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Conductix-Wampfler SingleFlexLine Program 0815, Operating Instructions Manual

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Conductix-Wampfler SingleFlexLine Program 0815 Operating Instructions Manual Download Page 48

Operating Instructions 

 

Single-pole Conductor Rail System 

SingleFlexLine Program 0815 

 

 

BAL0815-0002g-US 
www.conductix.us 

translated document 

page 48 of 128 

 

Fig. 38: Drilling jig for hanger clamp 

 

Fig. 39: Drill hole distance of the female connectors 

 

Fig. 40: Drill hole distance of the female connectors (detail C) 

→

 

Screw the hanger clamp (6) onto the EMS track rail (7) with the cylinder screw and hexagon nut M4 (5) using a 7 mm open-end 

wrench. 

Z

1

X

Summary of Contents for SingleFlexLine Program 0815

Page 1: ...Operating Instructions Single pole Conductor Rail System SingleFlexLine Program 0815 BAL0815 0002g US www conductix us translated document page 1 of 128 Order Number 0815xx...

Page 2: ...ns 8 2 2 2 Unauthorized personnel 9 2 2 3 Training 9 2 3 Personal protective equipment 9 2 4 Intended use 10 2 5 Unintended use 11 2 6 Protective measures to be taken by the operator user 12 2 7 5 Saf...

Page 3: ...ental contact at the conductor rail end 37 6 3 Procedure 38 6 3 1 Required tools 38 6 3 2 Customizing components 38 6 3 2 1 Trimming conductor rails 39 6 3 2 2 Making a notch for the PEplus rail 40 6...

Page 4: ...spection list 100 7 2 2 Initial commissioning of the conductor rail system 101 8 Operation 102 8 1 Safety 102 8 2 Normal operation 104 8 3 Stopping the system 105 8 4 Continuing operation 105 8 5 Perf...

Page 5: ...erating 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 operating instructions...

Page 6: ...age 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 complete failure Always u...

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: ...ians Personnel are also considered qualified who have been employed correspondingly for several years have been educated in theory and practice during that time and whose knowledge and skills in the t...

Page 9: ...g for better trace ability Example of instruction log Date Name Type of Training Training given by Signature 11 5 2009 John Doe First safety training for person nel Horst M ller 2 3 Personal protectiv...

Page 10: ...ded use Observe the information on unintended use in Section 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 u...

Page 11: ...ble to the public Operation within manual reach Use in non industrial applications Overloading of the conductor rails by excessive current or voltage Overloading of individual current collectors by ex...

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

Page 13: ...ult of an electrical shock Work on the following components is dangerous Main power supply Parts under voltage Line feed cables connections conductor rail connectors current collectors products and co...

Page 14: ...l hazards and sources of danger DANGER Risk of injury due to ensnarement or impact Ensnarement and or impact with moving conductor rails slip ring or current collectors con nected to the machine and o...

Page 15: ...trafficked facilities take ef fective 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 equipm...

Page 16: ...he plastic parts which can then pose dangers breakage loss of function For example hanger clamps can break and the conductor rail sys tem can fall down Check influences depending on temperature time o...

Page 17: ...unctions Measures to take in the event of accidents Shut down the system and secure it against unauthorized unintentional and or erroneous activation Secure the danger zone Remove persons from the dan...

Page 18: ...ross section 25 mm2 Conductor material Copper Protection class Protection against contact according to IP 23 insertion from below Protection against contact according to IP 21 insertion from the side...

Page 19: ...act surface must be precisely complied with WARNING Loss of contact or increased heating Risk of injury due to loss of contact or increased heating if the current collector is operated outside the per...

Page 20: ...mbient air that contains flammable or explosive gases or dusts In dusty environments Outdoors with free weathering In environments with relative humidity of more than 85 In close proximity to splashin...

Page 21: ...zontally and vertically The electrical energy is transmitted into the conductor rail through line feeds and then fed to the current collector The current collector head of the current collector is pre...

Page 22: ...llation spacing depends on the current collector type 65 mm 80 mm 92 mm Pos Name 1 End cap 2 Connector 3 Hanger clamp 4 Line feed 5 Expansion unit 6 Transfer caps long end caps 7 Current collector 8 H...

