Conductix-Wampfler 0832 User manual

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 1 of 27
Content Page
1General references for the operating instructions.................................................................................................................... 3
1.1 Intended use............................................................................................................................................................. 3
1.2 Safety regulations..................................................................................................................................................... 4
1.3 Icons used ................................................................................................................................................................ 4
1.4 Warnings .................................................................................................................................................................. 4
2System description................................................................................................................................................................... 5
3Transportation, storage and assembly preparation ................................................................................................................. 6
4Assembly of the modules and components / References for the assembly instructions ......................................................... 7
4.1 Example of the assembly sequence of a conductor rail 0832 .................................................................................. 7
4.2 Reference to additional assembly instructions ......................................................................................................... 9
5Start-up and operation ........................................................................................................................................................... 10
6Maintenance .......................................................................................................................................................................... 11
6.1 In general................................................................................................................................................................ 11
6.2 Safety regulations................................................................................................................................................... 11

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 2 of 27
6.3 Warnings ................................................................................................................................................................ 11
6.4 Tool and accessories.............................................................................................................................................. 12
6.5 Maintenance plan ................................................................................................................................................... 12
6.6 Start-up after maintenance..................................................................................................................................... 14
7Cleaning................................................................................................................................................................................. 15
7.1 In general................................................................................................................................................................ 15
7.2 Safety regulations................................................................................................................................................... 15
7.3 Selection of the cleaning method / Selection of the cleaning agents ..................................................................... 15
7.4 Insulation measurement ......................................................................................................................................... 15
7.5 Description of the individual products..................................................................................................................... 16
7.6 Environmental compatibility / Risks........................................................................................................................ 17
7.7 Use and application................................................................................................................................................ 17
7.8 Packaging / Processing / Supply source ................................................................................................................ 18
8Troubleshooting and repair.................................................................................................................................................... 19
9Decommissioning, dismantling and disposal ......................................................................................................................... 20
10 Glossary................................................................................................................................................................................. 23
Reprints and reproductions, even in excerpts, are only permitted with our approval.
© Conductix-Wampfler AG / 2009

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 3 of 27
1General references for the operating instructions
These operating instructions describe the structure of the conductor rail system 0832. Various system configurations are possible.
The particular conductor rail system was already designed during the selection of the components and includes tolerances and
temperature fluctuations within a specified range as well as additional system-related parameters.
Information (such as the layout, drawing and catalog KAT0832-0001-E) must be available to the installer of the system,
in order to include it accordingly in the planning, assembly and start-up.
1.1 Intended use
Conductor rail system 0832 was developed specifically for AS/RS (Automated Storage/Retrieval System) and can only be used in
enclosed areas!
Other uses must be discussed with the local representation of Conductix-Wampfler.
•The general application parameters and technical data may be derived from catalog KAT0832-0001-E.
•The tolerance within which 0832 must be assembled depend on the tolerances that the mounting surfaces present.
The tolerances within which the current collector moves with the conductor rail is ultimately relevant. These must be checked
and possibly adjusted prior to start-up after setting up the overall system.
•The system axes are defined as follows:
* X-direction = Aisle direction
Travel of storage retrieval system
* Y-direction = Height direction / vertical
* Z-direction = Travel from the aisle into the rack
•The max. tolerances of the current collector to the conductor rail are:
* X-direction = max. travel up to 200 ± 20 mm forward
End of the conductor strips
* Y-direction = ± 15 mm / ± 8 mm recommended
(± 5 mm for tangential entries)
* Z-direction = ± 10 mm / ± 5 mm recommended
The system is designed for a quick and secure assembly. The primarily used screw connections are M8; wrench size (SW) = 13 mm.
A torque of 25 Nm applies for these connections, provided no other deviating values have been mentioned at the relevant location.

