Conductix-Wampfler 0813 Series Operating Instructions Manual Download Page 84

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Operating Instructions

Insulated Conductor Rail System

SinglePowerLine Program 0813

BAL0813-0007-EN
www.conductix.com

translated document

page 84 of 108

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.

Recommended protective equipment:

WARNING!

Risk of injury due to improper commissioning!

Improper commissioning can lead to dangerous situations for personnel (see Section 7.2.1).

→

Before commissioning, conduct the inspections on the inspection list of the manufacturer.

→

Measure the insulation resistance (see MV0800-0018 or MV0800-0019) each time before

commissioning. Follow the locally applicable technical standards, directives, and legal regulations.

→

Always ensure that all the installation work has been fully completed before each commissioning.

→

Always ensure that all components have been properly installed before each commissioning.

CAUTION!

Ensure a free travel path before beginning the commissioning!

CAUTION!

Contact problems or increased heating!

→

Clean the sliding contact before commissioning and remove soiling, oxidation, pitting

corrosion and other impurities by means of a brass brush or abrasive paper (320 grit).

→

Avoid standstill operation with high currents during commissioning as much as possible. The

sliding contacts are not yet grounded and can therefore heat up more.

DANGER!

Risk of injury due to crushing of skin and limbs!

There is a risk of crushing of skin and limbs due to:

→

Do not stand directly below the conductor rail system.

→

Do not enter the danger zones of the system during operation. The operator/system

manufacturer must ensure that technical protective measures are taken (covers, protection
through distance, control technology, etc.).

Summary of Contents for 0813 Series

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

Page 2: ...ctive equipment 9 2 4 Intended use 10 2 5 Unintended use 11 2 6 Protective measures by the operator user 12 2 7 5 Safety Rules for working on electrical systems 12 2 8 Special hazards 13 2 8 1 Electri...

Page 3: ...ductor rail system 49 6 4 3 1 50 6 4 3 2 Mount hanger clamps 50 6 4 3 3 Mount conductor rail 54 6 4 3 4 Connect rails 57 6 4 3 5 Line feed 60 6 4 3 6 Mount anchor clamp 63 6 4 3 7 Mount heating wire o...

Page 4: ...Stopping the system 90 8 4 Continue operation 91 9 Maintenance and Service 92 9 1 Safety 92 9 2 Tools and materials 95 9 3 Maintenance plan 96 10 Troubleshooting 97 10 1 Safety 97 10 2 Fault correcti...

Page 5: ...ddition to these operating instructions the instructions located in the appendices for the individual assembled components also apply 1 2 Limitation of liability All data and information in these oper...

Page 6: ...laims remains unaffected 1 4 Replacement parts WARNING Incorrect replacement parts are a safety hazard Incorrect or faulty replacement parts can impair safety and result in damage malfunctions or comp...

Page 7: ...s situation which if not avoided may result in death or serious injury DANGER indicates an immediately hazardous situation due to electricity which if not avoided may result in death or serious injury...

Page 8: ...engineers or electrical technicians Personnel are also considered qualified who have been employed correspondingly for several years have been educated in theory and practice during that time and who...

Page 9: ...ing for better traceability Example of instruction log Date Name Type of Training Training given by Signature 11 05 2009 John Doe First safety training for personnel Horst M ller 2 3 Personal protecti...

Page 10: ...ction 2 5 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 Intended use The SinglePowerLine 0813 Con...

Page 11: ...ended use are excluded The operator bears sole liability for all damage that results from unintended use Unintended use particularly includes the following forms of use Operation in unsuitable environ...

Page 12: ...s The operator must provide personnel with all required protective equipment work clothes safety shoes hearing protection protective gloves safety helmet goggles breathing mask The operator must keep...

Page 13: ...s and connections within switching cabinets control systems etc Parts that have come under voltage due to a fault Before working on the parts listed above Disconnect the conductor rail system from the...

Page 14: ...ar conductor rails Check service and clean conductor rails regularly and as prescribed See Section 8 and 9 2 8 2 Mechanical hazards and sources of danger DANGER Risk of injury due to ensnarement or im...

