Conductix-Wampfler 0365 User manual

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 1 of 70

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 2 of 70
Contents
1General notes .......................................................................................................................................................................... 5
1.1 Information about these assembly instructions ........................................................................................................... 5
1.2 Limitation of liability ..................................................................................................................................................... 5
1.3 Copyright ..................................................................................................................................................................... 6
1.4 Spare parts.................................................................................................................................................................. 6
1.5 Material defects ........................................................................................................................................................... 6
1.6 Technical support ........................................................................................................................................................ 6
2Safety instructions.................................................................................................................................................................... 7
2.1 General safety information .......................................................................................................................................... 7
2.2 Personnel requirements .............................................................................................................................................. 8
2.2.1 Qualifications ............................................................................................................................................................... 8
2.2.2 Unauthorized personnel .............................................................................................................................................. 8
2.2.3 Instruction .................................................................................................................................................................... 8
2.3 Personal protective equipment .................................................................................................................................... 9
2.4 Intended use.............................................................................................................................................................. 10
2.5 Protective measures to be taken by the operator/user.............................................................................................. 11
2.6 Particular risks ........................................................................................................................................................... 12
2.7 Behavior in case of accidents and malfunctions........................................................................................................ 14
3Technical specifications ......................................................................................................................................................... 15
3.1 General information ................................................................................................................................................... 15
3.2 Interfaces................................................................................................................................................................... 15
3.3 Operating conditions.................................................................................................................................................. 15
3.4 Type plate.................................................................................................................................................................. 16
3.5 Track beam................................................................................................................................................................ 16
3.5.1 Smoothing of welded track beams ............................................................................................................................ 17
3.5.2 Use of even welded track beams .............................................................................................................................. 17
3.5.3 Girder joint for non-welded track beams.................................................................................................................... 18
3.5.4 Horizontal deviation of track beams .......................................................................................................................... 20
3.5.5 Vertical deviation of track beams............................................................................................................................... 20

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 3 of 70
3.5.6 Poor horizontal alignment between the crane beam and the track beam ................................................................. 21
3.5.7 Poor vertical alignment between the crane beam and track beam............................................................................ 21
4Product Description and Mode of Operation.......................................................................................................................... 22
4.1 Overview of the festoon system ................................................................................................................................ 22
4.2 Brief description......................................................................................................................................................... 23
4.3 Description of assemblies.......................................................................................................................................... 23
4.4 Working and danger areas ........................................................................................................................................ 27
4.5 Operating modes....................................................................................................................................................... 28
4.5.1 Automatic operation................................................................................................................................................... 28
4.5.2 Manual operation....................................................................................................................................................... 28
5Transport, packaging and storage ......................................................................................................................................... 29
5.1 Transport ................................................................................................................................................................... 29
5.1.1 Safety instructions for transport................................................................................................................................. 29
5.1.2 Transport inspection .................................................................................................................................................. 29
5.2 Packaging.................................................................................................................................................................. 30
5.3 Storage of packed parts ............................................................................................................................................ 30
6Installation and commissioning.............................................................................................................................................. 31
6.1 Safety ........................................................................................................................................................................ 31
6.2 Preparation ................................................................................................................................................................ 32
6.3 Installation ................................................................................................................................................................. 32
6.3.1 Mounting a pre-assembled festoon system............................................................................................................... 33
6.3.2 Mounting a towing clamp........................................................................................................................................... 34
6.3.3 Mounting the towing trolley........................................................................................................................................ 35
6.3.4 Assembling the festoon ............................................................................................................................................. 35
6.3.5 Mounting the end clamp ............................................................................................................................................ 36
6.3.6 Arrangement of round cables .................................................................................................................................... 37
6.3.7 Arrangement of flat cables......................................................................................................................................... 39
6.3.8 Mounting round cable clamps.................................................................................................................................... 40
6.3.9 Mounting flat cable clamps........................................................................................................................................ 42
6.3.10 Mounting the towing rope .......................................................................................................................................... 43
6.3.11 Damping device......................................................................................................................................................... 44

