Conductix-Wampfler ChargeLine 0865 User manual

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

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 2 of 51
Contents
1General Information ....................................................................................................................................................................4
1.1 Information about these operating instructions...............................................................................................................4
1.2 Limitation of liability ........................................................................................................................................................4
1.3 Copyright ........................................................................................................................................................................5
1.4 Replacement parts .........................................................................................................................................................5
1.5 Material defects ..............................................................................................................................................................5
1.6 Technical support ...........................................................................................................................................................5
2Safety Information.......................................................................................................................................................................6
2.1 Explanation of symbols...................................................................................................................................................6
2.2 Personnel requirements .................................................................................................................................................7
2.3 Personal protective equipment .......................................................................................................................................8
2.4 Intended use...................................................................................................................................................................9
2.5 5 Safety Rules for working on electrical systems ...........................................................................................................9
2.6 Special dangers..............................................................................................................................................................9
3Technical Data ..........................................................................................................................................................................15
3.1 Electrical .......................................................................................................................................................................15
3.2 Mechanical ...................................................................................................................................................................15
3.3 Operating conditions.....................................................................................................................................................17
4Description andFunctional Principle..........................................................................................................................................18
4.1 Brief description............................................................................................................................................................18
4.2 Description of assemblies.............................................................................................................................................19
5Transport, Packaging and Storage ...........................................................................................................................................23
5.1 Transport ......................................................................................................................................................................23
5.2 Storage of packaged parts ...........................................................................................................................................23
6Installation.................................................................................................................................................................................25
6.1 Safety ...........................................................................................................................................................................25
6.2 Procedure .....................................................................................................................................................................27
7Commissioning .........................................................................................................................................................................38
8Operation ..................................................................................................................................................................................40

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 3 of 51
8.1 Safety ...........................................................................................................................................................................40
9Maintenance and Service .........................................................................................................................................................41
9.1 Safety ...........................................................................................................................................................................41
9.2 Tools and materials ......................................................................................................................................................42
9.3 Cleaning .......................................................................................................................................................................42
9.4 Maintenance plan .........................................................................................................................................................42
10 Troubleshooting Table ..............................................................................................................................................................45
11 Disassembly and Disposal........................................................................................................................................................47
11.1 Safety ...........................................................................................................................................................................47
11.2 Disassembly .................................................................................................................................................................47
11.3 Disposal........................................................................................................................................................................49
12 Additional Documents ...............................................................................................................................................................50
12.1 Declaration of Conformity .............................................................................................................................................50
12.2 Replacement parts list ..................................................................................................................................................50
12.3 Applicable documents ..................................................................................................................................................50
13 Index .........................................................................................................................................................................................51

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 4 of 51
1General Information
1.1 Information about these operating instructions
The information provided in this document is designed to enable the equipment to be used safely and efficiently.
This document is a component of the system and must be kept accessible to personnel and in its immediate vicinity. Prior to
commencing any work, personnel must have carefully read through and understood these operating instructions. The basic
prerequisite for safe work is compliance with all safety information and operating guidelines in this document.
Local accident protection regulations and general safety guidelines for the area of use of the equipment also apply.
The illustrations in this document are provided for basic understanding and may deviate from the actual implementation of the
conductor rail system.
In addition to this document, the instructions for the installed components in the appendix apply.
1.2 Limitation of liability
All existing standards and regulations, the latest technological standards, as well as our long years of know-how and experience,
have been taken into account when formulating the information and notices in this document.
The manufacturer is in no way liable for damages resulting from:
Failure to comply with the operating instructions
Improper use
Use by untrained personnel
Unauthorized modifications
Technical modifications
Use of unauthorized replacement parts or accessories
The actual scope of delivery may differ from the explanations and descriptions provided here if the model in question is a special
one, if additional equipment has been ordered or due to recent technical modifications.
The obligations agreed upon in the Delivery Agreement and our General Terms and Conditions of Business apply, as do the
delivery conditions of the manufacturer and the legal regulations applicable at the time the contract was concluded.
All products are subject to technical modifications and the many years of technical expertise and experiences within the context of
improvement of function and further development.

