Conductix-Wampfler 0832 User manual

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 1 of 12
Content Page
1System module for conductor rail 0832 ................................................................................................................................... 2
2Tools for conductor rail 0832 ................................................................................................................................................... 6
2.1 Content of tool kit “Standard”....................................................................................................................................... 6
2.2 Content of tool kit “Profi”............................................................................................................................................ 10
Reprints and reproductions, even in excerpts, are only permitted with our approval.
© Conductix-Wampfler AG / 2009
First read the operating instructions BAL0832-0001 with the included system description. It is enclosed in the
basic module.

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 2 of 12
1System module for conductor rail 0832
•The conductor rail of series 0832 is constructed on an efficient logistics and module concept. Here, logical units that contain
all f the necessary parts are delivered pre-packaged, so that these can be delivered directly to the assembly location.
The following modules are available:
A) Basic module - Contains everything that is needed once in an aisle, such as the power feed and end caps.
Note: conductor strips, current collectors and displacement transducer system are not included.
Content:
1 x power feed (incl. conductor strip and insulation profile- 3 x support profile incl. 3 x insulation profile 1000 mm
anchor point and assembly instructions) (assembly instructions in the basic module)
1 x end cap “L” 1 x end cap “R”
(incl. assembly instructions) (incl. assembly instructions)

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 3 of 12
The small part service packet of the basic module contains the following:
2 x setscrew
10 x self-locking nut with serrated
bearing M8
2 x clamping plate
10 x connector pin 10 x insulating connector 10 x cable tie
6 x connector pin (compare
assembly instructions of the
support profile)
6 x insulating connector (compare
assembly instructions of the
insulation profile)
6 x clamping plate (compare
assembly instructions of the
support profile)

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 4 of 12
B) Expansion modules - Contain all aisle components for expanding the basic module to the aisle length.
They are available in 24, 8 and 4 m.
Content:
Insulation profile snapped into the support profile; 4 m.
Connector pin Insulating connector Clamping plate
Module length
24 m
8 m
4 m
Order No.
083215-024X7X12
083215-008X7X12
083215-004X7X12
Quantity (units)
Content
Support profile
6
2
1
Insulation profile
6
2
1
Connector pin
12
4
2
Insulating connector
12
4
2
Clamping sheet
12
4
2

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 5 of 12
C) Conductor strip module - Contains all conductor strips for each aisle including wiring (cross sections of 10 to 50 mm²).
The lengths of the conductor strips depend on the order. The cables can be obtained in any
length in reference to the conductor strip cross sections. It is a single-conductor Conductix-
Wampfler rubber-sheathed flexible cable T-3 of the brand H07RN-F.
“Green-yellow” cores are also possible for any cross section. These are single core fine wire
PVC wire conductors of model H07V-K. Crimp type sockets with M6 are provided to connect
the cables to the power feed.
The conductor strip module can be equipped with the following components and cross
sections:
Conductor strip
Cable
Green-yellow cable
10
10
10
16
16
16
25
25
25
35
35
35
50
50
50
Conductor strip and cable cross section in mm²
D) Connector module For connecting the conductor strip ends in longer systems. The index is located
in the assembly instructions of the conductor strip connector module.
E) Positioning module Attachment of the barcode measuring system manufactured by Leuze.
The description of contents is located in the assembly instructions of the positioning
module.
F) Repair module For repairing damaged system sections. The description of contents is located in the
assembly instructions of the repair module.
•The necessary assembly instructions are always located in the modules. Operating instructions of the system are located
in the basic module, as well as the repair and tool module.
•If small parts are lost at the construction site, a limited replacement is available with the small part service packet, which is
enclosed in the basic module. Additional small part service packets are available separately!
•Shorting system components:
The conductor rail 0832 is designed as a 4 m system. The support profiles and the insulation profiles are delivered and
installed in this length. It is always possible that collisions of connecting points, especially those of the support profile and
the system hangers/rack consoles or other assemblies develop. In order to prevent these problems, 3 pieces of 1 m each
are enclosed in the basic module. The rail joint can be repositioned by inserting such a section, thereby preventing the collision.
•If difficulties should occur, which cannot be prevented by these 3 sections, for example, because this problem occurs more
than 3 x per aisle or because too much projection remains at the end of the aisle, which results in space problems,
the support profile and the insulation profile can be simply shortened. The following must be hereby observed:
- Angularity and linearity of the cut.
- Non-deformation of the support profile.
- Deburring and slitting the insulation profile (using the saw jig).

