collects in the conductor rails and the guideway profile. This dust is very fine and is categorized as a health hazard.
  • Page 14 Operating Instructions Conductor Rail System ChargeLine 0865 2.6.4 Dangers related to the operational environment These characteristics of the conductor rail can cause danger if the conductor rail is installed in an operational environment with: Electrical power  Sparking  Dust due to abrasion ...

  • Page 15: Technical Data

    Operating Instructions Conductor Rail System ChargeLine 0865 Technical Data 3.1 Electrical Rated current 100 A for complete 0865 units when using 2 line feeds 32 A for conductor rail systems from 0835 and 0865 or units connected by 0835 connectors.
  • Page 16 The conductor rail must be installed within the following tolerances. Conductix-Wampfler does not guarantee the trouble-free function of the conductor rails 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 trouble-free.

  • Page 17: Operating Conditions

    Operating Instructions Conductor Rail System ChargeLine 0865 3.3 Operating conditions Specification Value Notes Temperature range In temperatures of 0 °C and below, the - 5 °C to + 60 °C max. relative humidity must not exceed 30%. Max. Relative humidity 85 % Max.

  • Page 18: Description Andfunctional Principle

    Conductor Rail System ChargeLine 0865 Description and Functional Principle 4.1 Brief description The Conductor Rail System ChargeLine 0865 is a system that charges during movement and standstill. The conductor rail system consists of the following components: Hanger clamp  Conductor rail with one or two pickup guides ...

  • Page 19: Description Of Assemblies

    Operating Instructions Conductor Rail System ChargeLine 0865 4.2 Description of assemblies Fig. 4: Conductor rail with pickup guide (both sides) Conductor Rail 0865 with two pickup guides  There are pickup guides on both sides. An infeed and outfeed point is possible on both sides. Connecting cables are also possible on both sides.
  • Page 20 Operating Instructions Conductor Rail System ChargeLine 0865 Anchor Point 0865/sliding bearing  If the fixing web (Pos. 1) is not broken away at the rear of the pickup guide, this functions together with the hanger clamp as an anchor point.
  • Page 21 Operating Instructions Conductor Rail System ChargeLine 0865 Current Collector 0865  The current collector supplies the track-guided mobile consumer with the required energy. It was specially designed for the new Pickup Guide 0865 and includes strain relief as well as cables (always double insulated, cable diameter: 4 mm²).
  • Page 22 Operating Instructions Conductor Rail System ChargeLine 0865 In a worst case scenario, disassembling the connectors can cause a fire! The connectors cannot be removed. Disassembled connectors are defective and can no longer be used because they are deformed during disassembly and their trouble-free function can no longer be DANGER! guaranteed.

  • Page 23: Transport, Packaging And Storage

    Operating Instructions Conductor Rail System ChargeLine 0865 5 Transport, Packaging and Storage 5.1 Transport 5.1.1 Safety information for transport Risk of injury from falling conductor bars when transported incorrectly! When being transported on the installation site, there is a risk that the conductor bars may slide out of the insulation profiles if they are not held relatively vertical during transport.
  • Page 24 Operating Instructions Conductor Rail System ChargeLine 0865 If stored within this temperature range, stacking the conductor rails on top of each other can cause the plastic insulation to deform! → Unpack the conductor rails. ATTENTION! BAL0865-0001-EN www.conductix.com Translated from: BAL0865-0001-DE...

  • Page 25: Installation

    Operating Instructions Conductor Rail System ChargeLine 0865 Installation 6.1 Safety 6.1.1 Personnel → The system must only be installed by specialist personnel! → The system must be installed by at least 2 persons. Required protective equipment: 6.1.2 Safety information Risk of injury due to improper installation! Improper installation and commissioning can result in serious personal injury and/or material damage.
  • Page 26 Operating Instructions Conductor Rail System ChargeLine 0865 Required protective equipment: Risk of injury due to cutting and severing! The ends of the conductor bars can have sharp edges, particularly if they were cut to size at the installation site and have not been deburred.