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 4 of 27
1.2 Safety regulations
Safetyregulations known from relevant compendiums of guidelines and regulations and country-specific specifications for working
on electrical systems apply (i.e. VDE/UVV/VBG4).
Safety regulations for accessing and entering the systems defined by the respective system operator apply.
Work on the conductor rail may only be performed by specifically trained skilled personnel in correspondence with relevant
technical standards, regulations and laws.
Only qualified electricians may perform work on the electrical system of the facility in correspondence with the relevant electrical
standards (such as VDE, IEC) and country-specific regulations and laws.
Conductor rails are a part of the electrical system and must therefore be checked repeatedly and routinely according to the accident
prevention regulations (i.e. VBG4).
Only original Conductix-Wampfler spare parts may be used! Conductix-Wampfler cannot take any responsibility for a perfect
and safe operation when using other components.
1.3 Icons used
Warning of general injury risks
and property damages
Warning of injuries from electric shock
Warning of hazards from crushing Notes for a proper operation
1.4 Warnings
Risk of injuries from electric shock!
Prior to working on the conductor rail, the system must be switched off by using the master switch and secured
against unauthorized and/or accidental restarting. If a master switch is not available in special cases, the system
must be switched off according to the specifications of the AS/RS manufacturer. First, check that the connected
parts are free from voltage, then ground these and short circuit. Insulate adjacent live parts!
An insulation test in correspondence with local technical standards, regulations and laws must be performed
prior to each start-up.
Risk of injuries between stationary and movable parts of the system!
The system must be switched off with the master switch prior to working on the conductor rail!

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 5 of 27
2System description
•The conductor rail program 0832 is an extandable conductor rail feed-in system. The expansions are accomplished by
connecting individual conductor rail sections via pick-up guide transits, insulation separating points or conductor strip
connectors.
•The positions of power feeds, expansion elements and possibly the anchor point are important for the assembly of the
individual sections – if available. The installer of the section must know the planning guidelines (such as the layout, drawing,
etc.), in order to include the assembly direction and sequence.
•It is important for the proper setting of the section to know the temperature guidelines and the assembly temperature. If the conductor
rail system expands freely in one direction (i.e. without anchor points), the gap adjustment of the expansion element is
accomplished according to the table in catalog KAT0832-0001-E. If one or several anchor points are available in the conductor
rail system, please obtain the coordination of the gap adjustment of the expansion element with Conductix-Wampfler.
•All relevant sections of these operating instructions must be read completely prior to starting the work. In the event of any
doubts, please contact Conductix-Wampfler!
The system modules and tools are described in operating instructions BAL0832-0002-E. It is included in the
basic module.
Illustration of the support
profile
Illustration of
the insulation profile
Nominal offset of the
insulation and support profile changeover
System hanger
Support profile
Power feed with cover
Left end cap
Current collector
Insulation profile/power feed
Insulation profile
Current collector
Right end cap
1) min. 200 + expansion path
System hanger
Support profile
Insulation profile
Conductor strip (from 35 – 200A)
n x 4000
n x 4000
n x 4000
n x 4000

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 6 of 27
3Transportation, storage and assembly preparation
•Modules (basic and extension module) are prepackaged for transportation and storage. They must be protected
from moisture.
•Note the labels when entering into the aisle: “The assembly position sets the feed in direction!”
•A wheel set can be used for transporting, if necessary (refer to tool set “Profi” or BAL0832-0002-E)!
•Only unpack directly at the assembly site. All of the required parts are enclosed with the modules in the proper
quantity!
The basic and extension module can be transported into the individual aisles with the aid of a wheel set (only included in the tool
set “Profi”). The aisle marking on the top must be noted! The arrow points to the aisle side to which conductor rail system 0832
will be assembled. The extension module should be ideally placed in the center of the aisle. This results in the shortest travel.
The basic module is placed in the area of the power feed.
Do not remove the protective covers until immediately prior to the assembly!
The individual poles of the insulation profile are intended for feeding conductor strips (compare conductor strip module).
All modules must be protected from contamination and moisture.