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 6 of 12
2Tools for conductor rail 0832
There are 2 tool kits for the simplified assembly - Standard and Profi. The Profi tool kit can also be leased.
2.1 Content of tool kit “Standard”
•1 x small part – service packed (compare the basic module for the content).
•1 x feed in aid (compare the assembly instructions for strip insertion).
•1 x straightening jig (compare the assembly instructions for the strip insertion)

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 7 of 12
•1 x disassembly tool
A disassembly tool is provided to separate the connected insulation profile ends. It is marked with “TOP” for proper handling.
The wing nut must be released [A], so that the bracket can be shifted upward in longitudinal hole [B]. The disassembly tool
must be attached below in the C-groove of the support profile [C]. When turning upward [D], it must be aligned so (compare
image) that the bridge directed in the direction of the insulation profile can be inserted in the slits of the insulation profile (E).
By pressing the bracket down (F: shifting in the longitudinal hole) and tightening the wing nut [G], the disassembly tool is
attached in the upper C-groove. When the wing nut is tightened, the bridge presses into the slits of the insulation profile.
This unlocks the snap hooks of the insulating connectors. When using the 2 disassembly tools, 2 connected insulation
profiles are released again, independent from each other, can be shifted in X direction [H].
B
A
C
D
E

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 8 of 12
If an attachment in the C-grooves of the support profile is not possible, the disassembly tool must be turned and pushed
manually into the slits of the insulation profile with its handle [I], in order to release the snap hooks.
F
H
H
I
I
G

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 9 of 12
•1 x saw jig
The slits must be sawed into the PVC profile with the aid of the saw jig. The device must be pressed into the insulation profile
up to the stop (compare the following illustrations).
2 slits each are then produced with a hacksaw [1] on the left and right flush in the respective saw clearance. Thereby must be
noted that the cutting depth provided with the gauge must be adhered to!
1

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 10 of 12
The remaining intermediate bridges (2) must be broken out with a small screwdriver.
By using such an insulating connector it must be checked to determine if the individual snap hooks snap easily
behind the sawed areas.
2.2 Content of tool set “Profi”
•1 x small part – service packet (compare the basic module for the content).
•2 x feed in aid (compare the assembly instructions for the conductor strip insertion).
•1 x straightening jig (compare the assembly instructions for the strip insertion).
•1 x uncoiling device (compare the assembly instructions for the conductor strip insertion).
•1 x disassembly tool (compare set “standard”).
•1 x saw jig (compare set “standard”).
•1 x wheel set.
2
Saw blade
2

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 11 of 12
The wheel set (compare illustration) simplifies the transport of the extension module. The wheel sets function by pushing
underneath (A) and then pushing up (B).
One of the two wheel sets has movable rollers (1), so that turning is also possible.
2 modules can also be placed on top of each other and secured for transport with the aid of retaining straps (not included in
the delivery). An opening (2) is provided for feeding through the retaining strap. We recommend transporting the expansion
modules separately. 2 holes each are provided in the wheel sets for customer-specific applications (3). Additional adapters can be
attached here with the aid of clamping plates (not included in the delivery).
Comments:
- This Operating Instruction - the modules and the tools - is included in the basic module.
- The illustrations are intended as aids. They may not show the current status of a component or assembly!
Note:
Conductix-Wampfler will not assume any liability and warranty for operation breakdowns and damages as a result
of non-compliance with these assembly instructions!
2
3
1
A
B

Operating instructions
Conductor rail program 0832
System module and tools
BAL0832-0002a-EN
www.conductix.com Page 12 of 12
Conductix-Wampfler GmbH
Rheinstraße 27 + 33
79576 Weil am Rhein - Märkt
Germany
Phone: [phone]
Fax: [phone]
[email protected]
www.conductix.com
Importer for the United Kingdom:
Conductix-Wampfler Ltd.
1, Michigan Avenue
Salford
M50 2GY
United Kingdom
Phone: [phone]
Fax: [phone]
in[email protected]
www.conductix.com