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 5 of 51
1.3 Copyright
These operating instructions are protected by copyright and exclusively intended for internal use by the customer.
Provision of the operating instructions to third parties, reproductions in any form – even in part – as well as the reuse and/or
disclosure of their content are not permitted without the written approval of the manufacturer, except for the customer's internal
use.
Breach or infringement will result in liability for damages. Our right to further claims remains unaffected.
1.4 Replacement parts
WARNING!
Safety risk due to incorrect replacement parts!
Incorrect or faulty replacement parts can impair safety and result in damage, malfunctions or
complete failure.
→Always use original replacement parts from the manufacturer!
Replacement parts must be purchased via authorized dealers or directly from the manufacturer.
See Section 13 for the contact details for ordering replacement parts.
1.5 Material defects
The terms governing material defects can be found in the General Terms and Conditions of Business.
1.6 Technical support
Our Customer Support staff is available for technical support.
Replacement parts ordering: See Section 13 for contact details.
We are also always interested in new information, experiences and feedback from the field that can help us improve our products.

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 6 of 51
2Safety Information
2.1 Explanation of symbols
Safety and hazard information is identified in these operating instructions using symbols. Safety and hazard information is
introduced by signal words that indicate the degree of the hazard. Always observe safety and hazard information and work
carefully to avoid accidents, bodily injury and material damage!
DANGER!
... indicates an immediately hazardous situation, which if not avoided, may result in death or serious
injury.
DANGER!
… indicates an immediately hazardous situation due to electrical current, which if not avoided, may
result in death or serious injury.
WARNING!
... indicates a potentially hazardous situation, which if not avoided, may result in death or serious injury.
WARNING!
… indicates a potentially hazardous situation from electrical current, which if not avoided, may result in
death or serious injury.
CAUTION!
… indicates a potentially hazardous situation that, if not avoided, may result in moderate or minor injury
and material damage.
Tips and recommendations:
... refers to useful tips and recommendations as well as information for efficient and trouble-free
operation.
ATTENTION!
… indicates actions that will help avoid material damage.

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 7 of 51
2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Inadequately trained persons are at risk of injury!
Improper use can result in serious injury to persons and material damage.
→All activities may only be conducted by personnel who are qualified for the respective activity!
The following qualifications for the various levels of activities are indicated in these operating instructions:
Trained personnel/operators
have been instructed in a training session by the operator with respect to the tasks assigned to them and the potential dangers
arising from improper actions.
Specialist personnel
consists of persons capable of performing assigned tasks and independently identifying dangers and avoiding potential
hazards based on their specialist training, knowledge and experience as well as their understanding of the applicable standards
and regulations.
Personnel are considered qualified if they have successfully concluded training, e.g. as electricians, master electricians,
electrical engineers, or electrical technicians. Personnel are also considered qualified if they have been correspondingly
employed for several years, have been educated in theory and practice during that time, and whose electrical knowledge and
skills have been tested.
The operator of the electrical system must document that the corresponding certification or other documentation of qualification
are present or have been demonstrated.
2.2.2 Unauthorized persons
WARNING!
Danger due to unauthorized persons!
Unauthorized persons who do not meet the requirements described here are not acquainted with the
dangers in the work area.
→Keep unauthorized persons away from the work area.
→In case of doubt, address the persons and direct them away from the work area.
→Stop working as long as unauthorized persons are in the work area.

