Conductix-Wampfler MultiLine 0835 User guide

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 1 of 81

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 2 of 81
Contents
1General information ....................................................................................................................................................................5
1.1 Information about this mounting instruction....................................................................................................................5
1.2 Limitation of liability ........................................................................................................................................................5
1.3 Copyright ........................................................................................................................................................................5
1.4 Spare parts.....................................................................................................................................................................6
1.5 Material defects ..............................................................................................................................................................6
1.6 Technical support ...........................................................................................................................................................6
2Safety instructions.......................................................................................................................................................................7
2.1 General safety information .............................................................................................................................................7
2.2 Personnel requirements .................................................................................................................................................8
2.2.1 Qualifications ..................................................................................................................................................................8
2.2.2 Unauthorized personnel .................................................................................................................................................8
2.2.3 Training...........................................................................................................................................................................9
2.3 Personal protective equipment .......................................................................................................................................9
2.4 Intended use.................................................................................................................................................................10
2.4.1 Improper use ................................................................................................................................................................10
2.5 Protective measures to be taken by the operator/user.................................................................................................11
2.6 5 safety rules for working on electrical systems ...........................................................................................................12
2.7 Specific hazards ...........................................................................................................................................................12
2.7.1 Electrical hazards and sources of danger ....................................................................................................................12
2.7.2 Mechanical hazards and sources of danger.................................................................................................................14
2.7.3 Danger from dust and vapours.....................................................................................................................................16
2.7.4 Hazards arising from the operating environment..........................................................................................................17
2.8 What to do in the event of an accident or a malfunction...............................................................................................18
3Technical specifications ............................................................................................................................................................20
3.1 Electrical .......................................................................................................................................................................20
3.2 Mechanical ...................................................................................................................................................................20
3.2.1 Length...........................................................................................................................................................................20
3.2.2 Installation orientation...................................................................................................................................................21
3.2.3 Tolerances....................................................................................................................................................................22

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 3 of 81
3.3 Operating conditions.....................................................................................................................................................23
3.3.1 Unsuitable environmental conditions............................................................................................................................23
4Description and mode of operation...........................................................................................................................................24
4.1 Brief description............................................................................................................................................................24
4.2 Description of assemblies.............................................................................................................................................24
4.3 Accessories ..................................................................................................................................................................26
4.4 Overview of the system ................................................................................................................................................27
4.4.1 Expansion.....................................................................................................................................................................28
5Shipment, storage and packing ................................................................................................................................................29
5.1 Transport ......................................................................................................................................................................29
5.1.1 Safety instructions for transport....................................................................................................................................29
5.1.2 Transporting the packed parts......................................................................................................................................30
5.1.3 Transport inspection.....................................................................................................................................................30
5.2 Storing the packed parts..............................................................................................................................................30
5.3 Removing the packaging..............................................................................................................................................31
6Installation.................................................................................................................................................................................32
6.1 Safety ...........................................................................................................................................................................32
6.1.1 Personnel .....................................................................................................................................................................32
6.1.2 Safety instructions ........................................................................................................................................................32
6.1.3 Attaching the contact guard..........................................................................................................................................35
6.2 Procedure .....................................................................................................................................................................35
6.2.1 Required tools ..............................................................................................................................................................35
6.2.2 Required accessories ...................................................................................................................................................36
6.2.3 Structural specifications for installing the system .........................................................................................................36
6.2.4 Separating connected elements...................................................................................................................................36
6.2.5 Replace a rail along the course....................................................................................................................................37
6.2.6 Adjusting the size .........................................................................................................................................................38
6.2.7 Installation example......................................................................................................................................................40
6.2.8 Installation instructions for systems with rail segment and/or end segment power feeds ............................................53
7Commissioning .........................................................................................................................................................................57
7.1 Safety ...........................................................................................................................................................................57