Page 23: ...er bends 250 mm The SingleFlexLine Conductor Rail System consists of Current collector interface to the system engineer operator s machine Conductor rails Connectors Expansion units Fixed points Hange...

Page 24: ...ons 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 d...

Page 25: ...nciple Fig 7 Conductor rail Conductor rail Copper rail with PVC insulation as PH and PE as well as PEplus rails can be supplied in 4000 mm and special 6000 mm lengths on request PE and PEplus rails ar...

Page 26: ...ctions plug or quick screw technology The connect ors are easily accessible from the front of the conductor rail Each connection point is protected against contact by a plas tic connector cap NOTE The...

Page 27: ...ssive components but have the option of connecting an electrical supply cable The clamping unit for line feed modules differs from the passive components 1 End cap 2 Clamping unit with crimping cable...

Page 28: ...n The air gap insulation sections are used for the electrical isola tion of the conductor rail The air gap insulation section consists of 2 opposing end caps and a connecting bar that is clipped over...

Page 29: ...nstructions Single pole Conductor Rail System SingleFlexLine Program 0815 BAL0815 0002g US www conductix us translated document page 29 of 128 Fig 17 Current collector and current collector unit for P...

Page 30: ...le for checking for the pres ence of the sliding contacts and conditional wear measurement which can check the status of the sliding contacts in conjunction with control evaluation logic provided by t...

Page 31: ...only authorized lifting accessories and lashing elements with sufficient load capacity Do not use torn or damaged ropes or straps replace them with new ones Do not attach ropes or straps at sharp corn...

Page 32: ...rt Improper transport can result in substantial property damage When unloading packaged parts upon delivery and during internal transport proceed with caution and observe the symbols and information o...

Page 33: ...d local guidelines WARNING Environmental damage due to improper disposal Packaging materials are valuable resources and can be reused or usefully processed or recycled in many cases Dispose of packagi...

Page 34: ...g Improper installation and initial commissioning can result in serious injury to persons and or material damage Before starting work ensure that there is sufficient space for the installation Handle...

Page 35: ...ail system where suitable operating conditions prevail See Sec tion 3 3 DANGER Risk of injury due to ensnarement or impact Ensnarement and or impact with moving conductor rails slip ring or current co...

Page 36: ...omponents carrying electrical power can lead to death due to electrical shock or severe injury Risk of injury due to shock reactions falling or being thrown across the room due to electrical shock The...

Page 37: ...is under voltage can protrude from the end cap at the end of the conductor rail during operation Touching this sliding contact may cause injury due to an electrical shock as well as by falling or bei...

Page 38: ...for producing short lengths File for deburring cut edges after trimming Cordless drill and countersink bit Crimping tool Special tools Bending device Order No 081091 Rail disassembly tool Drilling ji...

Page 39: ...insulation to the same length Saw the metal rail and PVC insulation away from the contact area using a cutting tool Deburr the sawed end with a half round file Chamfer the contact surface in the entir...

Page 40: ...when cutting to length see Fig 22 this must be re made with the notching tool or a side cutter see Fig 23 Make a notch with the notching tool Slide the insulating profile approx 30 cm from the conduct...

Page 41: ...profile Drill the insulating profile 5 mm see Fig 24 Cut a 19 5 mm long slot with the side cutter on both sides up to the drill hole see Fig 26 Deburr the insulating profile and clean the conductor ba...

Page 42: ...bending device 081091 For large installations electrically driven bending devices are available on request Fig 28 Outer inner bends and horizontal bend Use of bends in horizontal and vertical curves...

Page 43: ...and the removed once the bending process is complete Fig 29 Making a horizontal bend with a plastic insert NOTE Ensure that the insert PEplus is installed in the correct position When bending the PEp...

Page 44: ...he rail section back and forth Bend the rail section by progressively advancing the central pressure roller Repeat this process until the required radius is achieved All subsequent rail sections that...