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 4 of 70
6.3.12 Installation of wind retaining device........................................................................................................................... 46
6.3.13 Adjusting the running gear......................................................................................................................................... 47
6.4 Testing and commissioning....................................................................................................................................... 48
6.4.1 Commissioning checklist ........................................................................................................................................... 49
7Operation ............................................................................................................................................................................... 51
7.1 Safety ........................................................................................................................................................................ 51
7.2 Function..................................................................................................................................................................... 52
8Maintenance and service....................................................................................................................................................... 53
8.1 Safety ........................................................................................................................................................................ 53
8.2 Maintenance / inspection plan................................................................................................................................... 54
8.2.1 Inspection on deactivated system ............................................................................................................................. 56
8.2.2 Inspection of towing ropes and criteria for replacement............................................................................................ 57
8.2.3 Inspection on moving system .................................................................................................................................... 58
8.2.4 Logging...................................................................................................................................................................... 58
8.2.5 Maintenance of the festoon system........................................................................................................................... 59
8.2.6 Wearing parts ............................................................................................................................................................ 61
8.2.7 Wear limits................................................................................................................................................................. 61
8.2.8 Repeat inspections .................................................................................................................................................... 62
8.2.9 Repair ........................................................................................................................................................................ 62
9Troubleshooting ..................................................................................................................................................................... 63
10 Disassembly and disposal ..................................................................................................................................................... 64
10.1 Safety ........................................................................................................................................................................ 64
10.2 Disassembly .............................................................................................................................................................. 65
10.3 Disposal..................................................................................................................................................................... 65
10.4 Documentation for electrical equipment .................................................................................................................... 66
10.5 Spare parts list........................................................................................................................................................... 66
10.6 Product observations................................................................................................................................................. 67
11 Final Acceptance Certificate (PFR05-15-02-E)...................................................................................................................... 69

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 5 of 70
1General notes
1.1 Information about these assembly instructions
These assembly instructions allow the safe, efficient use of the festoon system.
The assembly instructions are a component of the festoon system and must be kept in the immediate vicinity of the festoon system
and accessible to personnel at all times. Personnel must carefully read and understand these assembly instructions before starting
any work. The basic prerequisite for safe work is compliance with all safety and operating guidelines in these assembly
instructions.
Furthermore, local accident protection regulations and general safety regulations apply for the area of use of the festoon system.
Illustrations are provided for basic understanding and may deviate from the actual implementation of the festoon system.
In addition to these assembly instructions, the attached instructions for installed components also apply.
1.2 Limitation of liability
All data and information in these assembly instructions has been compiled while taking the valid standards and regulations as well
as the state-of-the art and our long years of experience and knowledge into consideration.
The manufacturer is in no way liable for damages resulting from:
Failure to comply with assembly instructions
Improper use
Employment of untrained personnel
Unauthorized modifications
Technical changes
Use of unauthorized replacement parts or accessories.
The actual scope of delivery may differ from the explanations and illustrations here depending on special implementations, the
inclusion of additional order options, or due to the latest technical changes.
The obligations specified in the scope of delivery, the general terms of business, and the delivery terms of the manufacturer apply,
along with the legal regulations valid at the time of conclusion of the contract.
All products are subject to technical changes during the process of improvement of characteristics of use and continued
development.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 6 of 70
1.3 Copyright
These assembly instructions are subject to copyright and exclusively intended for internal use.
Provision of the assembly instructions to third parties, duplications 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 internal use.
Violations will result in the obligation to compensate for damages. Other rights reserved.
1.4 Spare parts
WARNING!
Safety risk due to wrong spare parts!
Wrong or faulty spare parts can impair safety as well as result in damages, malfunctions or
complete failure.
→Use only original spare parts of the manufacturer!
Obtain spare parts from licensed dealers or directly from the manufacturer. See the last page of these operating instructions for the
address.
1.5 Material defects
The regulations about material defects are listed in the general terms and conditions of business.
1.6 Technical support
For technical support please contact our staff from the Customer Support Department. See the last page of these operating
instructions for contact information.
Our employees are also always interested in new information and experience from use that can be valuable for the improvement of
our products.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 7 of 70
2Safety instructions
2.1 General safety information
Safety and hazard information is identified in these assembly instructions by symbols. Signal words are used in these safety
instructions to indicate the degree of hazard. Always observe safety and hazard information and work carefully to avoid accidents,
bodily harm or property damage!
DANGER!
… indicates an immediately hazardous situation, which if not avoided, may result in death or serious
injury.
WARNING!
… indicates a possibly hazardous situation, which if not avoided, may result in death or serious
injury.
WARNING!
… indicates a possible danger of burning if not avoided.
WARNING!
… indicates a possible danger from electricity, which if not avoided, may result in death or serious
injury.
CAUTION!
… indicates a possibly hazardous situation, which if not avoided, may result in moderate or minor
injury and property damage.
NOTICE!
Tips and recommendations:
… refers to useful tips and recommendations as well as information for efficient and trouble-free
operation.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 8 of 70
2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Injury due to insufficient qualifications!
Improper use can result in serious injury to person and property.
→Allow only qualified personnel to carry out all activities!
The following qualifications have been mentioned in these operating instructions for different areas of operation:
•Trained personnel/operators
have been instructed by the operator about the tasks assigned to them and the possible hazards resulting from improper use.
•Qualified specialists
Due to their technical education, knowledge, and experience as well as knowledge of the applicable specifications, are capable
of carrying out the tasks assigned to them and to detect and avoid possible dangers independently.
•Personnel may only be authorized if it can be expected that they carry out their work reliably. Personnel whose reactions are
influenced by drugs, alcohol, or medications may not be authorized.
•Locally applicable age and qualification regulations must be followed during selection of personnel.
2.2.2 Unauthorized personnel
WARNING!
Danger due to unauthorized personnel!
Unauthorized personnel who do not meet the requirements described here do not understand the
danger in the work area.
→Keep unauthorized persons away from the working area.
→In case of doubt, address the persons and direct them away from the working area.
→Stop work as long as unauthorized persons are in the working area.
2.2.3 Instruction
Before commissioning, the personnel must be instructed by the operator. For better tracking, log the performance of this instruction
as follows:
Date Name Type of instruction Instruction given by Signature

