Conductix-Wampfler 0815 Series User manual

CONDUCTOR BAR 0815 SERIES MANUALMV0815-0007-US | 01.08.19
www.conductix.us Conductor Bar
0815 Series Manual

CONDUCTOR BAR 0815 SERIES MANUAL 01.08.19 | MV0815-0007-US
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The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS
MANUAL. Conductix makes no warranty (and assumes no liability) as to function of equipment or operation of systems built according to customer design or of the ability
of any of its products to interface, operate or function with any portions of customer systems not provided by Conductix.
Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered and reported to Seller within one
year after shipment of such goods to Buyer.
Except where the nature of the defect is such that it is appropriate, in Seller’s judgment, to effect repairs on site, Seller’s obligation hereunder to remedy defects shall
be limited to repairing or replacing (at Seller’s option) FOB point of original shipment by Seller, any part returned to Seller at the risk and cost of Buyer. Defective parts
replaced by Seller shall become the property of Seller.
Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended by Seller and altered only as
authorized by Seller. Seller is not responsible for defects which arise from improper installation, neglect, or improper use or from normal wear and tear.
Additionally, Seller’s obligation shall be limited by the manufacturer’s warranty (and is not further warranted by Seller) for all parts procured from others according to
published data, specifications or performance information not designed by or for Seller.
Seller further agrees to replace or at Seller’s option to provide a refund of the sales price of any goods that do not conform to applicable specifications or which differ from
that agreed to be supplied which non-conformity is discovered and forthwith reported to Seller within thirty (30) days after shipment to the Buyer. Seller’s obligation to
replace or refund the purchase price for non-conforming goods shall arise once Buyer returns such goods FOB point of original shipment by Seller at the risk and cost of
Buyer. Goods replaced by Seller shall become the property of Seller.
There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title and freedom from encumbrances and, except as
herein expressly stated and particularly, and without limiting the foregoing, there is no guarantee or warranty, express or implied, of merchantability or of fitness
for any particular purpose or against claim of infringement or the like.
Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyer’s design or of the ability of any goods to interface,
operate or function with any portions of Buyer’s system not provided by Seller.
Seller’s liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of, connected with, or resulting from
the manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in no case exceed the price paid for the product or services or any
part thereof which give rise to the claim. In no event shall Seller be liable for consequential, special, incidental or other damages, nor shall Seller be liable in respect
of personal injury or damage to property not the subject matter hereof unless attributable to gross misconduct of Seller, which shall mean an act or omission by Seller
demonstrating reckless disregard of the foreseeable consequences thereof.
Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities and design functions or under
abnormal conditions. Seller assumes no liability for loss of time, damage or injuries to property or persons resulting from the use of Seller’s products. Buyer shall hold
Seller harmless from all liability, claims, suits and expenses in connection with loss or damage resulting from operation of products or utilization of services, respectively,
of Seller and shall defend any suit or action which might arise there from in Buyer’s name - provided that Seller shall have the right to elect to defend any such suit or
action for the account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.
CONDUCTIX INCORPORATED

CONDUCTOR BAR 0815 SERIES MANUAL
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CONDUCTIX-WAMPFLER FIELD SERVICE
Need Field Service for our products? We Can Handle It!
Ask us for a quote on expert system installations,inspections, preventative maintenance, and repairs/retrofits.
As the world’s largest single source manufacturer of mobile electrification products, Conductix-Wamplfer has the unique ability to offer a
degree of service not found anywhere else. Conductix-Wampfler’s team of highly qualified service technicians and engineers have years of
experience servicing our complete line of products.
We can provide:
Annual Service contracts
Installation
Commissioning
Installation supervision to ensure your installers avoid common mistakes.
Troubleshooting to get you up and running.
Pre-planned inspections to complement your preventive maintenance program.
Call 1-800-521-4888 for further details.