  • Page 27: Procedure

    Operating Instructions Conductor Rail System ChargeLine 0865 6.2 Procedure 6.2.1 System overview Fig. 11: 0865 system overview Pos. Name Customer-side support structure/substructure Hanger clamp Current collector Pickup guide Conductor rail Fixing web on pickup guide Line feed/Outfeed BAL0865-0001-EN www.conductix.com Translated from: BAL0865-0001-DE...
  • Page 28 Once fitted, connectors and connector caps cannot be removed again! This is why the  connectors must always be carefully aligned first before they are fitted. If they need to be changed, please contact Conductix-Wampfler before doing so. See Section 6.2.4 → When using copper conductor bars, use copper-plated connectors. Connector caps The connector caps must be supported by the installation surface in order to be able to withstand ...
  • Page 29 Operating Instructions Conductor Rail System ChargeLine 0865 6.2.4 Installing the conductor rail 6.2.4.1 Installing anchor points Work steps: → Together with a hanger clamp (Pos. 2), the fixing web (Pos. 3) of the pickup guide (Pos. 1) can be used as an anchor point (see Fig.
  • Page 30 Operating Instructions Conductor Rail System ChargeLine 0865 6.2.4.2 Installing the expansion joint Because the individual conductor bars are combined in one component, the entire conductor rail expands together.  The connector caps are firmly connected to the conductor bars and move in line with the expansion of the conductor bars.
  • Page 31 Operating Instructions Conductor Rail System ChargeLine 0865 Determine the position of the hanger clamp from the expansion joint: The position of the hanger clamp of the expansion joint should be central. The current collector must be de-energized outside the conductor bar.
  • Page 32 Operating Instructions Conductor Rail System ChargeLine 0865 6.2.5 Installing the line feed Required tools: Plastic hammer  Crimping tool  Cable stripper  → Allow the connecting cables that protrude from the line feed end of the conductor rail to be connected to the terminal box by a qualified electrician.
  • Page 33 Operating Instructions Conductor Rail System ChargeLine 0865 Fig. 21: Slide pickup guide over line feed point Fig. 22: Tap expanding rivet into hole BAL0865-0001-EN www.conductix.com Translated from: BAL0865-0001-DE page 33 of 51...
  • Page 34 Operating Instructions Conductor Rail System ChargeLine 0865 6.2.6 Installing the hanger clamps Required tools: ø Drill 9 mm  Work steps: → If there are no holes in the customer's support structure/substructure, these must still be drilled (see Fig. 23).
  • Page 35 Operating Instructions Conductor Rail System ChargeLine 0865 Fig. 27: Hanger clamp is installed on customer's support structure/ Fig. 26: Insert hanger clamps into customer's support substructure structure/substructure → Hang the Conductor Rail Segment 0865 in the hanger clamp (see Fig. 28).
  • Page 36 Operating Instructions Conductor Rail System ChargeLine 0865 6.2.8 Adjusting the length The Conductor Rail 0835 or the Conductor Rail 0865 may be affected by a length adjustment. See MAL0835-0001 for length adjustment of Conductor Rail 0835. Only an open Conductor Rail 0865 may be sawn.
  • Page 37 Operating Instructions Conductor Rail System ChargeLine 0865 6.2.10 Installing the current collector Current collector with connecting cable: Cross-section 4 mm² Always double insulated Line length is configurable 2-pole unit PH and PE version The current collector poles on the towing plate of the current collector can be assigned as required.

  • Page 38: Commissioning

    Operating Instructions Conductor Rail System ChargeLine 0865 Commissioning Before switching the system on! → Each time before the equipment or system is started, measure the insulation resistance according to locally applicable technical standards, directives and legal regulations. CAUTION! → Carry out locally required electrical tests.
  • Page 39 Operating Instructions Conductor Rail System ChargeLine 0865 Check the current collector's connecting cables. Fig. 30: Connection cable is correctly laid Fig. 31: Do not compress or kink connecting Fig. 32: Connection cable must not rest Fig. 33: Do not load connection cable cable Fig.

