Conductix-Wampfler ProfiDAT Programm 0514 Mounting Instructions Download Page 37

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Mounting Instructions

ProfiDAT

Data Transmission System

Programm 0514

MAL0514-0005b-EN

www.conductix.com

translated document

page 37 of 82

6.2

Preparations

Required tools:



Open-ended spanner, SW10



Open-ended spanner, SW17



Open-ended spanner, SW24



Set of Allen keys, SW3



Allen key, SW5



Phillips screwdriver



Torque wrench



Lubricant



Hot air blower



Chop saw

Required material:



Cable ties



Shrink sleeve



Conductive paste 080021



Lubricant for stainless-steel screws, recommended: Klüber 46 MR 401 paste

Klüber Lubrication München KG
Geisenhausenerstr. 7
D-81379 Munich

Screw tightening torques:



M6 screw (SW10 open-ended spanner): 8 Nm



M10 screw (SW17 open-ended spanner): 40 Nm

Summary of Contents for ProfiDAT Programm 0514

Page 1: ...Mounting Instructions ProfiDAT Data Transmission System Programm 0514 MAL0514 0005b EN www conductix com translated document page 1 of 82...

Page 2: ...g 10 2 3 Personal Protective Equipment 10 2 4 Intended Use 11 2 4 1 Improper use 11 2 5 Protective Measures to be taken by the Owner Operator 12 2 6 Special Hazards 14 2 6 1 5 Protective Safety Rules...

Page 3: ...ProfiDAT System 28 4 3 2 Electrical Components 30 4 4 Modes of Operation 32 4 4 1 Normal Operation 32 5 Transport Packaging and Storage 33 5 1 Shipment 33 5 1 1 Safety Instructions for Transport 33 5...

Page 4: ...tional 55 6 4 15 Mounting a Temperature Sensor optional 56 6 4 16 Retrofitting of a PE Rail Connector Ground 56 6 5 Electrical Installation 59 6 5 1 Installing the ProfiDAT Infeed Switching Cabinet 60...

Page 5: ...conductix com translated document page 5 of 82 9 Troubleshooting 78 10 Dismantling and Disposal 79 10 1 Safety 79 10 2 Dismantling 79 10 2 1 Dismantling the Assembly 79 10 3 Disposal 80 11 Additional...

Page 6: ...anding and may deviate from the actual versions of individual compo nents In addition to these instructions the instructions in the appendices for the individual installed components also apply 1 2 Li...

Page 7: ...Parts WARNING Incorrect spare parts are a safety hazard Incorrect or faulty spare parts can impair safety as well as resulting in damage malfunctions or complete failure Always use original spare par...

Page 8: ...situation that will result in death or serious injury if not avoided DANGER indicates an immediately hazardous situation due to electricity that will result in death or se rious injury if not avoided...

Page 9: ...t personnel consists of persons capable of performing assigned tasks and independently identifying and avoiding potential hazards based on their specialist training knowledge and experience as well as...

Page 10: ...k clothing Primarily for protection against entrapment 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...

Page 11: ...datory for the installation The maximum permitted traversing speed of the mobile transceiver is 5 m s The profile may only be installed horizontally with the access aperture facing down Side access is...

Page 12: ...hen disconnected from the power supply The owner must become acquainted with the applicable occupational safety regulations and perform a risk analysis to identify additional hazards arising from the...

Page 13: ...luding Radio equipment EN 301 489 1 V1 8 1 EN 301 489 17 V2 2 1 Protection requirements with regard to EMC EN 300 328 V1 8 1 EN 301 893 V1 7 1 Use of the radio frequency spectrum EN 300 440 1 V1 6 1 A...

Page 14: ...Systems Work on electrical systems only when they are disconnected from the power supply Follow the 5 safety rules see DIN VDE 0150 100 2009 10 EN 50110 1 2004 11 before starting work 1 disconnect th...

Page 15: ...efore switching on Every time before the system is started test the insulation resistance according to locally applicable technical standards directives and legal regulations Carry out locally require...

Page 16: ...chapter 8 2 4 Only install the system where suitable operating conditions prevail See chapter 3 5 Risk of injury when cutting and trimming The ends of profiles and connectors can have sharp edges esp...