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 4 of 81
7.2 Testing and initial commissioning.................................................................................................................................58
7.2.1 Inspection list................................................................................................................................................................58
7.2.2 Initial commissioning ....................................................................................................................................................59
8Operation ..................................................................................................................................................................................60
8.1 Safety ...........................................................................................................................................................................60
8.1.1 Personnel .....................................................................................................................................................................60
8.1.2 Safety instructions ........................................................................................................................................................60
8.2 Normal operation ..........................................................................................................................................................62
8.3 Stopping the system.....................................................................................................................................................62
8.4 Continuing operation ....................................................................................................................................................62
9Servicing and maintenance.......................................................................................................................................................63
9.1 Safety ...........................................................................................................................................................................63
9.2 Tools and materials ......................................................................................................................................................66
9.3 Cleaning .......................................................................................................................................................................66
9.4 Servicing schedule .......................................................................................................................................................66
10 Repairing faults .........................................................................................................................................................................70
10.1 Fault remedy table........................................................................................................................................................72
11 Dismantling and disposal..........................................................................................................................................................74
11.1 Safety ...........................................................................................................................................................................74
11.2 Dismantling...................................................................................................................................................................76
11.2.1 General information on dismantling the system ....................................................................................................76
11.2.2 Tools needed.........................................................................................................................................................76
11.2.3 Dismantling the conductor rail...............................................................................................................................77
11.3 Disposal........................................................................................................................................................................78
12 Additional documents................................................................................................................................................................79
12.1 Conformity declaration..................................................................................................................................................79
12.2 Spare parts list..............................................................................................................................................................79
12.3 Other applicable documents.........................................................................................................................................79
13 Appendix ...................................................................................................................................................................................80
13.1 Table with standard lengths..........................................................................................................................................80
14 Index .........................................................................................................................................................................................81

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 5 of 81
1General information
1.1 Information about this mounting instruction
The information provided in this mounting instruction is designed to enable the above device to be used safely and efficiently.
The mounting instruction forms part of the device and must be kept accessible to personnel at all times and stored right by the
device. Personnel must read these instructions carefully and understand them before starting any work. The basic prerequisite for
safe work is compliance with all safety and operating guidelines in this mounting instruction.
Local accident protection regulations and general safety guidelines for the area of use of the device also apply.
Illustrations in this document are provided for illustration purposes only and can deviate from the actual design of the conductor
rail system.
In addition to this mounting instruction, the instructions in the appendix for the individual system components also apply.
1.2 Limitation of liability
All of the data and information in this document has been compiled taking into account all valid standards and regulations, as well
as the state-of-the art and our long years of experience and knowledge.
The manufacturer is in no way liable for damage resulting from:
Failure to comply with this installation and mounting instruction
Improper use
Use by untrained personnel
Unauthorized modifications
Technical changes
Use of unauthorized replacement parts and accessories
The actual scope of delivery may differ from the explanations and descriptions provided here if the model in question is a special
one, if additional equipped has been ordered or due to recent technical changes.
The obligations agreed upon in the delivery agreement and our General Terms of Business apply, as do the delivery conditions of
the manufacturer and all legal regulations applicable at the time the contract was concluded.
All products are subject to technical modifications in the context of improvement of function and further development.
1.3 Copyright
This installation and mounting instruction is subject to copyright and exclusively intended for internal use by the customer.
Provision of the installation and mounting instruction to third parties, duplications in any form – even in part – as well as the reuse
and/or disclosure of their content are not permitted without the written approval of the manufacturer, except for internal use by
the customer.
Breach or infringement will result in liability for damages. This shall not affect our right to assert claims for further loss or damage.

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 6 of 81
1.4 Spare parts
WARNING!
Wrong spare parts are a safety hazards!
Wrong or faulty spare parts can result in damage, malfunctions, complete failure and affect safety.
→Always use original spare parts from the manufacturer!
Replacement parts can be ordered from your contracted dealer or directly from the manufacturer.
See section 14 for the contact details for ordering spare parts.
1.5 Material defects
The regulations about material defects are listed in the general terms and conditions of business.
1.6 Technical support
For technical support please contact our staff from the Customer Support Department.
Spare part orders: See section 14 for contact details.
We are also always interested in new information, experiences and feedback from the field that can help us improve our products.