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TABLE OF CONTENTS
SECTION 1 - SAFETY 5
Safety Information Responsibility 5
Safety Messages 5
SECTION 2 - SYSTEM DESCRIPTION 6
SECTION 3 - ASSEMBLY 7
Safety 7
Providing additional protection against accidental contact at the conductor-rail end 10
Procedure 11
Required tools 11
Customizing components 11
Assembling the conductor rail system 15
Installing the current collector 29
Additional documents 33
CONDUCTIX-WAMPFLER FIELD SERVICE 38
NOTES 39

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SECTION 1 - SAFETY
Safety Information Responsibility
All owner, operator, and maintenance personnel must read and understand all manuals associated with this product before installation,
operation, or maintenance.
The manual provides information on the recommended installation, operation, and maintenance of this product. Failure to read and follow
the information provided could cause harm to yourself or others and/or cause product damage. No one should install, operate, or attempt
maintenance of this product prior to familiarizing themselves with the information in this manual.
Safety Messages
The following safety messages are used in this manual to alert you to specific and important safety related information.
CAUTION
CAUTION indicates unsafe actions or situations that have the potential to cause injury, and/or minor equipment or property damage.
DANGER
DANGER indicates hazards that have the potential to cause severe personal injury or death.
WARNING
WARNING indicates unsafe actions or situations that have the potential to cause severe injury, death, and/or major equipment or property
damage.
NOTE
NOTE is used to alert you to installation, operation, programming, or maintenance information that is important, but not hazard related.

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SECTION 2 - SYSTEM DESCRIPTION

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Safety
Installation and initial commissioning may only be carried out by specially trained technicians.
Required protective equipment:
WARNING
Risk of death due to suspended loads!
Falling loads can lead to severe injuries or even death.
• Never walk under suspended loads.
• Only move loads under supervision.
• Set down the load when leaving the workplace.
• Use personal 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.
SECTION 3 - ASSEMBLY

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DANGER
Risk of injury by crushing skin and limbs!
There is a danger of crushing of skin and limbs due to:
• Spring force/gravity (stored energy).
• Current collector (spring force) during installation, dismantling and maintenance.
• Falling conductor-rail system components if they have not been properly installed or if operated in inappropriate operating conditions
(e.g. environment that contains solvents)
• Have installation done only by trained technicians.
• When working on the conductor-rail system, wear safety boots, safety gloves, and a safety helmet
• When changing the collector brush, follow the separate instructions for this task. See chapter 12.1 in BAL0815-0002-EN
• Only install the conductor-rail system where suitable operating conditions prevail. See chapter 3.3 in BAL0815-0002-EN
DANGER
Risk of injury due to grasping or impact!
Grasping and/or impact with moving conductor-rails (slip ring) or current collectors connected to the machine and other components must
be prevented.
• Cordon off the work area.
• Caution when working in the vicinity of the danger zone, in particular if protective devices (covers, enclosures, control devices) have
been removed or disabled.
• Caution when working in the vicinity of the danger zone, in particular below the conductor-rail.
• Falling conductor-rail system components if they have not been properly installed or if operated in inappropriate operating conditions
(e.g. environment that contains solvents).
• Use personal protective equipment!
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!
SECTION 3 - ASSEMBLY

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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!
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 power feeds.
• 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 symbol 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!
SECTION 3 - ASSEMBLY

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ATTENTION
To the side of the conductor-rail there must, a clearance of at least 4 mm from metal components must be maintained (see Figure 3-1) to
prevent mechanical collisions and guarantee sufficient electrical insulation distances!
Providing additional protection against accidental contact at the conductor-rail end
An end cap is attached to the conductor-rail end as protection against accidental contact. When using dual current collectors, one of the
collector brushes, which will be live, might protrude from the end of the conductor-rail. Touching this collector brush might cause injury
from an electric shock, as a result of falling or being thrown across the room. The system operator must ensure that the current collector
does not project, instead remaining within the conductor-rails, or must make the danger area inaccessible (e.g. by providing protection
against accidental contact).
CAUTION
Take structural protective measures!
• Use control technology to ensure that the current collector never travels beyond the end of the conductor-rail.
• Also fit a contact guard that will safely cover the collector brush if it leaves the conductor rail!
CAUTION
Alert personnel to the hazard!
• Attach a sign saying “Risk of death by electrocution” with the relevant hazard symbol in all areas with live components.
SECTION 3 - ASSEMBLY
Figure 3-1: Conductor side rail clearance

