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Operating Instructions

Single-pole Conductor Rail System

SingleFlexLine Program 0815

BAL0815-0002g-US
www.conductix.us

translated document

page 22 of 128

Fig. 2: System overview

*The installation spacing depends on the current collector type (65 mm, 80 mm, 92 mm)

Pos.

Name

End cap

Connector

Hanger clamp

Line feed

Expansion unit

Transfer caps/ “long” end caps

Current collector

Hanger clamp with fixed point caps

Air gap insulation section without expansion travel

Fig. 3: Outer/inner bends and horizontal bend

Pos.

Name

Inner bend

Outer bend

Horizontal bend

Содержание SingleFlexLine Program 0815

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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