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 7 of 81
2Safety instructions
2.1 General safety information
Safety and hazard information are always marked with corresponding symbols in this mounting instruction. Safety instructions are
introduced by signal words that signal the scale of the hazard. Always observe safety and hazard instructions, and work carefully
to avoid accidents, bodily injury and damage to property!
DANGER!
… indicates an immediate hazard that, if not avoided, may result in death or serious injury.
DANGER!
… indicates an immediate hazard due to electrical current, which, if not avoided, may result in death or
serious injury.
WARNING!
… indicates a potential hazard that, if not avoided, may result in death or serious injury.
WARNING!
… indicates a potential hazard due to electrical current, which, if not avoided, may result in death or
serious injury.
CAUTION!
… indicates a potential hazard that, if not avoided, may result in moderate or minor injury and property
damage.
NOTICE!
Tips and recommendations:
… refers to useful tips and recommendations as well as information for efficient and trouble-
free operation.

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 8 of 81
2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Personnel who are not adequately trained are at risk of injury!
Improper use can result in serious injury to persons and property.
→Work on and with the system must only be performed by personnel with adequate training for the
relevant task.
The following qualifications are mentioned in this mounting instruction for different areas of operation:
•Trained personnel/operators
Have been instructed in a training session by the operator with respect to the tasks assigned to them and the potential dangers
arising from improper actions.
•Qualified specialists
Are, due to their specialized training, knowledge, experience and knowledge of applicable regulations, capable of carrying out
work assigned to them, while independently recognizing and avoiding possible risk.
Personnel are considered qualified if they have successfully concluded training, for example, as electricians, master
electricians, electrical engineers, or electrical technicians. Personnel are also considered qualified who have been employed
correspondingly for several years, have been educated in theory and practice during that time, and whose electrical knowledge
and skills have been tested.
The operator of the electrical system must document that the corresponding certification or other documentation of qualification
are present or have been demonstrated.
•Only those persons are authorized as personnel who can be expected to perform their work reliably. People whose capacity for
reaction is influenced e.g. by drugs, alcohol, or medications are not authorized.
•When selecting personnel, all age- and occupation-specific guidelines must be observed that are applicable at the
deployment site.
2.2.2 Unauthorized personnel
WARNING!
Danger due to unauthorized personnel!
Unauthorized persons, who do not meet the requirements described here, are not acquainted with the
dangers in the working area.
→Keep unauthorized personnel away from the working area
→In case of doubt, address the person and direct them away from the working area
→Stop work as long as unauthorized personnel is in the working area

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 9 of 81
2.2.3 Training
Before commissioning the equipment, personnel must be trained by the operator. This training has to be documented as shown in
the template below in order to create a record of the training.
Date Name Type of training Training given by Signature
05.11.2009
John Doe
First safety training for
personnel
Horst Müller
2.3 Personal protective equipment
Always wear
For all work, always wear
Protective clothing
Protective clothing serves primarily as protection against entrapment by moving machine parts. Working
clothes must fit tightly and have a low resistance to tearing; they must have close-fitting sleeves and no
protruding parts.
Protective footwear
Used to protect feet from heavy falling parts and slipping on slippery floors.
To be worn for
special tasks
When carrying out certain tasks, personnel must wear special personal protective equipment. The
need for such personal protective equipment will be detailed in the individual sections of this manual.
Protective gloves
For the protection of hands against friction, scrapes, stabbing or deep wounds, as well as against contact with
hot surfaces.
Protective headgear
For protection against falling or flying parts and materials.
Safety goggles
To protect the eyes from harmful influences, such as strong light, chemicals, dust, splinters or effects of
the weather.
Breathing mask (FFP-3 – according to country-specific requirements)
For protection against substances, particles and organisms. Here: Protection against dust, which is generated
by abrasion by the carbon brushes and the PVC insulation of the conductor rail.