Page 17: ...nstallation commissioning or service Moving parts include for instance the crane and the current collectors attached to it Do not enter the hazardous area of the system when in operation except for re...

Page 18: ...workplaces with long term exposure and heavily use systems take effective measures to protect employees from the dust Use personal protective equipment during all work performed on the data transmissi...

Page 19: ...measure to provide protection from these dangers is to install the ProfiDAT system only in locations where suitable operating conditions prevail See chapter 3 5 2 6 6 Unexpected Startup unexpected Mo...

Page 20: ...r objects within the movement range hazard area Exception Repair and maintenance work Traversing is only permitted at reduced speed Make sure that the system cannot start up in an uncontrolled manner...

Page 21: ...o safety devices The system is always operated in conjunction with the plant in which the data transmission system is installed Therefore pay attention to the safety equipment of the plant WARNING Ris...

Page 22: ...gency vehicles Measures to take in the event of malfunction Shut down the system and secure it against unauthorized unintentional and or erroneous reactivation Secure the work area against entry Consu...

Page 23: ...ee the manufacturer s documentation chapter 11 2 Other applicable Documents 3 2 Interfaces 3 2 1 Electrical The interfaces to the customer system are Data interface Power supply control voltage PE Dat...

Page 24: ...or objects Observe and comply with the prescribed supply voltages Keep persons and objects out of the hazard area see chapter 2 6 6 On commissioning of the transceiver devices please observe that the...

Page 25: ...See the data sheet for the transceiver Deviations may occur see the manufacturer s documentation chapter 11 2 Other applicable Documents Country specific deviations may occur Please note the informati...

Page 26: ...C At a relative humidity of 100 at 20 C Wind speed in operation 25 m sec 10 Bft Wind speed when not in operation 32 7 m sec 12 Bft CAUTION Faults due to incorrect operating conditions Operating condit...

Page 27: ...iable length It consists of at least one fixed and one mobile transceiver the infeed antenna and the consumer antenna Hanger clamps are used to fasten the profiles to the steel construction which is p...

Page 28: ...lts which are provided by the customer The hanger clamps are pushed onto the profiles Two hanger clamps are installed for each profile The spacing between hanger clamps is 2500 mm Fig 5 Hanger clamp f...

Page 29: ...e emissions are produced for other equipment in the vicinity of the data transmission system Fig 11 Expansion element Expansion element The expansion element connects two ProfiDAT profiles together co...

Page 30: ...brushes Use of the single collector If there are no transitions in the traversing range If there are no expansion joints in the system With end infeed 4 3 2 Electrical Components Fig 15 Overview and...

Page 31: ...chapter 11 2 Other applicable Documents ProfiDAT power feed cabinet Fig 17 Infeed switching cabinet The power feed cabinet contains the component needed to mount a ProfiDAT transceiver on the system...

Page 32: ...ed for connector cables and adapter cables for the transmission of data between the transceiver and antennas see Fig 15 4 4 Modes of Operation The ProfiDAT data transmission system is used in the norm...

Page 33: ...and lashing components with sufficient load capacity Do not use torn or worn ropes or straps Do not attach ropes or straps at sharp corners and edges and do not knot or twist them Damage due to improp...

Page 34: ...individually packaged parts are packed in accordance with the anticipated transport conditions Only environmentally friendly materials have been used for packaging The packaging is designed to protect...

Page 35: ...lace Do not expose to aggressive media Protect from direct sunlight Avoid mechanical vibrations Storage temperature 15 to 35 C Relative humidity max 60 When storing for more than 3 months check the ge...

Page 36: ...death due to suspended loads Falling loads can cause serious injuries or even death Never walk under suspended loads Only move loads under supervision Set down the load before leaving the workplace I...

Page 37: ...ed spanner SW24 Set of Allen keys SW3 Allen key SW5 Phillips screwdriver Torque wrench Lubricant Hot air blower Chop saw Required material Cable ties Shrink sleeve Conductive paste 080021 Lubricant fo...

Page 38: ...ding installation Install a conductive connection between all parts of the steel structure Use toothed washers for screw connections or other suitable components to establish a conductive connection b...

Page 39: ...ame air gap The hanger clamps are designed as sliding suspension devices so that profiles can expand or contract as the temperature changes To this end it is necessary to install defined anchor points...