Page 45: ...e installation structure in accordance with the layout and allocation plan Prepare the line feed and section transfers Assemble the conductor rail see Section 6 3 3 1 Install conductor rail sections i...

Page 46: ...ust be set so that hanger clamp collisions with other components of the system are avoided during expansion of the system Hanger clamps are screwed or clipped into customer specific guideway profiles...

Page 47: ...support profile height 180 mm Order No 2 08 V015 0474 001 and the drilling jig for support profile 240 mm Order No 08 V015 0474 002 are available to set the drill holes quickly and easily The holes fo...

Page 48: ...s translated document page 48 of 128 Fig 38 Drilling jig for hanger clamp Fig 39 Drill hole distance of the female connectors Fig 40 Drill hole distance of the female connectors detail C Screw the han...

Page 49: ...anning the system The correct positioning of the fixed points is crucial for the thermal expansion behavior of the conductor rail system Establishing a fixed point Install a fixed point to the left an...

Page 50: ...lexLine Program 0815 BAL0815 0002g US www conductix us translated document page 50 of 128 Fig 42 Drill the hole for the insertion cam insulating profile and copper element Fig 43 Rotate the fixed poin...

Page 51: ...to screw on 4 Guideway profile 5 Hanger clamp screw connection with cylin der screw and hexagon nut M4 CAUTION Additional fixing of the hanger clamp is required for clip in hanger clamps For clip in h...

Page 52: ...industry the protective conductor PE is provided as the 4th pole counted from above This also corresponds to the standards of conductor rail manufacturers Fig 46 Connector and 2 conductor rails Screw...

Page 53: ...7 Slide the rails onto the connector Fig 48 Correct position of the clamp Fig 49 Incorrect position of the clamp Fig 50 Tighten the connector Fig 51 Slide the connector cap over the rail connection NO...

Page 54: ...the hanger clamps see Fig 52 Fig 52 Support profile with a conductor rail installed CAUTION Conductor rails can become deformed when bent Check conductor rail bends for the correct profile since cond...

Page 55: ...or rail may need to be taken out of a hanger clamp again There is a disas sembly tool for this Order No 081092 This is used to disassemble the conductor rail fixed in the hanger clamp and end cap bars...

Page 56: ...tructure substructure at the appropriate distance Required tool Plastic hammer Work steps Mount the first conductor rail bend in the hanger clamp B up to but not in the last hanger clamp A In order to...

Page 57: ...hammer see Fig 59 Fig 59 Tap the connector Pos 2 into conductor rail bend Pos 1 The connector stopper Pos 3 must be in contact with the insulating profile of the conductor rail see Fig 60 Fig 60 The...

Page 58: ...g profile from behind see Fig 62 in order to mount the connector cap Pos 5 in the insulating profile see Fig 62 and Fig 63 The connector cap Pos 5 must completely enclose the insulating profile see Fi...

Page 59: ...bend up to the stopper see Fig 60 Mount the last conductor rail bend Pos 7 in the hanger clamp B up to but in the last hanger clamp A in order for the last connection point to be flexible This means t...

Page 60: ...onductor rail bend see Fig 66 Fig 66 Connect the last connection point Slide the connector cap over the connection point from behind and mount it in the insulating profile see Fig 62 Fig 64 Mount the...

Page 61: ...nsion units and expansion modules are also used when the support profile has an expansion joint e g at building transfers Then the expansion path of the support profile must be absorbed by an expansio...

Page 62: ...us pole see Table 1 The individual modules can be combined with each other in such a way that multi pole overall modules result This not only results in a variety of possible combinations with regard...

Page 63: ...onductix us translated document page 63 of 128 Fig 68 4 pole and 4 pole expansion modules result in an 8 pole expansion module NOTE A rear cable protrudes from the 3 pole expansion module version This...

Page 64: ...ues can be taken from Table 2 and Table 3 No expansion unit required Interme diate length a Freely expanding end Example Possible total length with n expansion units and 2 freely expanding ends 1 2 3...

Page 65: ...tor Rail System SingleFlexLine Program 0815 BAL0815 0002g US www conductix us translated document page 65 of 128 Fig 69 System layout example Building expansion point Expansion module Fixed point Curv...