Page 15: ...cked plants take effective measures to protect employees from the dust During all work on the conductor rail system in which collected dust can be stirred up wear personal protective equipment In part...

Page 16: ...ts For example hanger clamps can break and the conductor rail system can fall down Check the influencing factors of temperature exposure time concentration and interactions Use in chemical works galva...

Page 17: ...lfunctions Measures in the event of accidents Shut down the system and secure it against unauthorized unintentional and or erroneous reactivation Secure the danger zone Remove persons from the danger...

Page 18: ...um conductor temperature 85 C 115 C for heat resistant version PPE SB briefly 125 C Protection type With current collector insertion from below IP23 DIN EN 60529 VDE 0470 1 with current collector inse...

Page 19: ...stainless steel sliding surface CopperECO Copper Information regarding resistances are general notes and depend on the temperature exposure time concentration and interactions and must be verified in...

Page 20: ...ased heating if the current collector is operated outside the permissible installation position 3 2 Tolerances The conductor rail must be installed within the following tolerances Conductix Wampfler d...

Page 21: ...or explosive gases or dusts In flammable or explosive materials in the vicinity particularly below the conductor rail In dusty environments Outdoors with free weathering In environments with relative...

Page 22: ...ent collector The current collector head of the current collector is pressed against the conductor rail with a continuous contact pressure The electrical energy is transferred to the current collector...

Page 23: ...translated document page 23 of 108 Fig 2 System overview 0813 Pos Name 1 End cap 2 Support arm 3 Hanger clamp 4 Anchor clamps 5 Connector 6 Line feed connector 7 Towing arm 8 Single current collector...

Page 24: ...ated document page 24 of 108 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...

Page 25: ...crews Electrical interfaces The current collector head is connected to the electrical system of the mobile consumer via a flexible connecting cable The connecting cable can be supplied in the scope of...

Page 26: ...bracket bracket The conductor rails are fastened to a straight smooth surface provided by the customer using hanger clamps The conductor rails are electrically and mechanically coupled using connector...

Page 27: ...e Fig 11 Hanger clamp 0813 without insulator hexagon 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 hange...

Page 28: ...compact screw connectors 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...

Page 29: ...ing caps Line feed connector 081351 The line feed takes place via line feed connectors These are used instead of normal connectors The electrical connection is made via spacer bolts and tubular cable...

Page 30: ...expanded from this point The fixed point is typically attached near the line feed If several fixed points are projected for example with transfers or curves natural fixed point the route between the f...

Page 31: ...odate a maximum 45 mm expansion The expansion units are delivered pre assembled on a conductor rail 5000 mm The middle section of the expansion unit must be supported with a hanger clamp not included...

Page 32: ...allation dimension between towing arm and sliding surface 125 mm Fig 27 Double current collector Double current collector 08130 Contact pressure 2 x 28 N Lateral deflection 100 mm Working stroke in in...

Page 33: ...pport arm Sendzimir hot dip galvanized steel Fig 29 Bracket for screwing on with 2 hole connection plate steel galvanized Fig 30 Support arm bracket Bracket steel blank Small parts steel galvanized Su...

Page 34: ...ckets anti twist clamping thickness 6 25 mm galvanized steel Clamping brackets 020180 020181 08 Clamping brackets can also be used for example to attach a support arm to the customer s support structu...

Page 35: ...ons 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 36 Towing arm for current collector steel galvanize...

Page 36: ...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 curr...

Page 37: ...ix com translated document page 37 of 108 Fig 40 Tool 1 Fig 41 Tool 2 Disassembly tool 0813 08 V015 0493 The disassembly tool consists of two tools and is an aid for removing a hanger clamp from the c...

Page 38: ...ones Do not attach ropes or straps at sharp corners and edges and do not knot or twist them Only move loads under supervision Set down the load before leaving the workplace Cordon off the work area Us...

Page 39: ...use the attachment points provided Only remove packaging shortly before installation 5 2 Transport Immediately upon receipt check the delivery for completeness and transport damage In case of visible...

