Conductix-Wampfler 0815 Series User manual

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 1 of 26
Order number:
0815xx-…
Contents
1Terminology............................................................................................................................................................ 3
2Function and Use ................................................................................................................................................... 3
3Technical Specifications........................................................................................................................................ 4
4Structure of an Expansion Module ....................................................................................................................... 5
5Determining the Number and Position of Expansion Modules .......................................................................... 6
5.1Expansion Modules in Sections ≥20 m ..................................................................................................... 7
5.2Calculating the Number of Expansion Elements at Building/Load Profile Expansion Joints ...................... 8
6Installation............................................................................................................................................................... 9
6.1Safety ......................................................................................................................................................... 9
6.2Installing Expansion Modules: Segment................................................................................................... 12
6.3Installing Expansion Modules: Building/Load Profile Expansion Joints .................................................... 17
6.4Installing Media Feeds and Expansion Modules ...................................................................................... 21
6.5Installing Expansion Elements in Existing Systems.................................................................................. 21
7Adjusting the Gap Dimension ............................................................................................................................. 23
7.1Expansion Module.................................................................................................................................... 23
7.2Adjusting Expansion Elements ................................................................................................................. 24
7.2.1Case 1: Copper Conductor Rail on Steel Load Profile .............................................................................24
7.2.2Case 2: Copper conductor rail on aluminum load profile..........................................................................24

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 2 of 26
7.2.3Case 3: Steel Conductor Rail on Steel Load Profile .................................................................................25
7.2.4Case 4: Steel Conductor Rail on Aluminum Load Profile .........................................................................25
7.3Installing an Air Gap ................................................................................................................................. 25

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 3 of 26
1Terminology
Expansion element: Component to compensate for changes in length of a pole in a conductor rail.
Expansion module: The module contains multiple expansion elements for multiple poles and contains conductor rails
for a specific segment length.
Load profile: Customer-provided rail or carrier rail.
Expansion distance: Maximum expansion for which the expansion element can compensate.
Expansion joint: Construction-provided joint in the load profile.
Adjustment aid: Spacer part to adjust the expansion element during installation.
2Function and Use
The expansion element compensates for temperature-dependent changes in length between the conductor rail and the
load profile. It use is necessary if expansion takes place between two fastening points that cannot be compensated or
absorbed by the individual components of the conductor rail system. Short lengths of < 20 m and small temperature
changes < 40 K can be compensated for by the individual components in the conductor rail system.
Expansion elements are also used when the load profile has an expansion joint, for example at building transitions. The
expansion distance of the load profile must be compensated for by an expansion element or an expansion module.
Fastening points in the sense of thermal expansion are end caps or rail fastening points in the conductor rail system.
This is where the conductor rail is fastened rigidly to the load profile. Curves and bends in the path of the load profile
can also prevent thermal expansion in a conductor rail and are therefore also considered fastening points (natural
fixed points).
Fig. 1: Expansion module in load profile

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 4 of 26
3Technical Specifications
Number of poles 4-, 6-, and 8-pole
Length of expansion
module max. 1250 mm
PE position In fourth place after L1, L2, and L3 (counting from the top)
PE system PEplus error prevention
Conductor cross-
section Rail 25 mm², expansion point 6 mm² with conductor loop
Current load max. 54 A
Cable type Double-insulated line (UL)
DANGER!
Danger of overloading!
Feeds must be designed and provided in such a way that the maximum current load
for the expansion module of 54 A is not exceeded.