Page 66: ...e handled like fixed points 2 Length 8 m but 40 m Lies between 2 fixing components 1 Curve radii 30 m In case of doubt curves must be handled like fixed points 2 Length 8 m but 80 m Lies between 2 fix...

Page 67: ...segment with a building expansion point 40 mm 2 When determining the num ber of expansion modules it must be taken into account that the expansion gap of the expansion module includes the building ex...

Page 68: ...clamp must be 125 mm Move a hanger clamp if necessary see Fig 70 If a hanger clamp must be moved or supplemented with another hanger clamp the distance to the next hanger clamp must not be greater th...

Page 69: ...w conductix us translated document page 69 of 128 Fig 72 Setting aid Pos 1 is incorrectly mounted Fig 73 Setting aid Pos 1 is correctly mounted Required tools Optional Setting aid for setting the expa...

Page 70: ...74 Ensure that the clamping unit is fully seated in the conductor bar The clamping unit must not slip over the insulating profile see Fig 75 and the conductor rail must not shift backward see Fig 76 F...

Page 71: ...unit see Fig 79 Ensure that the connector cap Pos 4 only fits over the clamping unit from one side e g the higher side Pos A of the connector cap Pos 4 must point in the direction in which the expansi...

Page 72: ...expansion module in the hanger clamps Carefully tap the expansion module into the clamping unit of the connector see Fig 83 with light taps tool plastic hammer and tighten the socket head screw Pos 5...

Page 73: ...n ductor bar and over the insulating profile Pos 2 Fig 85 Recess in the insulating profile of the expansion module Pos 2 Slide the clamping unit of the connector Pos 3 completely into each conductor r...

Page 74: ...pansion module is to be mounted see Fig 81 and Fig 80 Fig 87 Slide connector cap Pos 4 over the clamping unit of the connector Hang the next conductor rail poles in the hanger clamp and carefully tap...

Page 75: ...ge 75 of 128 Do not remove the setting aids from the expansion module until the following fixed point see also BAL0815 0002 has been mounted Check whether the dimension of every expansion gap is 20 mm...

Page 76: ...on the basis of a full temperature range of 40 K and ensures easy setting Fig 91 Example for reading the setting dimension For example This example assumes a hall with a temperature range of 0 to 40...

Page 77: ...15 BAL0815 0002g US www conductix us translated document page 77 of 128 The setting dimension measures from plastic cap to plastic cap Pos 2 e g the setting dimension always includes the plastic bar P...

Page 78: ...installed with or without a line feed The installation of the air gap insulation section with line feed is described in the following The end cap is mounted to the air gap insulation section without...

Page 79: ...rail at the desired point see project specific documents and cut it out with a cutting tool see Section 6 3 2 1 see Fig 94 Deburr the rail ends and clean any contaminants shavings etc see Fig 95 Fig 9...

Page 80: ...nto both conductor rail ends see Fig 97 Fig 97 Slide the line feed clamp into the conductor rail ends Slide the end caps Pos 4 over both conductor rail ends see Fig 98 Ensure that the end cap Pos 4 co...

Page 81: ...anslated document page 81 of 128 Fig 99 End cap Pos 4 encloses the insulating profile Pos 5 Fig 100 Tighten cylinder screws Pos 6 After mounting the end cap check the connection for solidity by gently...

Page 82: ...Program 0815 BAL0815 0002g US www conductix us translated document page 82 of 128 Fig 101 Line feed clamp correctly mounted Fig 102 Line feed clamp incorrectly mounted Clip the connecting bar Pos 7 o...

Page 83: ...f the end cap to the hanger clamp is 30 mm see Fig 104 Ensure that the air gap insulation section is in contact with the support structure and not with a recess see Fig 106 and Fig 105 Fig 104 Distanc...

Page 84: ...ap with room for a connecting cable to run out of it are used Fig 107 Correct position of the clamping unit Fig 108 Incorrect position of the clamping unit Fig 109 Slightly loosen the screw connection...