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 7 of 27
4Assembly of the modules and components / References for the assembly
instructions
4.1 Example of the assembly sequence of a conductor rail 0832
1. Install the rack consoles (if included in the delivery) according to the system layout.
The assembly instructions MV0832-0001-E are enclosed in the package of the consoles.
Consoles are used when the conductor rail 0832 is not assembled to existing
rack consoles.
2. Assemble system hangers for various rack consoles.
MV0832-0002-E is enclosed in the package of the system hangers.
The system hangers are assembled on the rack consoles or the pre-assembled consoles.
3. Assemble support profiles with insulation profiles.
MV0832-0003-E is enclosed in the package of the basic module.
The support profiles are attached to the system hangers and screwed together with the
connectors. The system layout must thereby be observed.
The insulating profiles are pre-assembled on the support profiles and can be easily moved.
The connection of the insulating profiles is described in assembly sequence 7!
Assembly sequences 3 and 4 can be interchanged – depending on the system!
4. Assemble the power feed.
MV0832-0004-E is enclosed in the package of the basic module.
The power feed is assembled according to the system layout.
5. Assemble the expansion element.
MV0832-0005-E is enclosed in the package of the expansion module.
The expansion module also serves the adjustment of the expansion of the insulating profile
during temperature fluctuations. The position is defined in the system layout.

Operating instructions
Conductor rail program 0832
System description
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6. Conductor strip feed.
MV0832-0006-E is enclosed in the package of the basic module.
The conductor strips are assembled according to the system layout.
The allocation of the cross-sections to the poles must be observed!
7. Assemble the insulation profile (including the connection of the insulation profiles).
MV0832-0007-E is enclosed in the package of the basic module.
The insulation profiles are plugged together with the connector parts.
8. Assemble the insulation separating point.
MV0832-0008-E is enclosed in the package of the insulation separating point.
The insulation separating point typically serves the electrical separation of system segments.
The installation is performed according to the system layout.
9. Assemble the end cap (left and right).
MV0832-0009-E is enclosed in the package of the basic module.
The end caps serve the end and the contact protection on the conductor rail ends.
10. Assemble the current collector for the stacker crane (with and without change support).
MV0832-0010-E is enclosed in the package of the current collector.
The current collector must be mounted to the stacker crane according to the system layout.
The installation dimensions with the approved tolerances must be observed in compliance
with the projection documents and technical data in KAT0832-0001-E.
11. Assemble the positioning module (system manufactured by Leuze).
MV0832-0011-E is enclosed in the package of the positioning module.
The positioning module enables to quickly incorporate the LEUZE barcode strip for designating
the position with barcode readers. It is assembled according to the projection documents.

Operating instructions
Conductor rail program 0832
System description
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www.conductix.com Page 9 of 27
12. Assemble the conductor strip-connector module.
MV0832-0012-E is enclosed in the package of the conductor strip-connector module.
The module serves the connection of conductor strips in systems with system lengths beyond
the max. roll length of the conductor strips. It is assembled according to the projection principles.
4.2 Reference to additional assembly instructions
13. Assemble the pick-up guide.
MV0832-0013-E is enclosed in the package of the pick-up guide.
14. Assemble the repair module.
MV0832-0014-E is enclosed in the package of the repair module.
The repair module serves the exchange of a segment of the conductor rail in case of accidental
damages.
15. Tools
MV0832-0015-E is enclosed in the package of the basic module.

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 10 of 27
5Start-up and operation
CAUTION! Machine/property damages!
Only trained personnel may perform the start-up!
The following items must be checked prior to start-up:
•Is the conductor rail system completely assembled?
•Are damaged components installed?
•Are all components clean?
•Max. hang-up distance of 3.2 m on the rack consoles or consoles
•Proper fit of the support profiles with the adapters and system hangers
•Are all insulating profiles snapped into the support profiles?
•Are the connecting elements, insulating connectors, clamping sheets and connector pins available on all change overs?
•Are the clamping sheets centered on all support profile change overs and are the nuts tightened?
•Proper electrical connection of the power feed
•Proper electrical connection of the current collectors (including the strain relief to be attached by the customer)
•Are conductor strips inaccessible with fingers
•Are end caps available
•No scattered parts in the operating area (all assembly tools removed)
•Proper fit of the current collector or change support, if available, on the stacker crane
•Securing the change support – if available – with the cable tie
•No conflict of the current collector lines during all operating conditions
•Insulation test in correspondence with local technical standards, regulations and laws
The movement of the individual current collectors must be evaluated over the entire travel section in manual or “slow travel”
(compare chapter 1 for installation tolerances) and potential conflicts must be eliminated.
Conductor rail system 0832 (EcoClickLine) can be operated at the following parameters after a successful start-up:
•Rated voltage: max. 690 V / USA/Canada --> 500 V
•Approved ambient temperatures are system related (from -30 to +55°C)
•The difference of the usage temperature is system related (max. 50 K)
•Max. travel speed on the track: 600 m/min
•Max. travel speed in the pick-up guide area: 80 m/min
It must be verified during the operation that no personnel is located in the aisle.
CAUTION! Machine/property damages!
Damages of the conductor rail system due to improper assembly!