Page 40: ...age a specialist to handle disposal 5 4 Storage of packaged parts Store packaged parts under the following conditions Do not store outdoors Store in a dry dust free place Do not expose to aggressive m...

Page 41: ...ury due to improper installation Improper installation can result in serious injury to persons and property Before starting work ensure that there is sufficient space for the installation Handle open...

Page 42: ...e equipment DANGER Risk of injury due to ensnarement or impact An ensnarement and or impact with moving conductor rails slip ring or current collectors connected to the machine and other components mu...

Page 43: ...ock The main power supply from the building must be disconnected in the installation area and secured against switching on again Disconnect all voltage supply to the line feeds Check whether a voltage...

Page 44: ...due to an electrical shock as well as by falling or being thrown across the room The system operator must ensure that the current collector does not protrude or must ensure that the danger area is in...

Page 45: ...ing 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 42 Components in a...

Page 46: ...Drilling jig for systems with guides Order No 08 W100 0223 Contact grease conductive paste Order No 080021 Personnel Installation only by technical personnel at least 2 persons 6 4 2 Trim conductor r...

Page 47: ...ainless steel strip will loosen in the conductor bar Always adhere to the cutting direction Fig 44 Note the sawing direction for the conductor bar Saw the insulating profile accordingly It must always...

Page 48: ...file NOTE 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 Use...

Page 49: ...e layout and allocation plan on the substructure Prepare the line feed and guide if present Install the conductor rail see Section 6 4 3 1 Install conductor rail sections Check the mechanical installa...

Page 50: ...astening and or increased requirements e g vibration the fastening must be adapted to the respective application e g by means of additional screw locking with Loctite 242 The system manufacturer is re...

Page 51: ...e project specific documents Distance between hanger clamps Hanger clamp to end cap 250 mm up to max 400 mm Hanger clamp to hanger clamp 2500 mm Work steps mounting with support arm C rail Slide the f...

Page 52: ...see Fig 54 The phase offset of either 80 mm standard or 70 mm reduced can be set with the mounting comb Depending on which phase offset is to be implemented the corresponding side 4x80 mm or 4x70 mm...

Page 53: ...e screw connection from the hanger clamp Insert the hanger clamp into the hole in the retaining plate and tighten the screw connections from above with an open end wrench SW 17 14 Nm see Fig 57 throug...

Page 54: ...nalysis The operator must take appropriate measures Requirements The hanger clamps are correctly mounted on the support structure Work steps Mount the conductor rails according to the project specific...

Page 55: ...ductor rail and hanger clamp see Fig 62 Press the conductor rail against Tool 1 or against the hanger clamp see Fig 63 At the same time insert Tool 2 on the open side of the conductor rail see Fig 65...

Page 56: ...3 BAL0813 0007 EN www conductix com translated document page 56 of 108 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 tens...

Page 57: ...3 6 Anchor clamps are positioned to the right and left of a hanger clamp Please refer to the project specific documents for the exact position of the anchor clamps NOTE Aluminum stainless steel and Co...

Page 58: ...n the function a gap of 2 to max 3 mm between the rail ends is functionally necessary The clamping plate Pos 7 see Fig 78 must lie in the hollow profile of the conductor bar NOTE In the case of alumin...

Page 59: ...ide the insulating cap halves of the connector over the connection point see Fig 76 and tighten the two fillister head tapping screws Pos 6 see Fig 77 Fig 76 Slide the insulating cap halves of the con...

Page 60: ...as possible to the feed cable of the permanent installation see Section 6 4 3 4 If the line feed is provided within a section of rail that has been cut to length the insulating profile must be separa...

Page 61: ...beforehand and connecting it to the sleeve with a hot air blower after installation Fig 81 Slide the cable ends through the sleeves To ensure a good current transfer over the long term the conductor...

Page 62: ...ug 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 Slide the two insulating cap halves Pos 1 together and scre...

Page 63: ...animation Connecting Rails and Mounting Line Feed 6 4 3 6 Mount anchor clamp The conductor rail is fixed at one point by means of anchor clamps and can expand freely from this point The fixed point is...