  • Page 40: Operation

    Operating Instructions Conductor Rail System ChargeLine 0865 Operation 8.1 Safety In order to follow the most important safety measures, the suitable operating conditions specified in Section 3.3.1 and the following sections must be observed. The conductor rail environment may be exposed to electrical current!

  • Page 41: Maintenance And Service

    Operating Instructions Conductor Rail System ChargeLine 0865 Maintenance and Service 9.1 Safety Requirements: Required protective equipment: Risk of injury due to improperly performed maintenance work! Improper maintenance can result in serious injury to persons or material damage. Loosely stacked or scattered components and tools that are left lying around are a source of danger.

  • Page 42: Tools And Materials

    Operating Instructions Conductor Rail System ChargeLine 0865 9.2 Tools and materials The maintenance work on the conductor rail must be performed using commercially available metric tools. Maintenance work Tool Measure height of sliding contacts Calipers Determine contact pressure of sliding contacts Spring scale with a measuring range of 0 to 20 N 9.3 Cleaning...
  • Page 43 Operating Instructions Conductor Rail System ChargeLine 0865 To be Interval Service work performed by Daily Visual inspection Operator Are coarse dirt or objects in the conductor rail?  4 weeks after Visual inspection: Specialist commissioning Check if sliding contacts are worn in the contact area.
  • Page 44 Operating Instructions Conductor Rail System ChargeLine 0865 Functional test: Specialist technician Ensure correct contact pressure.  → Check for the presence of springs. → Check the correct installation height of the current collector 72.5 (see Fig. 35). → Adjust the fastening position in the event of deviation.

  • Page 45: Troubleshooting Table

    10 Troubleshooting Table Requirements: Required protective equipment: Fault observed Source Cause Only use original Conductix-Wampfler The current collector head's range of movement is current collectors, check cable position restricted. (ensure that cables can move freely). Sliding contacts are unevenly worn.
  • Page 46 Operating Instructions Conductor Rail System ChargeLine 0865 Fault observed Source Cause Install current collector as specified in Current collector not properly connected. Fig. 29; correct connecting cable, replace if necessary. Install current collector as specified in Contact pressure too low.

  • Page 47: Disassembly And Disposal

    Operating Instructions Conductor Rail System ChargeLine 0865 11 Disassembly and Disposal 11.1 Safety Requirements: Required protective equipment: Required protective equipment: Risk of injury due to improper disassembly! Stored residual energy, angular components, sharp points and edges on and in the equipment or the required tools can cause injury.
  • Page 48 WARNING! → Handle open, sharp-edged components carefully. → Contact Conductix-Wampfler GmbH in case of ambiguities. → Slide (1) and turn (2) the screwdriver between the clip of the hanger clamp and the conductor rail so that the conductor rail can be removed from the hanger clamp.

  • Page 49: Disposal

    Operating Instructions Conductor Rail System ChargeLine 0865 11.3 Disposal In the absence of return and disposal agreements, recycle the disassembled components: Metal components must be sent for recycling.  Plastic components must be sent for recycling.  The other components are to be disposed of according to their material composition.

  • Page 50: Additional Documents

    ChargeLine 0865 12 Additional Documents 12.1 Declaration of Conformity The Declaration of Conformity for this product can be obtained from Conductix-Wampfler GmbH upon request. 12.2 Replacement parts list The replacement parts are listed in the relevant catalogs. 12.3 Applicable documents Seq.No.

  • Page 51: Index

    Operating Instructions Conductor Rail System ChargeLine 0865 13 Index Applicable documents ............50 Material defects ..............5 Commissioning ..............38 Operating conditions ............17 Copyright ................5 Personnel ................7 Dangers ................9 Product description ............18 Declaration of Conformity ........... 50 Replacement parts ...............

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