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 11 of 27
6Maintenance
6.1 In general
CAUTION! Machine/property damages!
A routine and sufficient maintenance is necessary for the proper function of the conductor rail. It prevents any risk of
the operational safety and the contact protection and is the requirement to maintain the warranty. An intermediate
maintenance may become necessary at special events.
6.2 Safety regulations
Safety regulations known from the relevant specifications and country-specific regulations for work on electrical systems apply
when performing maintenance (such as VDE/UVV/VBG4).
Safety regulations for accessing and entering the systems defined by the respective system operator apply.
Maintenance and repairs on the conductor rail may only be performed by suitably trained skilled personnel in correspondence with
the relevant technical standards, regulations and laws.
Only qualified electricians may perform maintenance and repair on the electrical system in correspondence with the relevant electrical
standards (such as VDE, IEC) and country-specific regulations and laws.
Conductor rails are a part of the electric system and must therefore be repeatedly and routinely checked according to the accident
prevention regulations (i.e. VBG4).
Only original Conductix-Wampfler spare parts may be used. Conductix-Wampfler cannot assume any responsibility for a perfect
and safe operation when using other components.
6.3 Warnings
CAUTION! Risk of injuries due to electrical current
The system must be disconnected with the master switch prior to the inspection, maintenance, repair or dismantling
the conductor rail system and/or secured against unauthorized, accidental and/or mistaken restarts. If a master
switch is not available in special cases, the voltage cutoff must be performed according to the system manufacturer’s
guidelines. First, check the disconnected parts that they are disconnected, then ground and short circuit.
Insulate adjacent live parts which are energized!
An insulation test in correspondence with the local technical standards, regulations and laws must be performed prior
to each start-up.
CAUTION! Risk of crushing between stationary and movable parts of the system!
The system must be switched off with the master switch prior to the inspection, maintenance, repair or dismantling!

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 12 of 27
CAUTION! Health hazard due to carbon dust!
Abrasion of the collector shoe accumulates in the conductor rail system and on the floor. This dust is very fine and is
classified as harmful. Personal protective gear, such as safety glasses, dust mask and gloves are mandated for all
work on the conductor rail system, especially for cleaning. Contact with mucous membranes must be avoided.
Do not inhale the dust. Clean skin surfaces with water and appropriate cleaning agents after work. Rinse with clean
water in case of eye contact.
Dust deposits can be raised and inhaled during maintenance work. A dust mask must be worn!
6.4 Tool and accessories
Conventional tools (metric) and measuring instruments are used for the maintenance of the conductor rails. A caliper gauge is
required for measuring the collector shoe content. A spring balance with a measuring range from 0 to 20 N or 0 to 50 N is used to
define the contact pressure of the collector shoe.
6.5 Maintenance plan
A maintenance contract is recommended, which controls the maintenance and inspection. Maintenance and inspection
is performed by Conductix-Wampfler service personnel or authorized local service partners of Conductix-Wampfler.
The advantages of a maintenance contract are an increased availability of the system and a cost-effective, as well as precise
performance of the maintenance work by trained personnel.
Maintenance cycle: 6 months (1st maintenance for new systems: 4 weeks after start-up).
Current collector:
CAUTION! Risk of injuries by electric current!
Visual inspection of the collector shoe due to abrasion in the contact area. Replace the current collector head,
when the minimum height of the collector shoe reaches 4 mm on at least one point opposite the collector insulation
(compare illustration below). This is the case at least after 15,000 km when performing routine maintenance.
Coverage of more than 30,000 km is possible at a low contamination degree and clean deburred transit points
(in the areas of the connector module, repair module, insulation separating point and pick-up guide).
Visual inspection of the collector insulating for cracks and abrasion points. Replace the current collector head, if the insulation is
scraped through and the collector shoe is visible or if the collector insulation displays cracks.