Page 40: ...allation and mark it horizontally 3 Drop a line down from the intersection of the two lines and read off the air gap to adjust Example as entered 1 tmax 40 C tmin 30 C 2 Ambient temperature during ins...

Page 41: ...ion on a C rail Insert the ProfiDAT profile 2 with hanger clamps 1 into the support structure 3 from below or push it into the C rail and secure the hanger clamps with the nut 5 and washer 4 Pay atten...

Page 42: ...level with one another and deburred Secure the PE rail connector 8 to the ProfiDAT profile 2 with the two threaded pins 9 Tighten the four lateral flange screws 10 on the connector Fig 24 Mounting the...

Page 43: ...ent Fasten the PE rail connector 1 with the two threaded pins 2 Push the next ProfiDAT profile 4 into the rail holder and push it into the rail connector 1 until it reaches the center ATTENTION Both p...

Page 44: ...l all further ProfiDAT profiles 4 in the same way Check that all four flange screws 5 are secured by a locking edge washer 6 between the screw head and rail connector Fig 27 Screw lock with locking ed...

Page 45: ...aces on the insulating profile Mark the two sections A and B so that they are not confused during installation The gap must be at least 86 mm Remove the insulating profile from the aluminum profile Fi...

Page 46: ...le and align them Comply with the distances specified in Fig 31 Fasten the PE rail connector with the two threaded pins Tighten the four lateral flange screws on the connector Fig 32 Pushing on the an...

Page 47: ...e entry funnel 1 onto the drive in zone from underneath and fasten with two screws 2 with nuts 3 and washers 4 CAUTION Note that there are left and right handed versions of the entry funnel Install th...

Page 48: ...lation profile and aluminum rail separately and at right angles with a chop saw Use the clamping surface A see Fig 36 so that the inside of the aluminum rail is not deformed After cutting the aluminum...

Page 49: ...ontal hexagonal socket headed screws 2 of the end cap 3 Infeed antenna on the profile Fig 39 Install the infeed antenna on the profile Push a connector 6 onto the last ProfiDAT profile 7 and secure it...

Page 50: ...ofiDAT section infeed Attaching the connecting cable to the expansion element Push the heat shrink sleeve onto one end of the connecting cable Fasten screw the connecting cable to the socket 1 of the...

Page 51: ...le infeed antenna 2 to the next ProfiDAT profile 3 Trim a ProfiDAT profile to dimension Y see chapter 6 4 3 Insert and connect the trimmed ProfiDAT profile 6 4 10 Installing the Terminating Unit The t...

Page 52: ...llectors The dual current collector consists of two identical current collecting arms These are connected with the screws supplied and at tached to the towing arm Minimum conductor spacing 50 mm Fig 4...

Page 53: ...he towing arm with the screws supplied Fig 45 Installing a single current collector Work steps Position the current collecting arm 1 and the counterpart 7 on the towing arm 2 Secure the current collec...

Page 54: ...e lug to the connector 1 At each 5th rail connection point a PE connector and a grounding wire connected to the steel construction must be installed For this purpose an expansion element can be used T...

Page 55: ...vent the running surface of the profiles from icing The trace heater is an additional conductor that has to be introduced during the installation of the ProfiDAT profile It is led out of the groove in...

Page 56: ...emperature sensor is connected directly to the ProfiDAT profile Fig 51 Temperature sensor at the infeed antenna Fig 52 Temperature sensor at the infeed antenna for funnel Work steps The temperature se...

Page 57: ...To do this loosen the four lateral flange screws 2 and the threaded pins 3 of the two rail connectors 4 on the left and right of the profile Move the rail connectors 4 so that the marked profile 1 ca...

Page 58: ...rail connector Push section A onto the aluminum profile Push a PE rail connector 10 onto the aluminum profile and align it with the marking Secure the PE rail connector 10 with the threaded pins 3 Ti...

Page 59: ...across the room as a result of an electrical shock Disconnect the system from the power at the main switch If there is no main switch disconnect the energy source from the system according to the inst...

Page 60: ...lled only by professional electricians Fig 58 Dimensions and holes for the power feed cabinet Fig 59 Transceiver Ethernet connection Work steps Fasten the switching cabinet to the angle bracket with f...