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 5 of 26
4Structure of an Expansion Module
The expansion elements (1) are preassembled at the factory as multipole expansion modules. They are preferred for
use in new systems. The expansion module includes two expansion elements per pole, each with an expansion dis-
tance of 8 mm. This means that each expansion module has a total expansion distance of 2x8 mm = 16 mm.
The expansion module includes hanger clamps (3) and the wiring for the expansion elements. The wiring (cable loop)
is placed on the back of the expansion module. The adjustment aid (2) (not included in delivery) is used to adjust the
expansion elements during installation. The roughly 1.25 m long assemblies are engaged in hanger clamps on the
structure and connected with the segment using rail connectors.
NOTICE!
The adjustment aids are separately available as an adjustment aid set
(material no.: 08-Z009-0014P).
Fig. 2: Expansion module
3 1
2
Item Name
1 Expansion element
2 Adjustment aid
3 Hanger clamp

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 6 of 26
5Determining the Number and Position of Expansion Modules
The number and position of expansion modules depends on the system layout, the temperature range during use, and
any existing expansion joints in the building/load profile.
Procedure:
1. Calculate the required expansion modules at building/load profile expansion points.
2. Calculate the required expansion modules on straight load profile sections over 20 m.
NOTE!
If the system is operated at a constant temperature (including the installation tem-
perature), it can be assumed that no changes in length will result. In this case, no
expansion modules are needed. Any temperature fluctuations of ± 2.5 K or less can
be considered constant! The temperature range specified for the system must
be noted.
Fig. 3: Example system layout

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 7 of 26
5.1 Expansion Modules in Sections ≥20 m
The calculation of the number of expansion modules required is based on a temperature spread of 40 K. This covers
the usual operating temperature of +5 °C to +45 °C.
Procedure:
From the layout, take all the relevant track segments between physical and/or natural fixed points, that is, all straight
track segments that lie between:
Two curves/bends
Two end caps
A curve/bend and an end cap
A curve/bend and an anchor clamp
For track segments, the number of expansion modules is determined according to the following table:
Length Temperature spread Number of expansion modules
0 m - 20 m
40 K
0
20 m – 36 m 1
n x 36 m n
Fig. 4: Determining the number of expansion modules
When using multiple expansion modules within a straight track segment, fastening points must be provided between
them (see section 6.3.3.5 in BAL0815-0002). A fastening point must be located in the middle between two expansion
modules.
Fig. 5: Determining the number of expansion points needed
NOTE!
Expansion elements are not designed for use in bends or curves, and may only
be installed in straight sections!

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 8 of 26
5.2 Calculating the Number of Expansion Elements at Building/Load Profile Expan-
sion Joints
Use the layout or the position of load profile expansion joints observed on-site to determine the appropriate expansion
distance. The number of expansion modules needed per load profile expansion joint is determined by the basic formu-
la:
Expansion distance of load profile expansion joints (mm) / 16 mm = number of expansion modules (round up to the
nearest whole number)
Example from Fig. 3:
Load profile expansion joints with 20 mm expansion distance at one position:
20 mm / 16mm = 1.25 2 expansion modules next to one another, with 32 mm max. expansion distance
Fig. 6: Expansion joint and expansion element
Item Name
1 Expansion joint
2 Expansion element
1
2
1
2

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 9 of 26
6Installation
6.1 Safety
Installation and initial commissioning may only be carried out by specially trained technicians.
Required protective equipment:
DANGER!
Injury due to improper installation and initial commissioning!
Improper installation and initial commissioning can result in serious injury to persons
and/or material damage.
Before starting work, make sure there is sufficient space for assembly.
Handle open, sharp-edged components carefully
Make sure the installation area is tidy and clean! Loosely stacked or scattered
components and tools are a source of hazards
Install components properly. Comply with the specified screw tightening torques
DANGER!
Poisonous gases in case of fire!
In case of fire in the facility, the plastic parts (PVC) of the conductor-rail system emit
poisonous gases (HCL).
The system operator must take this into account accordingly when planning and
take the appropriate protective measures
The building must be evacuated immediately.
The fire brigade must be informed.
DANGER!
Risk of injury by crushing skin and limbs!
There is a danger of crushing of skin and limbs!
Wear safety gloves when working on the expansion module.
Only install conductor rail systems where suitable operation conditions pertain
(see section 3.3 in BAL0815-0002-EN)