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 13 of 27
Visual inspection of the connector lines for kinks, damages of the insulations or the stranded conductors, wiring, plug connections
and screw connections (European-style terminal strips). Replace the current collector head, if the connecting line has one of
the described damages.
Checking the contact pressure: attach a suitable spring balance on the current collector arm, possibly near the joint of the current
collector head. Pull the current collector head (in z-direction) vertically from the conductor rail with the aid of the spring balance.
Reading the measurement: if the collector shoe varies from the conductor surface!
The contact pressure must be between 7 and 12 N. The mounting position on the AS/RS (Z direction) must be adjusted in
the event of deviations.
Checking all connecting and fuse elements (incl. cable ties for change support, if available), as well as the easy movement of each
individual current collector arm; if necessary, replace.
Check the stroke and side tolerance of the current collectors with the conductor rail (compare chapter 1). Adjust the attachment
position on the AS/RS, if necessary.
Conductor strip and insulation profile:
CAUTION! Risk of injuries by electric current!
Visual inspection of the conductor strips for wear, damages, contamination or burnt spots; replace the conductor strip, if
necessary. Verify that the conductor contact areas are completely free of burrs. Burrs on junctions, connector module, repair
module, insulation separating point and pick-up guide may result in an increased carbon loss.
Contamination on the conductor area can be removed mechanically with a cleaning brush. The local Conductix-Wampfler service
partner will provide information concerning the cleaning brushes.
Visual inspection of the insulation profile for wear, damages, contamination or burnt spots; clean or replace the insulation profile,
if necessary.
Verify that there are no bottlenecks in the individual poles of the insulation profile (i.e. due to adhering contamination or offset due
to the overheating of the conductor rail system). Clean and replace the insulation profile, if necessary.
Visual inspection for areas with local overheating (possibly with a thermal imaging camera, if available).
Manually check the movability of the insulation profiles with a loose current collector.
Verify that the insulation of the insulation profile is not obstructed by foreign bodies (chips, liquids, contaminations, etc.)
(Risk of short circuits).
Expansion element, connector module, repair module, insulation separating point and pick-up guide:
CAUTION! Risk of injuries by electric current!
Abrasion may accumulate in the individual poles. This must be removed with a vacuum cleaner or a brush. It must be guaranteed
that the covers of the expansion element and the connector or repair module are snapped in. Snap in or replace the covers, if necessary.
Verify on the connector or repair module that all conductor strip change overs are free from gaps; if necessary, shift the conductor
strips and secure these again with the stud screws.
The distance between the individual conductor strip ends and the insulation separating point or the pick-up guide may not be 0 mm,
but may also not have a gap greater than 30 mm (refer to the respective assembly guidelines). Shift the conductor strips, if
necessary.
Check the plastic transit strip of the insulation separating point. Replace the separating point in the event of excessive wear or a loose
change over strip.
Check the pick-up guide transit by manually or slowly moving the AS/RS. Clean or readjust, if necessary.
Check the stability of the pick-up guide. If necessary, retighten or replace.