Page 61: ...the transceiver Work steps Fasten the ProfiDAT transceiver to the DIN rail 35 mm in the switching cabinet of the mobile system component Connecting the cable to the power supply 24 V on the transceive...

Page 62: ...cess cable neatly CAUTION Do not crush the cable Comply with the bending radius of the cable Push both heat shrink sleeves over the plugs and socket and shrink them with a heat gun 6 5 4 Installing th...

Page 63: ...oint sensors The profile heating is switched on if the temperature falls below a certain value and reaches the dew point Electrical hazards and sources of danger DANGER Risk of death by electrical sho...

Page 64: ...the switching cabinet for the profile heating with the three indicators on the front side The green lamp 1 indicates the operational readiness of the controller The white lamp 2 indicates whether the...

Page 65: ...ile insulation see chapter 6 4 14 The external dimensions are designed such that the trace heating cable passes through the lateral groove on the infeed antenna or expansion element as well as through...

Page 66: ...he checklist is intended for qualified professionals who install and commission electrification systems and are familiar with the regulations on safety at work and accident prevention The report on th...

Page 67: ...he terminating unit is correctly installed 1 10 The protective conductor cable at the start of the ProfiDAT profiles is correctly installed 1 11 The protective conductor cables are correctly installed...

Page 68: ...ta can only occur once the system has been switched on and a connection has been established between the antenna on the current collector and the infeed antenna via the ProfiDAT profile No Description...

Page 69: ...able the safety systems during operation Maintain order and cleanliness in the working area Loosely stacked or scattered components and tools are sources of hazards Danger for unauthorized personnel U...

Page 70: ...y friendly manner Safety devices that have been removed for installation service or repair work must be installed and inspected immediately after the work is complete Observe the inspection and mainte...

Page 71: ...d 4 shift op eration 30 days 2 shift operation after no more than 300 hours Visual inspection of ProfiDAT system components Proper condition Proper function Firm seating of screws and nuts Deformation...

Page 72: ...Wampfler must be informed immediately of any defects or malfunctions that occur during the test phase and within the warranty period 8 2 2 Replacement of the ProfiDAT Antenna Required tools Allen key...

Page 73: ...ion CAUTION Make sure that the carbon brushes 5 do not fall out Loosen the coupling ring of the cable 6 and disconnect the cable from the antenna 4 Clean the head of the current collector 1 with a cle...

Page 74: ...from below 8 2 3 Maximum Wear of the Carbon Brushes WARNING Destruction of the system due to lack of grounding Carbon brushes that have been worn down beyond the permitted limit can no longer make goo...

Page 75: ...Replacement of Carbon Brushes on the ProfiDAT Current Collector Required tools Allen key SW5 Work steps Pull the current collecting head 1 down and out of the ProfiDAT profile 2 Fig 69 Loosening screw...

Page 76: ...4 in an upward direction Pull out the antenna 5 in an upwards direction The cable on the antenna does not have to be disconnected Clean the head of the current collector 1 with a clean cloth Insert b...

Page 77: ...7 of 82 CAUTION Make sure that the antenna 5 and at the carbon brushes 4 make contact with the current collecting head 1 Tighten both hexagonal socket headed screws 3 see Fig 69 Fig 72 Inserting the c...

Page 78: ...ing Improper troubleshooting can result in serious injury to person and property Contact the manufacturer in case of malfunction Allow troubleshooting to be carried out only by personnel from or autho...

Page 79: ...10 2 Dismantling After the end of its service life the data transmission system must be disassembled and disposed of in an environmentally friendly manner Remove operating and auxiliary materials as w...

Page 80: ...ce of a return or disposal agreement dismantled components must be recycled as follows All metal parts must be scrapped Plastic components must be sent for recycling The other components are to be dis...

Page 81: ...product can be obtained from Conductix Wampfler on request 11 2 Other applicable Documents Seq no Document No Document name 01 C79000 G8900 C322 03 Industrial Wireless LAN SCALANCE W760 W720 Operating...

Page 82: ...ioning 36 Intended Use 11 Interfaces 23 Limitation of Liability 6 Maintenance and Servicing 70 Maintenance plan 71 Material defects 7 Mechanical Installation 39 Modes of Operation 32 Operating Conditi...

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