Page 85: ...ble lug Loosen the screw with a hexagonal screwdriver SW3 and insert the connector parts into the installed rail with insulation profile see Fig 109 Slide the next rail section into the free end of th...

Page 86: ...lifter and for angled cuts e g switches For further information see MV0815 0006 For further information see MV0815 0006 Fig 114 Clearance for mounting the end caps Fig 115 Drilling jig Order No 08 V0...

Page 87: ...Trim the feed cable and strip the insulation to the desired length Crimp the crimping cable lug of the end line feed onto the end of the cable Do not remove the crimping cable lug from the connector f...

Page 88: ...ment page 88 of 128 NOTE It is recommended that the conductor rail is not yet engaged in the adjacent hanger clamp Fig 120 Clip the conductor rail into place Engage the end cap end line feed into the...

Page 89: ...of Poles b B 4 42 54 6 70 82 8 70 110 10 70 120 NOTE If the cable package with the strain relief 1 cannot be used it must be ensured that the connection cables in the area directly behind the current...

Page 90: ...om the order number For example 081055 14X08X006X000 In this example the last digit of the second to last block of digits is 0 but rather a 6 This means that the location of the PE slot is in the 6th...

Page 91: ...systems Fig 126 EMS current collector 08150A B The screw is not part of the scope of delivery It must be ordered separately Tolerances in the X axis and Y axis 15 mm 1 Integrated cable 2 Hexagon scre...

Page 92: ...using the PE current collectors in assembly types 081506 081507 081508 081509 without cams and the assembly types equipped with interchanging pro tection 081506 081507 081508 081509 with cams Special...

Page 93: ...h protective cap for the flexible connecting cables For phases double insulated connecting cables must be provided for voltages 48 V Do not bundle fix or attach identification signs to the current col...

Page 94: ...ce from the wheel contact point is too great the permissible tolerances may be exceeded in tighter curves Result Damage high wear Compliance with the installation tolerances must therefore be checked...

Page 95: ...se contact spray formation of silicon carbide abrasive and or damage of plastic parts Only use abrasives or brushes as tools for removing heavy build ups at minor burns under supervision Persistent us...

Page 96: ...ument page 96 of 128 6 4 Additional documents Read and respect the additional operating instructions You can find further information on the installation of conductor rail systems in the following ins...

Page 97: ...ssible to the public and out of manual reach The danger zone must be enclosed by the customer or protection ensured by distance WARNING Risk of injury due to improper commissioning Improperly performe...

Page 98: ...tolerances Take the following measures Conduct electrical testing as specified Permissible current values must be observed Maintain tolerances during operation Do not remove the specified electrical s...

Page 99: ...nd legal regulations Carry out locally required electrical tests Ensure adequate stability on the device system for the commissioning engineer CAUTION Before working on these components Disconnect the...

Page 100: ...he hanger clamp distances as specified see Section 6 3 3 1 Have the end caps been fitted correctly and to the first and end section Are the end cap bars and fixed points properly installed as specifie...

Page 101: ...0204 1 2006 1 M at a measuring voltage of 500 VDC Exception for conductor bars conductor rails and slip rings 50 k EN 60204 1 18 3 2006 4 Visual inspection of the product system Current collector unda...

Page 102: ...tance 8 1 Safety NOTE The system must only be operated by trained personnel WARNING Danger for unauthorized personnel Unauthorized personnel are not familiar with the hazards in the working area Keep...

Page 103: ...r se vere injury Risk of injury due to shock reactions falling or being thrown across the room due to electrical shock The conductor rail must not be operated under the following circumstances If the...

Page 104: ...ate electrical protective devices WARNING Risk of injury due to hot components Components can get hot during operation Operation is only permitted in areas inaccessible to the public and out of manual...

Page 105: ...ve de vices are installed and working properly Before switching the system back on ensure that The current collector heads are laying within the conductor rail for the entire length and the specified...

Page 106: ...They are a trip hazards and improperly stored components can fall over or fall to the ground Before starting work ensure that there is sufficient space for installation Ensure that the installation ar...