Operating instructions
Conductor rail program 0832
System description
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www.conductix.com Page 14 of 27
Support profile, system hanger and adjustments for rack consoles:
CAUTION! Machine/property damages
Visual inspection for damages, breakages, contamination or corrosion; if necessary, replace. Check the height of
the horizontal contact of the current collector arms (Y direction). Adjust, if necessary.
Check the even course of the support and insulation profile (compare chapter 1 for tolerances) and adjust to
the system hanger or the adapter, if necessary.
Check screw connections and retighten, if necessary.
Check, if the conductor rail system bends partially in Z direction during the operation. The max. deflection during
the operation equals 15 mm. This may occur on support profile change overs between rack consoles or consoles.
Greater deviations on the change over points may be reduced with a reinforcement bracket.
Power feed:
CAUTION! Risk of injuries by electric current!
Only skilled electricians who know and observe the relevant accident prevention regulations may open and close,
as well as working without covers.
Visual inspection for wear, damages, contamination, burnt spots or corrosion; possibly replace the components concerned.
Visual inspection of the connecting lines for kinks, damages of the insulation or the stranded wire. The wiring
installation as well as the plug or screw connections must be checked.
Check screw connections and retighten, if necessary.
PE conductor: visual inspection; continued inspection within the system and on interfaces, measurement of
the grounding resistance.
Phase: measure the insulation resistance.
Visual inspection for areas with local overheating (possibly with a thermal imaging camera, if available).
End caps:
CAUTION! Machine/property damages
Visual inspection for wear, damages, contamination, burnt spots or corrosion; replace the components, if necessary.
6.6 Start-up after maintenance
Prior to restarting, verify that
- all work was completed according to chapter 6.5.
- the system was inspected and tools, scrap, etc. are removed from the process area.
- that personnel is not located in the process area.
- the guidelines of the system manufacturer have been observed.
A trial run of the entire system must be performed.
The system must be observed during the first operating hour.

Operating instructions
Conductor rail program 0832
System description
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7Cleaning
7.1 In general
Cleaning is a part of the maintenance of the conductor rail system. Cleaning prevents a risk to the operating safety as well as
the protection against contact.
Cleaning targets the following:
•Removing the dust on collector shoes.
•Removing the dust of the conductor rail insulations.
•Removing insulating layers from the conductor surface (oxidation of the conductor surface, condensate and film development).
•Removing extensive contamination from the surrounding system (dust, fluids, such as oils and syrup, etc.).
The cleaning process assumes an inspection of the conductorrail system by skilled personnel from the Conductix-
Wampfler AG.
Exempt are only repeated cleaning processes within the scope of maintenanceplans that have been authorized by the “conductor
rail engineering department” of the Conductix-Wampfler AG.
7.2 Safety regulations
CAUTION! Risk of injuries by electric current!
Safetyregulations known from relevant regulations apply for work on electrical systems.
The safety regulations issued by the respective system operator apply for entering and working in systems.
The relevant safety data sheets and processspecifications apply for the use of cleaning agents.
7.3 Selection of the cleaning method / Selection of the cleaning agents
The cleaning method and cleaning agents used therein must be coordinated with the “conductor rail engineering department”
of the Conductix-Wampfler AG prior to their application.
Disassembly/reassembly/adjustment of the conductor rail system or parts of the conductor rail system within the scope of cleaning
requires the approval of the “conductor rail engineering department” of the Conductix-Wampfler AG.
7.4 Insulation measurement
In order to determine the necessity for cleaning, and/or the success of cleaning the conductor rail system, measurements
of the insulation resistance before/after cleaning must be performedand recorded in a protocol.
CAUTION! Risk of injuries by electric current!
The following work must be performed by a skilled electrician!
Prior to performing work on the conductor rail system, it must be disconnected and secured against unauthorized,
accidental and/or mistakenrestarting!

Operating instructions
Conductor rail program 0832
System description
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www.conductix.com Page 16 of 27
In order to prevent incorrect measurements, the conductor rail system must be insulated, i.e. on the power feeds belonging
to he onductor rail system, as well as on the current collectors/terminal boxes belonging to the conductorrail system.
The current collectors must be in the operating position.
Deviations from these guidelines based on the respective system/installation or the selected measuring method must be noted
in protocol (drawing of the measured section with the enclosed system components).
Entrances/transits and insulation separating points must be included in the definition of the measured section. The conductor rail
system must therefore be divided into individual measuring sections.
The following insulation resistances must be determined:
- Between adjacent poles.
- Between each pole and ground.
The arrangement of the poles and/or the designation of the poles must be recorded in the protocol (possibly with a drawing).
The fluctuation range in deviating insulation resistances must be determined via repeated measurements.
The following applies for low voltage systems (rated voltage < 1000 V):
- The insulation resistance is measured with provided ohmmeters, which operate with DC voltage.
- The insulation resistance in systems with ≤a rated voltage of 500 V ≥must equal 0.5 MΩ.
The DC voltage of the measurement must equal 500 V.
- The insulation resistance for systems with a rated voltage of > 500 Vmust equal ≥1.0 MΩ.
The DC voltage of the measurement must equal 1000 V.
Sufficient insulation resistances are a requirement to restart the system.
7.5 Description of the individual products
- Vacuuming and removing rough residue
- Cleaning brush / sand paper with a grain of 180 or finer.
- Damp cloth without the addition of a cleaning agent.
- Cleaning concentrate “Rivolta B.W.R. 210”:
Low alkaline, biodegradable, non-combustible, physiologically harmless cleaning concentrate with a pleasant odor / insulating residue!
- High performance cleaner “Rivolta S.L.X.-Top”:
Puncture proof, free of residue, evaporating, free of halogen-hydrocarbons, odorless, unmarked according to “Ordinance on
hazardous substances”, versatile cleaning concentrate.
- “Rivolta O.C.X. oxide dissolver”:
Dissolves oxide and sulfide layers, resinified oils, greases and mineral abrasion; must always be cleaned afterward with S.L.X.-Top.