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 10 of 26
DANGER!
Risk of injury from cuts and cutting!
Cuts and amputations can occur:
on sharp edges of the general components
on sharp edges of the conductor rails
on cut edges when trimming the conductor rails
on packaging materials (cartons, tapes, etc.)
Use personal protective equipment!
CAUTION!
Risk of puncture wounds and cuts!
The packaging material can contain sharp objects such as nails and wood splinters
that can cause injury to limbs.
Use personal protective equipment!
Cordon off the work area!
Caution when working in the vicinity, in particular below the conductor rail
DANGER!
Risk of injury due to conductor rails sliding out!
Risk of injury due to conductor rails sliding out when the packaging units are held at
an angle or carelessness with long loads.
Use personal protective equipment!
Cordon off the work area!

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 11 of 26
DANGER!
Risk of death by electrocution!
Contact with components carrying electrical power can lead to death by electrocution
or severe injury. Danger of injury due to shock reactions, falling, or being thrown
across the room due to electrical shock.
The main power supply (from the building) must be disconnected in the installation
area and secured against switching on again
Disconnect all electricity-supply infeeds
Check whether a voltage is still present in the components and take measures
where necessary
Install the conductor rail out of manual reach
Attach a sign saying "Risk of death by electrocution" with the relevant hazard sym-
bol in all areas with live components
The customer must ground metallic components
The customer must provide protective devices
Make sure there is sufficient stability in the area
WARNING!
The system must be designed and operated in accordance with the prevailing
ambient conditions!
WARNING!
Secure conductor rails against falling
In application areas with personnel traffic and at an installation height of 3 m or
more, conductor rails must be secured against falling!
ATTENTION!
To the side of the conductor rail there must, a clearance of at least 4 mm from
metal components must be maintained (see Fig. 7) to prevent mechanical col-
lisions and guarantee sufficient electrical insulation distances!
Fig. 7: Side clearance of at least 4 mm

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 12 of 26
6.2 Installing Expansion Modules: Segment
Prerequisites:
Hanger clamps are preinstalled in the rail at 500 mm intervals.
Fig. 8: Preinstalled hanger clamps on the load profile
The expansion module is designed with a length of about 1.25 m for direct installation in 3 hanger clamps.
It is connected to the existing installation using screw connectors.
The 4 hanger clamps used to install the expansion module (see Fig. 9) may not be removed for installation.
These hanger clamps are installed for fastening of the expansion module and are not
permanently connected to the load profile. This means they will not hinder the expan-
sion of the system.
Fig. 9: Hanger clamps on the expansion module
Fig. 10: Installed expansion modules
After determining the installation position of the expansion module (see above), install the conductor rails up to the
installation position of the expansion element. The conductor rails for all poles must be the same length (end flush).

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 13 of 26
Fig. 11: Load profile with hanger clamps and mounted rails (segment)
The expansion module, including the preinstalled hanger clamps, clips into the hanger clamps permanently mounted
on the load profile. The hanger clamps preinstalled on the expansion module remain on the expansion module and are
not connected to the load profiles (floating installation).
NOTE!
The hanger clamps fastened to the load profile must have enough distance
from the middle of the hanger clamp to the middle of the expansion element of
the expansion module (at least 100 mm)!
Fig. 12: Insert expansion module with hanger clamp into existing hanger clamp
If overlaps are possible with the mounted conductor rail and/or any hanger clamps already installed, proceed
as follows:
If necessary, the hanger clamps must be offset before installing the expansion module (Warning:
the distance between the individual hanger clamps may not be > 500 mm. Install any additional
hanger clamps before or after the installed expansion module!)