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Procedure
Required tools
Standard tool:
• Measuring tape
• Calipers
• Scribe
• Allen key (3 mm)
• Cutting tool (e.g. cordless angle grinder). For producing short lengths.
• File for deburring cut edges after trimming
• Cordless drill and countersink bit
• Screwdriver set
Special tool:
• Bending device (081091)
• Rail-dismantling tool
• Drilling jig for transition units
• Torque wrench (2 Nm) with 3 mm Allen key for rail connector
Personnel:
• Installation by technical personnel only
• At least two people
Customizing components
The customization of components is limited to the bending and trimming of the conductor-rail.
ATTENTION
The trimming of the conductor-rail must be done away from the installation area!
Trimming conductor-rail
The conductor-rails have a standard length of 4000 mm. Shorter lengths can be supplied but are generally produced at the building site.
Required tools:
• Cutting tool, preferably a battery angle grinder with 1 mm cutting disc
• Print cutter
Work steps:
• Cut the conductor material and insulation to the same length.
• Saw off the metal rail and PVC insulation away from the contact area using a cutting tool.
• Deburr the sawed end with a smooth file. Chamfer the contact surface in the whole rail base by 0.3–0.4 mm by 15° to guarantee a
problem-free passage of the collector brushes over the rail joint.
CAUTION
Sharp edges and burrs result in increased wear of the collector brushes!
A sharp edge and/or burr can rapidly wear away the carbon of the collector brushes.
SECTION 3 - ASSEMBLY

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• Clean the profile well and remove sawing debris
SECTION 3 - ASSEMBLY
Figure 3-2: Deburr the conductor rail with smooth file
Figure 3-3: PEplus rail without end machining

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ATTENTION
The PEplus rail has a plastic bar in the insulating profile!
• Remove the plastic bar at each end using a print cutter or other suitable tool so that the connector or the end cap can be fitted
• The cutting tool 08-W100-0603 can be used for producing the end machining
Making a bend in the conductor-rail
Read and respect the additional operating instructions!
You can find additional information on the making a bend in a conductor-rail in BAL0800-0004.
Conductor-rail bends can be fabricated in the factory or on site. They are prepared using the bending device 081091.
For large installations, electrically driven bending devices available upon request.
SECTION 3 - ASSEMBLY
Figure 3-4: PEplus rail with end machining (plastic bar removed)
Figure 3-5: Rear side of rail

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To avoid undesired deformations of the conductor-rail, the plastic insert supplied must be inserted in the slit in the contact surface before
forming the bend and the removed once the bending process is complete.
Required tools:
• Bending device 08191
Work steps:
• Scribe the required bend on a flat surface (e.g., the floor).
• When making horizontal bends: Insert the plastic insert in the slot on the conductor-rail contact surface with the insulating profile
slid open.
• Using the setting spindle, move the upper bending roller upwards until the rail section can be inserted into the cutout provided in
the bending device.
• Adjust the position of the bending roller downwards and move the 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 are to be formed to the same radius can now be bent using the existing setting.
• The rollers are designed for the various bends (horizontal/vertical, see BAL0800-0004 for the bending device for product ranges
0811 and 0815).
SECTION 3 - ASSEMBLY
Figure 3-6: Outside/inside bends and horizontal bend
Figure 3-7: Producing a horizontal bend w/ a plastic insert

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ATTENTION
Use modified PEplus rails for conductor-rail bends with radii < 1500 mm!
• Use modified PEplus rails (order no.: 081516-4x15) for preparing conductor-rail bends with radii < 1500 mm.
These rails are slotted on the rear side and can be bent without deformation of the insulation.
Assembling the conductor rail system
ATTENTION
To the side of the conductor-rail there must, a clearance of at least 4 mm from metal components must be maintained (see
Figure 3-9) to prevent mechanical collisions and guarantee sufficient electrical insulation distances!
Procedure during installation:
It makes sense to start the assembly at one end cap and to assemble the conductor-rail along the route.
SECTION 3 - ASSEMBLY
Figure 3-8: Slotted PEplus rail/Bending device
Figure 3-9: Rail side clearance of at least 4 mm