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 10 of 81
2.4 Intended use
This product is designed and built only for the intended use described here.
WARNING!
Danger from improper use!
Any application that deviates from or goes beyond the intended use of the devices can result in
hazardous situations.
→The specifications in this mounting instruction must be strictly complied with
→Do not use the system in any way that does not conform to its intended use!
→Observe the information on improper use in section 2.4.1
We do not accept any liability for damage arising from improper use.
The operator bears sole liability for all damage that result from improper use.
Intended use
The conductor rail system MultiLine 0835 is an electric power supply system for track-guided mobile consumers operated in indoor
spaces in the warehouse area not accessible to the public.
One of its typical applications is, for example, to supply power to shuttles inside a warehouse with horizontal storage racks.
The following technical requirements must always be strictly observed during installation:
The consumer's max. permissible travel speed is 300 m/min.
The conductor rail must only be fitted horizontally.
CAUTION!
To fit the conductor rail vertically, there are a number of extra points that need to be taken into
consideration and doing so is only possible using special components.
The conductor rail system must only be fitted and operated using either steel or copper materials, but on no account a mixture
of steel and copper components.
Max. permissible installation height above ground/platform without safety gear: 3 m
Conductor rails installed higher than 3 m above ground have to be fitted with safety gear to prevent them from falling down.
Max. permissible system length: 150 m
The conductor rail system must not be exposed to splashing water.
Electrotechnical operating conditions
The electrical system has to be protected with fuses in compliance with local guidelines.
2.4.1 Improper use
Improper use in particularly include the following types of use:
Operating the system outside the specified operating conditions (see section 3.3).
Exceeding the max. permissible travel speed.
Installing the conductor rail system with the opening for the current collector's access facing upwards.
Installing the conductor rail system at an angle.
Installing the system higher than 3 m above ground/platform without safety gear.
Installation in area accessible to the public.
Creating a conductor rail that is more than 150 m long.

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 11 of 81
Using the system in clean rooms or ultra-clean rooms.
Using the system in areas that must not be contaminated with abraded materials (e.g. unpackaged food).
Use of the system with accessories that have not been certified and have not been approved by the manufacturer.
Operation of the system by untrained personnel.
Using both steel and copper components in the system.
CAUTION!
Fire hazard, destruction of the conductor rail!
If the current or voltage used for the conductor rail system is too high, the system may be unable
to cope.
→Do not exceed the nominal current indicated in section 3!
CAUTION!
The conductor rail system must only be operated under the environmental conditions detailed
in section 3!
The conductor rail system must not be operated under the following environmental conditions:
→In areas with highly flammable materials. Risk of fire and explosion!
→In areas that contain solvents. Risk of components dropping!
→Near splashing water. Short circuit, risk of death through electrocution!
→In clean rooms or ultra-clean rooms. The conductor rail system generates dust through abrasion
2.5 Protective measures to be taken by the operator/user
The device is designed for use in an industrial setting. The operator of the device is therefore subject to compliance with the
relevant legal obligations concerning workplace safety. In addition to the safety guidelines in this installation and operating manual,
the safety, accident protection, and environmental protection regulations applicable to the place of operation of the unit must be
followed. This particularly includes:
Work on electrical components of the system may only be carried out when disconnected from the power supply.
The operator has to inform himself of applicable workplace safety guidelines and identify any additional hazards that may arise
under special working conditions at the deployment location of the device. This knowledge has to be expressed in the form of
operating instructions for the operation of the device.
During the entire time the device is in use, the operator must check that these operating instructions still correspond to the
current state of regulations and adapt these as necessary.
The operator must clearly manage and define responsibilities, for installation, operation, troubleshooting and maintenance.
The operator must ensure that all employees involved with the unit have read and understood this installation and operating
manual. He must furthermore train personnel at regular intervals and inform them of hazards.
The operator must provide personnel with all required protective equipment (work clothes, safety shoes, hearing protection,
protective gloves, safety helmet, goggles, breathing mask).
The operator must keep the keys for the switching cabinets in a safe place. "Safe" means that only explicitly authorized
personnel may have access to the keys. The keys may only be issued to technical personnel as described in section 2.2.1.