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 9 of 70
2.3 Personal protective equipment
Always wear:
For all work, always wear:
Work safety clothing
is close-fitting work clothing that has a low tearing strength with tight arms and
no parts that protrude. It is mostly used as protection from getting caught by
moving machine parts.
Do not wear any rings, chains or any other jewelry!
Safety shoes
used to protect from falling heavy parts and slipping on slippery floors.
For special tasks, wear:
When carrying out particular tasks, special safety gear is required. The
individual sections of these instructions specify this gear in detail. The
following particular safety gear is explained below:
Protective gloves
for the protection of hands from friction, scrapes, stabbing, or deep wounds, as
well as from contact with hot surfaces.
Hard hat
for protection from falling and flying parts and materials.
Protective goggles
for eye protection.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 10 of 70
2.4 Intended use
The festoon system is exclusively designed and built for the intended use described here.
Festoon systems program 0365, 0370 and 0375 are intended for the installation and operation of an electrical supply line for track-
based mobile consumers, such as cranes and lifting gears in industrial environment. Other uses are only permitted after written
approval by Conductix-Wampfler.
WARNING!
Possible injury resulting from improper use!
Any application that deviates from or goes beyond the intended use described here can result in a
hazardous situation.
→The festoon system may only be used as intended.
→Strictly comply with all specifications of these installation and operating instructions.
→Do not use the equipment for any other purpose than described here.
The following use of the festoon system is forbidden. Non-intended use particularly includes the
following:
•Using the festoon system with unapproved accessories or accessories not authorized by the
manufacturer.
•Operation of the festoon system by untrained personnel.
•Operation of the festoon system when installed on an improper foundation / base.
•Exceeding projected load capacities
•Exceeding projected speeds
•Excessive acceleration
•Use of unsuitable cables
•Operation under conditions other than the agreed environmental and operating conditions (including
a change to projected physical location).
Claims of any kind due to damages from improper use are excluded.
The operator bears sole liability for any damages due to unintended use.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 11 of 70
2.5 Protective measures to be taken by the operator/user
The festoon system is used in an industrial setting. The operator of the festoon system is thus subject to legal requirements related
to workplace safety. In addition to the safety guidelines in these assembly instructions, the safety, accident protection, and
environmental protection regulations applicable to the place of operation of the festoon system must be followed. This particularly
implies that:
The operator must ensure that the festoon system will only be used for its intended purpose.
The operator must be informed of applicable workplace safety regulations and carry out a risk assessment to detect additional
dangers resulting from the specific working conditions in the place of operation of the festoon system. This must be
implemented in the form of operating instructions for the operation of the festoon system.
For the entire period of use of the festoon system, the operator must check whether the operating instructions prepared
correspond to the current state of regulations, and update the operating instructions as needed.
The operator must clearly regulate and determine responsibilities for installation, operation, troubleshooting, and maintenance.
The operator must ensure that all employees involved with the festoon system have read and understood these assembly
instructions. Moreover, the operator must train personnel at regular intervals and inform them of the dangers.
The operator must provide personnel with the protective gear required.
Furthermore, the operator is responsible for ensuring that the festoon system is always in a technically perfect condition. The
following thus apply:
The operator must ensure that the maintenance schedule described in these assembly instructions is followed.
The operator must regularly have all safety systems checked for functionality and completeness.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 12 of 70
2.6 Particular risks
The following section lists residual risks determined based on a risk assessment.
Follow the safety instructions listed here and the warnings in other sections of these assembly instructions in order to reduce
