Conductix-Wampfler SingleFlexLine Program 0815 User manual

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 1 of 94
Order Number:
0815xx
-…

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 2 of 94
Contents
1General notes .............................................................................................................................................................................5
1.1 About this document....................................................................................................................................................5
1.2 Limitation of liability .....................................................................................................................................................5
1.3 Copyright .....................................................................................................................................................................6
1.4 Spare parts..................................................................................................................................................................6
1.5 Material defects ...........................................................................................................................................................6
1.6 Technical support ........................................................................................................................................................6
2Safety instructions.......................................................................................................................................................................7
2.1 Explanation of symbols................................................................................................................................................7
2.2 Personnel requirements ..............................................................................................................................................8
2.2.1 Qualifications...............................................................................................................................................................8
2.2.2 Unauthorized personnel ..............................................................................................................................................9
2.2.3 Training........................................................................................................................................................................9
2.3 Personal protective equipment....................................................................................................................................9
2.4 Intended use..............................................................................................................................................................10
2.5 Use other than the intended use ...............................................................................................................................11
2.6 Protective measures to be taken by the operator/user..............................................................................................12
2.7 5 safety rules for working on electrical systems ........................................................................................................12
2.8 Specific hazards ........................................................................................................................................................13
2.8.1 Electrical hazards and sources of danger .................................................................................................................13
2.8.2 Mechanical hazards and sources of danger..............................................................................................................14
2.8.3 Danger due to dust and vapors .................................................................................................................................15
2.8.4 Hazards arising from the operating environment.......................................................................................................16
2.9 Conduct in the event of accidents and malfunctions .................................................................................................17
3Technical specifications ............................................................................................................................................................18
3.1 Electrical ....................................................................................................................................................................18
3.2 Mechanical ................................................................................................................................................................18
3.2.1 Lengths......................................................................................................................................................................18
3.2.2 Installation orientation................................................................................................................................................19

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 3 of 94
3.2.3 Tolerances.................................................................................................................................................................19
3.3 Unsuitable environmental conditions.........................................................................................................................20
4Product description and method of functioning.........................................................................................................................21
4.1 Brief description.........................................................................................................................................................21
4.2 Interfaces...................................................................................................................................................................24
4.3 Description of the components..................................................................................................................................24
4.4 Accessories ...............................................................................................................................................................28
4.4.1 Tools and materials ...................................................................................................................................................29
5Transport, packaging and storage ............................................................................................................................................30
5.1 Safety ........................................................................................................................................................................30
5.2 Transport ...................................................................................................................................................................31
5.3 Packaging..................................................................................................................................................................32
5.4 Storage of packaged parts ........................................................................................................................................32
6Assembly ..................................................................................................................................................................................33
6.1 Safety ........................................................................................................................................................................33
6.2 Providing additional protection against accidental contact at the conductor-rail end ................................................36
6.3 Procedure..................................................................................................................................................................37
6.3.1 Required tools ...........................................................................................................................................................37
6.3.2 Customizing components ..........................................................................................................................................37
6.3.2.1 Trimming conductor-rail.............................................................................................................................................37
6.3.2.2 Making a bend in the conductor rail...........................................................................................................................40
6.3.3 Assembling the conductor-rail system.......................................................................................................................43
6.3.3.1 Setting the hanger clamps.........................................................................................................................................44
6.3.3.2 Installing conductor-rail and connectors....................................................................................................................47
6.3.3.3 Installing a section power feed ..................................................................................................................................51
6.3.3.4 Installing end caps and end power feeds ..................................................................................................................53
6.3.3.5 Mounting the fixed point ............................................................................................................................................55
6.3.4 Installing the current collector....................................................................................................................................57
6.4 Additional documents ................................................................................................................................................62
7Commissioning .........................................................................................................................................................................63
7.1 Safety ........................................................................................................................................................................63
7.2 Testing and initial commissioning..............................................................................................................................66

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 4 of 94
7.2.1 Inspection list.............................................................................................................................................................66
7.2.2 Initial start-up of the conductor-rail system................................................................................................................67
8Operation ..................................................................................................................................................................................68
8.1 Safety ........................................................................................................................................................................68
8.2 Normal operation .......................................................................................................................................................70
8.3 Stopping the system..................................................................................................................................................71
8.4 Continuing operation .................................................................................................................................................71
8.5 Perform regular maintenance and servicing..............................................................................................................71
9Maintenance and servicing .......................................................................................................................................................72
9.1 Safety ........................................................................................................................................................................72
9.2 Tools and materials ...................................................................................................................................................76
9.3 Maintenance plan ......................................................................................................................................................77
10 Troubleshooting ........................................................................................................................................................................81
10.1 Fault remedy table.....................................................................................................................................................85
11 Dismantling and disposal..........................................................................................................................................................87
11.1 Safety ........................................................................................................................................................................87
11.2 Dismantling................................................................................................................................................................90
11.2.1 Disassemble the conductor-rails ...............................................................................................................................90
11.3 Disposal.....................................................................................................................................................................91
12 Additional documents................................................................................................................................................................92
12.1 Other applicable documents......................................................................................................................................92
13 Index .........................................................................................................................................................................................93