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Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 12 of 81
The operator is furthermore responsible for ensuring that the device is always in perfect working order. The following thus applies:
The operator must ensure that the maintenance schedule described in this installation and operating manual is followed.
The operator must get all safety systems regularly inspected for functionality and completeness. If possible, this inspection
should be carried out once a year, but at least as often as required under the applicable national regulations.
If the device or system has been modified, the safety systems must be inspected again and adapted to the changed conditions
in such a way that the device or system is safe again.
2.6 5 safety rules for working on electrical systems
Requirement:
Work on electrical systems must only be carried out when they are disconnected from the power supply. The 5 safety rules
(see DIN VDE 0150-100:2009-10/EN 50110-1:2004-11) must always be followed before starting any work:
1. Disconnect system from the power supply at the main switch.
2. Secure the main switch against being switched back on,
3. Check that the system is disconnected by measuring the current
4. Ground and short-circuit the parts of the system on which work will be carried out
5. Cover or block off adjacent components that are still live
Only skilled electricians or personnel trained in electrical work may disconnect power or approve reconnection of power after
work carried out in the disconnected state!
2.7 Specific hazards
The following section lists residual risks, which were determined on the basis of a risk assessment. Follow the safety instructions
listed here and the warnings in other sections of this installation and operating manual in order to reduce health hazards and avoid
dangerous situations.
2.7.1 Electrical hazards and sources of danger
Requirement:
DANGER!
Risk of death by electrocution!
Contact with components carrying electrical power can lead to death by electrocution or severe injury.
There is also a risk of injury from shock, falling or being thrown across the room as a result of an
electrical shock.

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 13 of 81
DANGER!
Risk of injury from falling or being thrown across the room after an electrical shock!
Work on the following components is dangerous:
Main power supply
Live components:
Power feeds
Cables
Connections
Conductor rail
Connectors
Current collector
Equipment and connections inside switching cabinets
Control systems etc.

Components that have become electrically charged due to a fault
CAUTION!
Before working on these components!
→Disconnect the conductor rail system from the power supply according to the 5 safety rules and
secure it against being switched back on. For the 5 safety rules, see section 2.6
CAUTION!
Before switching the system on!
→Every time before the device or system is started, measure the insulation resistance according to
locally applicable technical standards, directives and legal regulations.
→Perform required country-specific electrical tests
CAUTION!
Maintain electrical safety!
→Regularly test and maintain electrical equipment
→If dangerous faults are identified, take measures to correct the faults immediately. Inform the system
operator immediately.
→If it is not possible to correct a dangerous fault, block off the area in question or turn the equipment
off, and secure it against being switched back on. Inform the system operator immediately
→Immediately reattach loose and replace damaged cables
→Always replace burned fuses with equivalent fuses

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 14 of 81
DANGER!
Fire hazard due to overload or spark formation!
A fire hazard can occur due to overloads of the cable, electrical arcing, short-circuits or the generation
of sparks. Sparks can occur due to badly maintained, dirty conductor rails or because required
tolerances are not observed during installation.
→The permitted current values must be observed
→The tolerances must be observed during installation
→Electrical fuses must be installed according to regulations
→Do not store easily combustible materials near conductor rails
→Conductor rails must be regularly inspected, maintained and cleaned in conformity with regulations.
See section 12.3
2.7.2 Mechanical hazards and sources of danger
Required protective equipment:
DANGER!
Risk of injury through crushing and impacts!
There is a risk of crushing skin and limbs from:
Current collectors (spring force) during installation, deinstallation 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)
Moving parts when the system is in operation
→Do not enter the system's danger zone during operation
→Installation work must only be carried out by trained personnel
→When working on the conductor rail system, protective footwear, protective gloves and protective
headgear must be worn
→When exchanging carbon brushes, observe the separate instructions on this topic. See section 12.3
→The conductor rail system must only be installed in locations with appropriate operating conditions.
See section 3.3.1