health hazards and avoid dangerous situations.
WARNING!
Danger of death due to hanging loads!
When lifting loads, there is a danger of death from falling parts or those swinging out of control.
→Never step under hanging loads.
→Move loads only under supervision.
→Follow the specifications for the attachment points provided.
→Do not attach to projecting machine parts or to eyes on installed components. Be sure the
connection elements are firmly seated.
→Use only authorized lifting accessories and connection elements with sufficient load capacity.
→Do not use torn or worn ropes or straps.
→Do not attach ropes or straps to sharp corners and edges, and do not knot or twist them.
→Set down the load when leaving the workplace.
WARNING!
Danger of injury from moving components!
Incautious handling of the festoon system can lead to severe injury or damage to the festoon
system.
→Be sure that the festoon system does not start by itself.
→While it is moving, do not reach into moving parts, particularly the interface between the buffer
and buffer plate.
→Block off the dangerous area under the system.
DANGER!
Danger of injury due to electric shock!
Danger of severe injury or death from electric current.
→Before working on the festoon system, the system must be disconnected from power using the
main switch, and secured against unauthorized, unintentional, and/or erroneous activation.
→In special cases where there is no main switch, the power disconnection must be carried out
according to the specifications of the system manufacturer.
→Check parts disconnected from power, then ground and short-circuit them. Insulate neighboring
parts that are connected to power.
→Before each commissioning, an insulation test must be carried out in accordance with the local
technical standards, guidelines, and law.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 13 of 70
WARNING!
Danger of burning!
Danger of burning when using insufficiently dimensioned cables!
→Always comply with the necessary cross-section of cables.
CAUTION!
Danger of tripping on projecting parts!
When working on the festoon system, there is a risk of tripping.
→When walking in the work and danger area, be careful of projections and depressions in the floor.
No loose objects may be left on the floor.
WARNING!
Danger of crushing!
When moving the festoon system, there is a danger of crushing limbs between the buffer and buffer
plate, as well as between the running gear and the track beam.
→When the system is moving, do not enter the danger area of the festoon system.
WARNING!
Danger of crushing!
During installation of a festoon system, there is a danger of crushing limbs between the load carrier
and the track beam.
→During installation, do not enter the danger area of the festoon system.
CAUTION!
Trap!
When the festoon system is moving, there is a danger of being trapped within it.
→When the system is moving, do not enter the danger area of the festoon system.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 14 of 70
2.7 Behavior in case of accidents and malfunctions
Measures to be taken in case of accident:
Secure the location of the accident.
Take first-aid measures.
Keep personnel out of the danger area.
Inform responsible parties at the place of operation.
Alarm the rescue services.
Make access ready for rescue vehicles.
Measures to be taken in case of malfunction:
Secure the work area against entry.
Involve qualified personnel for fault analysis.
Involve authorized personnel for maintenance and repair.
Shut down the system and secure it against unauthorized, unintentional, and/or erroneous activation.
If injury to person and property can occur during breakdowns then Conductix-Wampfler must be informed immediately.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 15 of 70
3Technical specifications
3.1 General information
Designation Value Notes
Max. load capacity
350 - 800 kg
Depending on the festoon product line selected
Max. travel speed 210 - 300 m/min Depending on the festoon product line selected,
together with Catenary and/ or motorized trolleys
3.2 Interfaces
Mechanical:
Machine Part
Load-bearing structure
End clamp, festoon, towing trolley
Towing arm
Towing trolley, towing clamp
Cables
Saddle, cable clamps, cable organizers
Track beam
Load carrier
Electrical, data, and media:
Machine Part
Switching cabinet
Cables
Media supply
Cables
Consumer
Cables
3.3 Operating conditions
Environment:
Designation Value Notes
Temperature range
-30 to +50°C
+80°C when working with steel rollers
Relative humidity, maximum
90%
100% possible after adaptation
Max. allowed wind speed (operating)
< 21 m/sec
Max. allowed wind speed (non-operating)
< 33 m/sec