Page 107: ...ad vacuum it up The vacuum cleaner must be equipped with a Class H fine filter Eating and or drinking at the workplace is prohibited Do not smoke while cleaning See Section 2 8 3 for further informati...

Page 108: ...e building must be disconnected in the maintenance ser vicing area and secured against switching on again Disconnect all voltage supply line feeds Check whether a voltage is still present in the compo...

Page 109: ...e danger zone particularly if protective de vices covers enclosures control devices have been removed or disabled Wear personal protective equipment CAUTION Alert personnel to the hazard Attach a sign...

Page 110: ...llow the separate instructions for this task See Section 12 1 Only install the conductor rail system where suitable operating conditions prevail See Section 3 3 Replacing conductor rails Required prot...

Page 111: ...ntact the manufacturer in case of any questions regarding maintenance tasks and intervals see the service address on the last page The operator must take responsibility for organizing the following ma...

Page 112: ...Cancer In workplaces with long term exposure and heavily trafficked facilities take effective measures to protect employees from the dust Personal protective equipment must be worn during all works o...

Page 113: ...rail Operators 4 weeks after commission ing 500 km Thereafter Quarterly semian nually Visual inspection Check whether the contact areas of the sliding contacts are worn If the wear limit a ratio betwe...

Page 114: ...Change the fastening position in the event of deviation The required contact force is ensured by the correct fastening position of the cur rent collector However if measurement of the contact force i...

Page 115: ...ed personnel DANGER Risk of injury due to crushing skin and limbs There is a risk of crushing of skin and limbs due to Spring force gravity stored energy Current collector spring force during installa...

Page 116: ...all Prevent contamination of the environment e g people goods production facilities etc while cleaning by taking appropriate measures use covers barriers filter systems WARNING Risk of injury due to m...

Page 117: ...ture wounds and cuts The packaging material can contain sharp objects such as nails struts steel bands and wood splin ters that can cause injury to limbs Wear personal protective equipment Cordon off...

Page 118: ...load or sparking Fire hazards occur due to overloaded cables electrical arcs short circuits or sparking Before recommissioning ensure that all work has been completed and all components have been prop...

Page 119: ...of the current collector The sliding contacts wear out too fast Sharp edges on the line feed clamps conductor rails con nections between the conductor rails Smoothen sharp edges with a file compresse...

Page 120: ...n such a way that they cannot be collided with replace damaged compo nents Abrasive dust has collected at one of the more frequently used transfer points where the direction of travel is re versed Adj...

Page 121: ...starting work Handle open sharp edged components carefully Ensure that the workplace is tidy and clean Loosely stacked or scattered components and tools are a source of hazards Dismount components pr...

Page 122: ...y and maintenance Falling parts of the conductor rail system in the case of improper disassembly Moving parts when the system is in operation Do not enter the danger zones of the system during operati...

Page 123: ...n facilities etc while cleaning by taking appropriate measures use covers barriers filter systems WARNING Risk of injury due to materials and substances Respiratory complaints and eye irritation may o...

Page 124: ...riate manner WARNING Be aware of dangers due to electric shock harmful dusts sharp edges and moving parts Clean the subassemblies and components properly and disassemble them under observation of appl...

Page 125: ...sposal DANGER Risk of death due to electrical shock Contact with components carrying electrical power can lead to death due to electrical shock or se vere injury Risk of injury due to shock reactions...

Page 126: ...Further Documents 12 1 Applicable documents Seq no Document number Document name 01 WV0800 0001 Cleaning conductor rails 02 WV0800 0002 Conductor rail maintenance plan 03 MV0815 0006 Transfers 04 MV0...

Page 127: ...Installation 34 Intended use 10 Limitation of liability 5 Maintenance and service 106 Maintenance plan 110 111 Malfunctions 17 Material defects 6 Operation 102 Operator 12 Packaging 33 Personnel 8 Pr...

Page 128: ...ourt Unit 5 Burlington ON L7L 0E6 Customer Support Phone 1 800 667 2487 Phone 1 450 565 9900 Fax 1 450 851 8591 info ca conductix com M xico Calle Trevi o 983 C Zona Centro Apodaca NL M xico 66600 Cus...

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