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Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 15 of 81
Required protective equipment:
DANGER!
Risk of injury from cuts and cutting!
The ends of the power rails can have sharp edges, especially if they were cut to size at the
construction site and have not been deburred.
→Wear protective gloves and protective footwear.
→During installation: Carefully deburr the insulation profile and the power rail after they have been cut
to size
→During disassembly: Cut, dismantled conductor rails must be handled carefully and properly stored
(container or transport box)
→Look out for sharp edges near the installation surface and avoid contact.
Required protective equipment:
DANGER!
Risk of injury from falling power rails when transported incorrectly!
When being transported on the construction site, there is a risk that the power rails may slide out of the
insulation profiles if they are not held roughly vertical during transport. This can cause serious injury and
even death if they fall from a great height and hit somebody with their front end.
→The conductor rails should be transported as close as possible to the site of installation inside
their packaging.
→The conductor rails must be carried to the installation site by two people and care must be taken
that the power rails do not slide out of the insulation profiles
→Do not transport the conductor rails in bundles with a crane
→Wear protective headgear
Required protective equipment:
DANGER!
Risk of injury due to entrapment!
There is a risk of being trapped by moving parts when the system is in operation. Moving parts
include, e.g. the shuttle and the current connector fitted to it.
→Do not enter the system's danger zone during operation
→Always disconnect the conductor rail system from the power supply according to the 5 safety
rules and secure it against being switched back on before working on it. For the 5 safety rules,
see section 2.6
→Wear close fitting working clothes

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Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 16 of 81
2.7.3 Danger from dust and vapours
Required protective equipment:
DANGER!
Risk of sensitization, irritations of the mucous membranes and disorders of the respiratory
tract through dust!
Dust from the carbon brushes collects in the conductor rails and the guide profile. This dust is very
fine and is categorized as a health risk. Working a lot with the conductor rail system and/or not
applying the requisite level of care when handling accumulated dust (e.g. cleaning the system with
compressed air) can lead to sensitization. People that frequently spend long periods of time inside a
busy facility without protective equipment may be affected by the following:
Irritation of the mucous membranes
Diseases of the respiratory tract
Cancer
→At workplaces that are continuously exposed, and also strongly frequented facilities, personnel must
be protected through effective measures against dust
→Personal protective equipment must be worn during all works on the conductor rail system during
which accumulated dust is disturbed
→The following personal protective equipment must be worn during cleaning operations:
Safety goggles
Dust mask class FFP3
Gloves
Disposable overall
→Before starting work, clean the conductor rails according to regulations. See section 12.3
→Protect the surroundings during cleaning work, for instance by covering or removing warehouse
goods and blocking access to those areas in which dust could fall down on persons
→Remove dust with a vacuum cleaner. Do not blow out dust with compressed air Vacuum
cleaners should be fitted with a class H fine filter
→Do not eat and/or drink while cleaning!
→Do not smoke while cleaning!
DANGER!
Poisonous gases in case of fire!
In case of fire in the facility, the plastic parts (PVC) of the conductor rail system will generate
poisonous gases (HCL).
→Evacuate the building immediately in the event of fire
→Notify the fire brigade if there is a fire

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Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 17 of 81
2.7.4 Hazards arising from the operating environment
The following conductor rail properties can give rise to hazards if it is installed in an operating environment where they can
be dangerous:
Electrical energy
Spark formation
Dust caused by friction
Material composition of the insulation profiles, which emits poisonous gases when burned
The most important measure for preventing these hazards is to install the conductor rail system only in operating environments
with appropriate operating conditions, see section 3.3.1.
DANGER!
Do not energize the conductor rail!
The conductor rail must not be energized under the following conditions:
If the conductor rail is very dirty
If the conductor rail becomes wet
When live components are exposed (insulation profile or the insulation of the connecting cable are
damaged)
If the hanger clamp or insulation profile fail
If the power rail falls down and contacts a conductive material
→Secure the electric system according to regulations
→Install the conductor rail as described in the installation manual
→Take environmental conditions into account, perform regular checks, maintain and clean as detailed
in the instructions
→The conductor rail must be regularly inspected and, if necessary, repaired
DANGER!
Fire hazard due to overload or spark formation!
A fire hazard can occur due to overloads of the cable, electrical arcing, short-circuits or the generation
of sparks. Sparks can occur due to badly maintained, dirty conductor rails or because required
tolerances are not observed during installation.
→The permitted current values must be observed
→The tolerances must be observed during installation
→Electrical fuses must be installed according to regulations
→Do not store easily combustible materials near to conductor rails
→Conductor rails must be regularly inspected, maintained and cleaned in conformity with the
regulations. See section 12.3
DANGER!
Poisonous gases in case of fire!
In case of fire in the facility, the plastic parts (PVC) of the conductor rail system will generate
poisonous gases (HCL).
→Evacuate the building immediately in the event of fire
→Notify the fire brigade if there is a fire