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 16 of 70
3.4 Type plate
Fig. 1: Sample type plate
The type plate is on the end clamp and includes the following information:
Model
Year of construction
Order number
Manufacturer
Manufacturer address
NOTICE!
Tips and recommendations:
In case of inquiries with regard to the festoon systems, always indicate the data on the type plate.
3.5 Track beam
The operator is basically responsible for ensuring that the track beam is securely fastened as well as checking it for wear, corrosion
or defects.
The following procedures are to be observed when installing the track beam:
In general, track beams are to be protected from corrosion using appropriate measures.
The running surfaces of the main rollers and the horizontal guide rollers must be clean and free of objects or defects that could
damage the rollers (scratches, cracks, holes, uneven segments, etc.).
If multiple beams are welded together, they must all have the same measurements, shape and positional tolerances.
The beam flanges are to be aligned with particular care in horizontal and vertical planes.
Track beams that have been damaged during transport or rolling are not permitted for use.
Modified areas (from welding, sanding, etc.) on the track beam are to be protected from corrosion with appropriate measures.
There may be no projecting contours on the sides of the track area or under the track beam.

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 17 of 70
3.5.1 Smoothing of welded track beams
Bumps and uneven areas on all sides of the welded track beams are to be ground smooth for a length of 100 mm.
Required tools and materials:
NOTICE!
Fig. 2: Smoothing of welded track beams
3.5.2 Use of even welded track beams
Weld seams on the track beams must be even at points that could come into contact with the cable trolleys. Mounting elements
and suspended objects that could come into contact with the trolleys are not permitted.
Fig. 3: Use of even welded track beams
No uneven areas, mounting elements, suspended
objects, etc.
grinded
grinded
grinded grinded

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 18 of 70
3.5.3 Girder joint for non-welded track beams
For non-welded girder joints, the gap between beams may be at most 8 mm. The cut is at a 45° angle.
Required tools and materials:
NOTICE!
Fig. 4: Girder joint for non-welded track beams
For non-welded girder joints, the horizontal and vertical deviation of the opposing sides of the joint may be at most 2 mm.
Transitions must be ground smooth within about 100 mm of the beginning of the cut. All transitions must be bevelled and
rounded off.
Required tools and materials:
NOTICE!
Fig. 5: Girder joint for non-welded track beams
Edges ground and rounded
Edges ground and
rounded
Horizontal and vertical deviation ±2mm

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 19 of 70

Mounting Instructions
Festoon Systems for I-Beams
Programs 0365 / 0370 / 0375
MAL0300-0004c-EN
www.conductix.com translated document page 20 of 70
3.5.4 Horizontal deviation of track beams
The horizontal deviation over the length of the track beam may not exceed ±5 mm. For lengths shorter than 2 m, deviation may
not exceed ±2 mm.
Required tools and materials:
NOTICE!
L = Total length
Fig. 6: Horizontal deviation of track beams
3.5.5 Vertical deviation of track beams
The vertical deviation over the length of the track beam may not exceed ±5 mm. For lengths shorter than 2 m, deviation may not
exceed ±2 mm.
L = Total length
Fig. 7: Vertical deviation of track beams