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 8 of 51
2.3 Personal protective equipment
Always wear
For all work, always wear:
Protective clothing
Primarily for protection against ensnarement by moving machine parts. Work clothing must be close fitting
with a low resistance to tearing; it must have close-fitting sleeves and no protruding parts.
Protective footwear
For protection against heavy falling parts and slipping on slippery floors.
To be worn for
special work
Specific protective equipment is required when conducting special work. Separate reference to this is
made in the individual sections.
Protective gloves
For the protection of hands against friction, scrapes, puncture or deeper wounds, as well as against contact
with hot surfaces.
Protective headgear
For protection against falling or flying parts and materials.
Protective eyewear
For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather
effects.
Breathing mask (FFP-3 – according to country-specific requirements)
For protection against materials, particles, and organisms. In this case: protection from dust caused by the
wear of sliding contacts and insulation profile of the conductor rail.

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 9 of 51
2.4 Intended use
The product is exclusively designed and built for the intended use described herein.
Claims of any kind due to damages from unintended use are excluded.
The operator bears sole liability for all damage that results from unintended use.
Intended use
The Conductor Rail System ChargeLine 0835 is an electric power supply system for track-guided mobile consumers operated in
indoor spaces in warehouse areas not accessible to the public.
One of its typical applications is, e.g. to supply power to shuttles inside a warehouse with horizontal storage racks.
Compliance with these technical conditions is mandatory for the installation:
The permissible max. travel speed of the consumer is 400 m/min (straight lines), 120 m/min (pickup guide entry).
Insertion from the side and laterally are both possible with a horizontal and floor-to-ceiling installation.
The conductor rail system must be exclusively fitted and operated using copper materials.
Max. permissible system length for standard installation: 50 m; max. 150 m when considering expansion.
For dry indoor applications.
Electrical-technical operating conditions
The electrical system must be protected in accordance with local regulations and guidelines.
2.5 5 Safety Rules for working on electrical systems
Requirements:
Work on electrical systems must only be carried out when they are disconnected from the power supply. The 5 Safety Rules
must always be observed before starting work (see DIN VDE 0150-100:2009-10/EN 50110-1:2004-11).
1. Disconnect the system from power at the main switch.
2. Secure the main switch against being turned back on.
3. Verify disconnection from power by measuring.
4. Ground and short-circuit parts of the system on which work will be conducted.
5. Cover or block off adjacent energized parts.
Only electricians or personnel trained in electrical work may disconnect power or approve reconnection of power after the work
is carried out in the disconnected state!
2.6 Special dangers
The following section lists residual risks determined on the basis of a risk assessment. Follow the safety information and the
warnings in other sections in these operating instructions in order to reduce health hazards and avoid dangerous situations.

Operating Instructions
Conductor Rail System
ChargeLine 0865
BAL0865-0001-EN
www.conductix.com Translated from: BAL0865-0001-DE page 10 of 51
2.6.1 Electrical hazards and sources of danger
Requirements:
DANGER!
Risk of death due to electric shock!
Contact with energized components can lead to death or severe injury due to electric shock. There is
also a risk of injury from shock reactions, falling or being thrown across the room as a result of an
electric shock.
DANGER!
Risk of injury from falling or being thrown across the room after an electric shock!
Work on the following components is dangerous:
Main power supply
Energized parts:
Line feed
Cables
Connections
Conductor rail
Connector
Current collector
Equipment and connections inside switching cabinets
Control systems etc.

Parts that have become energized due to a fault
CAUTION!
Before working on these components!
→Switch off the conductor rail system according to the 5 Safety Rules and secure it against
being switched on again.5 Safety Rules, see Section 2.5
CAUTION!
Before switching the system on!
→Each time before the equipment or system is started, measure the insulation resistance according to
locally applicable technical standards, directives and legal regulations.
→Carry out locally required electrical tests.
CAUTION!
Maintain electrical safety!
→Regularly test and maintain electrical equipment.
→If dangerous deficiencies are identified, take measures to correct the deficiencies without delay.
Inform the system operator immediately.
→If it is not possible to correct the dangerous deficiency, cordon off the area involved or switch the
equipment off and secure it against being switched on again. Inform the system operator
immediately.
→Immediately secure loose cables and replace damaged cables.
→Always replace blown fuses with fuses of the same rating.