Page 64: ...ls Open end wrench SW8 Work steps Slide the anchor clamps onto the clipped in conductor rail section on the right and left see Fig 87 When sliding on the anchor clamps ensure that the two side screws...

Page 65: ...ing loss of contact with the current collector The conductor rail is heated using an electrical heating conductor that is fed into the insulation profile It lies in the hollow cavity of the insulation...

Page 66: ...from the power supply The heating can be designed as a separate electrical circuit and may need to be disconnected from the power separately from the conductor rail Disconnect the power supply of each...

Page 67: ...luded in the scope of delivery on the customer s support structure substructure The use of a double current collector is recommended when using expansion units Required tools Open end wrench SW17 Work...

Page 68: ...ion of the two lines and read off the air gap to be installed Example Temperature range From 5 C to 45 C Ambient temperature during installation 23 C Air gap 20 mm per expansion point 2 x 20 mm for th...

Page 69: ...current collector Requirements The ends of the conductor rail ends are deburred see Fig 46 and not connected with a connector Please refer to the project specific documents for the exact position of a...

Page 70: ...with fastening elements consisting of hexagon screw DIN931 M6x50 Pos 5 8 Nm and lock nut DIN985 Pos 6 mounted on the end caps see Fig 93 Slide the hanger clamp onto the anchor clamp Fig 93 Mount the...

Page 71: ...o the screw on the side of the anchor clamp Place the bridging plate Pos 9 over the bolt of the hanger clamp and screw together with the DIN 934 nut Pos 13 14 Nm Mount the cover Pos 14 onto the hanger...

Page 72: ...d potential constructive differences Use the QR code click or scan to see our animation Mounting the Air Gap Insulation Section 6 4 3 10 Mount end caps Required tools Hexagon screwdriver SW5 Rubber ma...

Page 73: ...d Conductor Rail System SinglePowerLine Program 0813 BAL0813 0007 EN www conductix com translated document page 73 of 108 Fig 98 End cap on the conductor rail end Fig 99 The end cap is mounted correct...

Page 74: ...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 s...

Page 75: ...the x and y directions are not permitted The pickup guide centers the current collector with a maximum lateral and vertical offset of 25 mm settings of less than 10 mm are recommended NOTE For systems...

Page 76: ...Program 0813 BAL0813 0007 EN www conductix com translated document page 76 of 108 Fig 104 Important dimensions for systems with pickup guides NOTE Please also note the information on installing the P...

Page 77: ...lamps in front of the pickup guide was reduced from 80 mm to 65 mm Distances Pickup guide to the first hanger clamp 560 mm Required tools Rubber mallet Hexagon screwdriver SW5 Work steps The pickup gu...

Page 78: ...the single current collector 250 A Single current collector 250 A Maximum current load 250A Max travel speed 600 m min higher travel speeds on request Contact pressure 28 N Lateral deflection 100 mm...

Page 79: ...ted Conductor Rail System SinglePowerLine Program 0813 BAL0813 0007 EN www conductix com translated document page 79 of 108 Fig 108 Mount the central axis of the current collector exactly on the centr...

Page 80: ...e moving range of the current collector and connecting cables Choose foreign objects such as fastening screws in such a manner that the movement of cables and current collectors is not affected In sys...

Page 81: ...is Observe the current collector tolerances mounting dimensions check at the narrowest point in the case of curves The towing arm must not have any play or bend Required tools Open end wrench SW17 Wor...

Page 82: ...er Pos D is seated on the bottom 6 4 4 2 Typical mounting errors Rail joints and transfers have not been deburred Distance within connectors was not maintained on end with Alu CopperECO from 2 to max...

Page 83: ...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 For...

Page 84: ...and legal regulations Always ensure that all the installation work has been fully completed before each commissioning Always ensure that all components have been properly installed before each commiss...

Page 85: ...danger zone in particular if protective devices covers enclosures control devices etc have been removed or deactivated Use caution when working in the vicinity of the danger zone particularly below t...

Page 86: ...plate been affixed in a suitable location by the manufacturer The phase offset is 80 mm or 70 mm see Section 6 4 3 1 Has the phase offset of the 2 3 hanger clamps in front of a pickup guide if present...