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 14 of 26
The additional hanger clamps must be placed so that collisions with other components cannot
occur during expansion of the system (see section 2.3.3.1 in MV0185-0007). When installing ex-
pansion modules, a different permitted minimum distance of 100 mm applies between the hanger
clamp and other system components, which can be appropriately reduced due to the concept of
expansion modules with interdivisional cable guides.
Fig. 13: Example of potential overlap of the conductor rail
A = Additional hanger clamp is required
B = Hanger clamps are offset in the direction of installation
Fig. 14: System after offsetting the hanger clamps
If there is an appropriate gap in the system, the hanger clamps used for installation of the expansion module can be
offset to the front.
In this case, an additional hanger clamp must be placed after the expansion module for additional installation, so that
the maximum spacing between two hanger clamps of 500 mm is not exceeded.
Fig. 15: Potential gap between expansion module and end of the conductor rail already installed
If the expansion module should specifically be installed at a fastening point in the system, it is always possible to leave
all hanger clamps and to cut off the conductor rail to the correct dimension.
B
A

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 15 of 26
Fig. 16: Expansion module with adjustment aid
DANGER!
Damage to the conductor rail due to nonfunctional expansion module!
The adjustment aid remains in the expansion modules during conductor rail installation
and prevents the expansion module from closing during installation.
After completion of installation, of the section, be absolutely sure to remove the ad-
justment aid!

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 16 of 26
The conductor rail ends of the expansion module are connected to the preinstalled conductor rail using rail connectors
(see section 6.3.3.2 in BAL0185-0002-EN):
Fig. 17: Push the rails onto the connector
Fig. 18: Correct position of the clamp
Fig. 19: Incorrect position of the clamp
Fig. 20: Tighten the connector
Fig. 21: Slide the connector cap over the rail connection
Tighten the connector
with a 3-mm hex
screwdriver to 2 Nm.

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 17 of 26
6.3 Installing Expansion Modules: Building/Load Profile Expansion Joints
Fig. 22: Installed expansion module with expansion joint
The expansion modules are loaded in the middle of the range of the building load profile expansion joint. Fastening
points are located to their right and left (see section 6.3.3.5 in BAL0815-0002-EN). Depending on the further path of the
segment, it may be possible to omit the fastening points (e.g. if a curve is next; see instructions in chapter 5.1).
After determining the installation position of the expansion modules (see above), install the conductor rails up to the
installation position of the expansion element. The conductor rails for all poles must be the same length (end flush).
Fig. 23: Load profile with hanger clamp, installed rails, and expansion joint
The expansion module, including the preinstalled hanger clamps, clips into the hanger clamps permanently mounted
on the load profile. The hanger clamps preinstalled on the expansion module remain on the expansion module and are
not connected to the load profiles (floating installation).
NOTE!
The hanger clamps fastened to the load profile must have enough distance
from the middle of the hanger clamp to the middle of the expansion element of
the expansion module (at least 100 mm)!

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 18 of 26
Fig. 24: Insert expansion module with hanger clamp into existing hanger clamp
Fig. 25: Overview of the expansion module with hanger clamp
Item Name
1 Expansion module
2 Fastening point
3 Connectors
2
1
3
1
2

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 19 of 26
NOTE!
Do not position the connection elements over the building/load profile
expansion joint!
Fig. 26: Expansion element with adjustment aid
DANGER!
Damage to the conductor rail due to nonfunctional expansion module!
The adjustment aid remains in the expansion modules during conductor rail installation
and prevents the expansion module from closing during installation.
After completion of installation, of the section, be absolutely sure to remove the ad-
justment aid

Installation Instructions
Expansion Module and Expansion Element
Program 0815
MV0815-0005a-EN
www.conductix.com translated document page 20 of 26
The conductor rail ends of the expansion module are connected to the preinstalled conductor rail using rail connectors
(see section 6.3.3.2 in BAL0185-0002-EN):
Fig. 27: Push the rails onto the connector
Fig. 28: Correct position of the clamp
Fig. 29: Incorrect position of the clamp
Fig. 30: Tighten the connector
Fig. 31: Slide the connector cap over the rail connection
Tighten the connector
with a 3-mm hex
screwdriver to 2 Nm.