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
BAL0832-0001a-EN
www.conductix.com Page 8 of 27
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
BAL0832-0001a-EN
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!