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 18 of 81
Required protective equipment:
DANGER!
Risk of sensitization, irritations of the mucous membranes and disorders of the respiratory
tract through dust!
Dust from the carbon brushes collects in the conductor rails and the guide profile. This dust is very
fine and is categorized as a health risk. Working a lot with the conductor rail system and/or not
applying the requisite level of care when handling accumulated dust (e.g. cleaning the system with
compressed air) can lead to sensitization. People that frequently spend long periods of time inside a
busy facility without protective equipment may be affected by the following:
Irritation of the mucous membranes
Diseases of the respiratory tract
Cancer
→At workplaces that are continuously exposed, and also strongly frequented facilities, personnel must
be protected through effective measures against dust
→Personal protective equipment must be worn during all works on the conductor rail system during
which collected dust is disturbed
→The following personal protective equipment must be worn during cleaning operations:
Safety goggles
Dust mask class FFP3
Gloves
Disposable overall
→Before starting work, clean the conductor rails according to regulations. See section 12.3
→Protect the surroundings during cleaning works, for instance by covering or removing warehouse
goods and blocking access to those areas in which dust could fall down on persons
→Remove dust with a vacuum cleaner. Do not blow out dust with compressed air Vacuum
cleaners should be fitted with a class H fine filter
→Do not eat and/or drink while cleaning!
→Do not smoke while cleaning!
2.8 What to do in the event of an accident or a malfunction
Measures to take in the event of accidents:
Shut down the system and secure it against unauthorized, unintentional, and/or erroneous activation
Secure the danger zone
Keep personnel out of the danger zone
Initiate first-aid measures
Alarm the rescue services
Inform responsible parties at the operating site
Clear access roads for rescue vehicles
Measures to take in the event of malfunctions:
Shut down the system and secure it against unauthorized, unintentional, and/or erroneous re-activation

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 19 of 81
Secure the work area against entry
Consult qualified personnel when analysing the fault
Conductix-Wampfler must be informed immediately in the event malfunctions can cause personal injury or damage to property:
Conductix-Wampfler GmbH
Rheinstrasse 27 + 33
79576 Weil am Rhein - Märkt
Germany
Tel.: [phone]
Fax: [phone]
[email protected]
www.conductix.com

Mounting Instruction
Conductor rail system
MultiLine 0835
MAL0835-0001c-EN
www.conductix.com translated document page 20 of 81
3Technical specifications
3.1 Electrical
Rated current
max. 32 A at 100 % DC (DC = duty cycle)
Nominal voltage
without protective earth (PE)
max. 48 V AC/DC
with protective earth (PE)
max. 500 V AC
Number of pins
2
Assignment
2 phases or 1 phase, PE
Cross sections for connecting cables
1.5 – 2.5 mm² or 4 – 6 mm²
Conductor material
Copper or steel
Protection class
IP 2X
3.2 Mechanical
Max. travel speed
300 m/min
Direction of travel
Back and forth (reversing)
Gap between pins
14 mm
3.2.1 Length
Max. length of the installed conductor rail
150 m*
Power rails max. 4000 mm (standard),
500 to 3900 mm available on request
Min. permissible power rail length
300 mm
End segment with power feed (first section)
750 mm
End segment (end section)
750 mm
Longitudinally acting section of the connector*
2.5 mm + 1 mm per side
* Systems that are longer than 150 m are only available in consultation with Conductix-Wampfler.