Page 87: ...conductor bars conductor rails and slip rings 50 k EN 60204 1 18 3 2018 For systems with heating Test Tested Has the heating wire if present been connected according to the project specific documents...

Page 88: ...ter initial commissioning Current collector undamaged and without signs of heavy wear Conductor rail components undamaged and in the proper location No displacements or distortions Check hanger clamps...

Page 89: ...and contacts a conductive material Take the following measures Ensure proper electrical protection at all times Ensure grounding of metallic components at all times Ensuring the function of the custo...

Page 90: ...y with the required tolerances Take the following measures Conduct electrical testing as prescribed before commissioning Permissible current values must be observed Maintain tolerances during operatio...

Page 91: ...s in the conductor rails Perform a visual inspection The insulation resistance corresponds to the locally applicable technical directives As needed before the device or system is started measure the i...

Page 92: ...voltage supply Check whether a voltage is still present in the components and take measures where necessary The customer must provide grounding for metallic components The customer must provide protec...

Page 93: ...bars and plastic There is a health hazard due to airborne respirable dust Sensitization may occur if handling the conductor rail frequently and or carelessly handling dust accumulation Cancer mucous...

Page 94: ...hazard due to overload or sparking A fire hazard can occur due to overloads of the cable electrical arcing or short circuits Before recommissioning ensure that all work has been completed and all comp...

Page 95: ...this task See Section 12 1 Replacing conductor rails DANGER Risk of injury due to cutting and amputation The ends of the conductor bars can have sharp edges particularly if they were cut to size on si...

Page 96: ...he required maintenance intervals should be shortened according to the actual signs of wear Contact the manufacturer in case of any questions regarding maintenance tasks and intervals see the service...

Page 97: ...r rail system according to the 5 Safety Rules and secure it against switching on again For the 5 Safety Rules see Section 2 5 DANGER Risk of death due to electrical shock Contact with components carry...

Page 98: ...ipment Protective eyewear Dust mask Class FFP3 observe local regulations Protective gloves Disposable coveralls Prevent contamination of the environment e g people goods production facilities etc whil...

Page 99: ...ards directives and legal regulations Conduct locally required electrical tests WARNING Danger of injury due to hot surfaces Components can get hot during operation Wear personal protective equipment...

Page 100: ...height of the current collector Sliding contacts wear out too fast Sharp edges on the power terminal conductor rails connections between the conductor rails Smooth out sharp edges with a file compres...

Page 101: ...e damaged components Abrasive dust has collected at one of the more frequently used transfer points where the direction of travel is reversed Adjust the consumer s movement profile Move over the end p...

Page 102: ...ue to electrical shock Contact with components carrying electrical power can lead to death or severe injury due to electrical shock Danger of injury due to shock reactions falling or being thrown acro...

Page 103: ...hazards Disassemble components properly Be aware of the dead weights of the components If necessary use lifting gear Secure components so they cannot fall or topple DANGER Risk of injury due to cuttin...

Page 104: ...oduction facilities etc while cleaning by taking appropriate measures use covers barriers filter systems Do not blow out dust with compressed air but rather vacuum it away The vacuum must be equipped...

Page 105: ...ired tools Disassembly tool Order No 08 V015 0493 see work steps on P 55 Hexagon screwdriver SW 5 Open end wrench SW 17 Screwdriver set Cutting tool e g jigsaw angle grinder Tools for securing 11 3 Di...

Page 106: ...documents ID No Document Number Document Name 01 WV0800 0001 Cleaning of Conductor Rails 02 WV0800 0002 Maintenance Schedule Conductor Rails 03 MV0800 0018 Insulation measurement of heating wires 04...

Page 107: ...Operating Instructions Insulated Conductor Rail System SinglePowerLine Program 0813 BAL0813 0007 EN www conductix com translated document page 107 of 108 12 2 Air gap diagram...

Page 108: ...bility 5 Maintenance and Service 92 Malfunctions 17 Material defects 6 Operation 89 Operator 12 Packaging 39 Personnel requirements 8 Product Description 22 Protection against contact 44 Protective me...

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