Operating instructions
Conductor rail program 0832
System description
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www.conductix.com Page 17 of 27
7.6 Environmental compatibility / Risks
B.W.R. 210
S.L.X.-Top
O.C.X. oxide dissolver
Biodegradable
At more than 97%
-
-
Flashpoint
Non-combustible
> 55°C - class A III
> 65°C - class A III
Identification according to
“Ordinance on Hazardous
Substances”
Not required Not required Not required
Storage In plastic containers at room
temperature
In sufficiently ventilated rooms
at room temperature, close
containers tightly!
In sufficiently ventilated rooms
at room temperature, close
containers tightly!
7.7 Use and application
Start each cleaning process initially with the weakest possible cleaning agent for the contamination found (compare table below,
left column). The cleaning agent of the following column should only be used if no satisfactory result could be achieved.
Contamination / cleaning
agent Damp cloth
Fine brush /
fine-grained
sanding paper
B.W.R. 210 S.L.X.-Top O.C.X. oxide
dissolver
Dust, carbon abrasion or
light contamination
Insulation /
conductor
Conductor /
carbons
Insulation /
conductor
Greasy, oily, sooty or
other contamination
Insulation /
conductor
Conductor /
carbons
Corrosion Conductor Terminal / connector /
conductor
Other
Release for food-
industry; process
only cold!
Affects plastics!
Only for cleaning metal parts

Operating instructions
Conductor rail program 0832
System description
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7.8 Packaging / Processing / Supply source
B. W. R. 210
S.L.X.-Top
O.C.X. oxide dissolver
Packaging Loose items Loose items / spray
can
Loose items / spray can
Processing
Mix 1:50 / processing via a spray process
or high-pressure washer
(lance distance > 0.7 m)
Rinse cleaned areas with water.
Caution:
Only restart the system, if it is verified
that the water is completely evaporated
(Risk of short-circuits!)
Undiluted with
airless electrical
spray guns / airless
high-pressure
washers
Spray by using aerosol cans /
undiluted with airless electrical spray guns /
wait for 15 - 20 min
Caution:
Always clean with S.L.X.-Top afterward
Supply source Bremer & Leguil GmbH - Am Burgacker 30 - 42 - 47051 Duisburg / Germany
Tel.: + 49 (0) 203 99 230
Fax: + 49 (0) 203 25 901