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Work steps:
• Indicate the positions/installation locations for power feed, customer’s fixed points, junction boxes, expansion elements, isolating
gaps and the guideway profile on the installation structure in accordance with the layout and allocation plan.
• Prepare the power feed and section transitions.
• Assembling the conductor-rail (see Setting the hanger clamps section on this page).
• Install conductor-rail sections including cut sections, lifters, conductor-rail bends and fixed points.
• Prepare the cut sections and conductor-rail bends in the switches.
• Check the mechanical installation.
Test steps to be performed during installation:
• Check the design against the layout and allocation plan.
• Maintain the hanger-clamp intervals; the rails must be properly engaged in the hanger clamp.
• All screw connections for the power feeds, connectors and end caps must be tightened to 2 Nm.
• All transitions and bends must be tested for functionality. Current collectors must not jam when passing through. Check for free
passage with a single current collector.
• The cabling must be checked (routing, labeling, etc.).
• Conduct a continuity and insulation check.
• Check the set dimension of the expansion element.
Setting the hanger clamps
The following must be observed when setting the hanger clamps:
• Set the hanger clamps at intervals of approx. 500 mm and at intervals of 400 mm and 250 mm respectively for internal and exter-
nal horizontal bends. Mount the hanger clamps at a distance of 100 mm – 150 mm from the end cap (see Fig. 13).
• At transitions and connection points, a minimum distance to end caps, connectors and expansion elements of at least 200 mm
must be maintained. Here, the hanger clamps must be set such that collisions of hanger clamps with other components of the sys-
tem are avoided on expansion of the system.
• Hanger clamps are screwed or snapped into customer-specific guideway profiles. When installing, ensure that the pretensioning
is not too great. Excessive pretensioning will distort the hanger clamp. There is a risk that the hanger clamp will no longer rest flat
on the central bar of the EMS rails. Nevertheless, the hanger clamp must be so firmly seated in its position that it cannot dislocate
freely in the guideway profile.
• Frequently, the hanger clamps only become firmly seated in the EMS rail when the conductor-rails have been installed.
• Provide additional fixing for clip-in hanger clamps that do not remain in their positions.
SECTION 3 - ASSEMBLY

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SECTION 3 - ASSEMBLY
Figure 3-10: Hanger clamp in EMS rail
Figure 3-11: Distance from hanger clamp to end cap

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SECTION 3 - ASSEMBLY
Figure 3-12: Comparison of correctly- and incorrectly-engaged rail
Figure 3-13: Clip hanger clamp into conductor rail

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SECTION 3 - ASSEMBLY
Installing conductor-rail and connectors
• After installation of the hanger clamps and preparations of the transitions and power feed points, push the conductor-rails into
the hanger clamps. Make sure that the conductor-rails engage correctly and the hanger clamp covers the insulation above and below
(see Figure 3-12)
• To simplify the installation of the subsequent conductor-rail, it makes sense not to engage the final meter of the current conductor-
rail.
This provides better accessibility of the conductor-rail joint (EMS). According to the guidelines of the automotive industry, the protective
conductor (PE) is provided as the 4th pole counted from above. This also corresponds to the standards of conductor-rail
Screw connections are used to connect 2 conductor-rails. The connectors have a contact part and a rear clamping part.
• Push the connector into the conductor-rail such that the contact part sits in the interior of the conductor-rail and the clamping part
engages between the conductor-rail and the rear insulation (see Figure 3-16). A light pressure on both sides of the side surface of
the conductor-rail may make it easier to push the connector in.
• Push the connector into the two conductor-rails as far as the stops and then lightly tighten the connector from the front. Then
tighten the connector to 2 Nm with a torque wrench (see Figure 3-17).
• Put the insulating cap on from the back, engage it and check for secure hold.
• Push the conductor-rail into the hanger clamp next to the connection point until it engages.
Figure 3-14: Connector and two conductor rails

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SECTION 3 - ASSEMBLY
ATTENTION
Make sure that the connector cap is completely engaged on both sides of the insulating profile!
• Attach the connector cap centrally from behind clip it into the insulating profile.
• Engage the conductor-rails in the hanger clamps (see Figure 3-18).
Figure 3-16: Correct/incorrect position of the clamp
Figure 3-15: Push the rails onto the connector
Figure 3-17: Tighten connector/slide cap over rail connection