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 19 of 27
8Troubleshooting and repair
Defects that occur in reality are, as far as known to us, listed in the table below and are supplemented with repair measures.
Repairs may only be performed by qualified personnel.
Defect
Troubleshooting
Repair
Angular abrasion of
the collector shoes
Bushing clamps not installed free from rotation, kinking or
direction force
Assemble original current collector
head by Conductix-Wampfler
Sufficient ease of movement of the current collector
heads is not guaranteed
Bundling the individual terminals, for example with cable ties
Side abrasion of the
collector insulation up
to the collector shoe
The current collector contact widths are reduced in individual
poles of the insulation profile due to overheating of the
conductor rail system
Replace the insulation profile. Check,
if conductor strips used are suitable
Incorrect height adjustment of the current collector
(Y-direction)
Replace current collector heads; properly
adjust the height of the current collector
Excessive wear of
the collector shoes
Abrasion points on transits, such as the connector module,
repair module, insulation separating point or pick-up guide
Deburr sharp-edged transits with a
file, air grinder or sanding paper
Conductor strips contaminated or with burnt spots
Cleaning according to chapter 7.7;
possible replacement of the conductor
strips
Excessive contact pressure of the current collectors
Inspection according to chapter 6.5. If
the distance between the AS/RS mount
and the conductor strip is too small,
adjust according to MV0832-0010-E
Interruption of the power
feed or the data
transmission
Power feed is not properly connected
Tighten all screws
The conductor strip of a pole at the power feed is not
conducted through the clamping piece
Pull out the conductor strip and
reinsert again; if necessary, replace
the conductor strip
Insufficient contact pressure of the current collectors
Inspection according to chapter 6.5,
if he distance between the AS/RS
mounting is too great, adjust
according to MV0832-0010-E
Pressure piece for the current feed mounted incorrectly
or not centered at the connector module or the repair
module
Align clean and tighten the setscrew;
check the assembly situation according
to MV0832-0012-E or -0013 -E
The conductor strip gap at connector module or repair
module is too great
Push the conductor strip to the center
to block and tighten the setscrews
The distance of the double current collectors is too small
in a pole so that both current collector heads are
simultaneously on the insulation separating point
Enlarge the distance of the double
current collectors
Current collector is not properly connected
Tighten all screws
Conflict with the components of the system
Attach all components concerned free
of conflicts; possibly inspect the
system layout. Replace damaged
components

Operating instructions
Conductor rail program 0832
System description
BAL0832-0001a-EN
www.conductix.com Page 20 of 27
Defect
Troubleshooting
Repair
Insulation profile detaches
from the support profile
The insulation profile can detach from the lower flexible snap
hook when overheating the conductor rail system
Replace the insulation profile.
Check, if conductor strips used
are suitable
Individual conductor strips with a larger cross section were not
properly aligned when inserted and pull the insulation profile
from the support profile at the beginning/end of the system
Pull out the conductor strips and
align when pulling in; possibly
replace the insulation profiles at
the start/end of the system
The current collector has
detached itself from
the hange support
The interlock is not properly snapped in
Properly assemble the current
collector as described in
MV0832-0010-E
Fuse with cable tie is missing
The current collector or
the change support rattles
The screw connection to the AS/RS is loose
Tighten the screw and secure
against detaching
9Decommissioning, dismantling and disposal
Short-term decommissioning
If the conductor rail system is not used during a period of 3 weeks max. and no personnel has moved in the aisle within this time
(traversing range of the AS/RS), no actions are required. The system is ready for use.
Long-term decommissioning
If the conductor rail system will not be used after a period of 3 to 8 weeks max. or if personnel moved in the aisle during
a decommissioning (traverse range of the AS/RS), chapter 6.6 (start-up after maintenance) must be observed.
If the conductor rail system is used after a period of 8 weeks, chapter 6 must be observed and the appropriate maintenance must
be performed.
Dismantling
It is recommended to perform the dismantling in the described sequence.
Dismantling the positioning module:
CAUTION! Risk of cutting!
The potentially available barcode strips have sharp edge and may result in cuts.
Slacken the tightened barcode strip by shifting the tension unit (with the threaded rod). Remove the screw of
the tension unit, in order to remove the barcode strip (compare MV0832-0011-E). Release the barcode strip from
the individual band holders. Unscrew the holders of the tension units from the support profile!
Dismantling the pick-up guides:
Remove the attachment on the console. Remove the 4 nuts on the support profile attachment. Press in the insulating connectors
with the aid of the dismantling tool from the tool kit and remove the pick-up guide (compare MV0832-0015-E).
Dismantling the conductor strips:
Remove the covers on the back of the power feed (compare MV0832-0004-E), connector module (compare MV0832-0012-E) and
repair module (compare MV 0832-0013-E) and all setscrews. Pull out the conductor strips to the ends of the system.