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 5 of 94
1General notes
1.1 About this document
The information provided in this manual is designed to enable the conductor-rail system to be used safely and efficiently.
This document forms part of the conductor-rail system and must be kept accessible to personnel at all times and stored right by the
device. Personnel must read this document carefully and understand it before starting any work. The basic prerequisite for safe work
is compliance with all safety and operating guidelines in this document.
Local accident protection regulations and general safety guidelines for the area of use of the conductor-rail system also apply.
Illustrations in this document are provided for basic understanding and may deviate from the actual implementation of the system.
In addition to these operating instructions, the instructions located in the appendices for the individual assembled components also
apply.
1.2 Limitation of liability
All data and information in these operating instructions have been compiled while taking the valid standards and regulations as well
as the state-of-the art and our many years of experience and knowledge into consideration.
The manufacturer is in no way liable for damages resulting from:
Failure to comply with operating instructions
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.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 6 of 94
1.3 Copyright
This document is subject to copyright, and is exclusively intended for internal use by customers.
Provision of the operating instructions to third parties, reproductions 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 the customer's internal use.
Breach or infringement will result in liability for damages. This shall not affect our right to assert claims for further loss or damage.
1.4 Spare parts
WARNING!
Wrong spare parts are a safety hazard!
Wrong or faulty spare parts can result in damage, malfunctions, complete failure and affect
safety.
→Always use original spare parts from the manufacturer!
Order spare parts from your contracted dealer or directly from the manufacturer.
Contact details: See the last page of this document.
Replacement parts list: see chapter 12.1 Other applicable documents.
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.
Contact details: See the last page of this document.
Our employees are also always interested in new information and experience from the field that can be valuable for the improvement
of our products.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 7 of 94
2Safety instructions
2.1 Explanation of symbols
Safety and hazard information is identified in these operating instruction by symbols. Safety instructions are introduced by signal
words that indicate 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 immediately hazardous situation, which, if not avoided, may result in death or
serious injury.
DANGER!
... indicates an immediately hazardous situation due to electricity, which, if not avoided, may
result in death or serious injury.
WARNING!
... indicates a possibly hazardous situation, which, if not avoided, may result in death or serious
injury.
WARNING!
... indicates a possibly hazardous situation due to electricity, which, if not avoided, may result in
death or serious injury.
CAUTION!
... indicates a possibly hazardous situation, which, if not avoided, may result in minor or moder-
ate injury.
Tips and recommendations:
... provides useful tips and recommendations as well as information for efficient and trou-
ble-free operation.
ATTENTION!
... indicates actions that will help you prevent material damage.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 8 of 94
2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Persons who are not adequately trained are at risk of injury!
Improper use can result in serious injury to persons and property.
→All activities must only be performed by qualified personnel.
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 applicable at the deployment site must be observed.
The following qualifications have been mentioned in these operating instructions for certain areas of operation:
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 have whose knowledge and skills in the trade
required have been tested.
The operator of the machine or system must document that the corresponding certification, or other documentation of qualifica-
tion, is available or had been submitted previously.
The installation, maintenance and commissioning of electrical equipment may only be carried out by qualified personnel (electri-
cians) in accordance with local regulations. Work with higher installation positions usually requires additional qualifications and
certificates for the use of lifting devices and protective equipment. On the part the manufacturer, professional and proper handling
of components is required. It is recommended that the installation personnel be trained by the manufacturer or that accompani-
ment of the installation by specialist fitters/supervisor be scheduled.
Operators
have been instructed in an instruction session by the operator with respect to the tasks assigned to them and the potential
dangers arising from improper actions.
The operator of the machine or facility must document that the corresponding training has taken place.
Transport personnel
Trained person who transports the material indoors and outdoors in accordance with safety regulations.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 9 of 94
2.2.2 Unauthorized personnel
WARNING!
Danger due to unauthorized personnel!
Unauthorized persons who do not meet the requirements described here are not ac-
quainted with the dangers in the working area.
→Keep unauthorized personnel out of the working area
→In case of doubt, address such persons and direct them away from the working area
→Stop work as long as unauthorized persons are in the working area
2.2.3 Training
Before commissioning the equipment, personnel must be trained by the operator. For better tracking, the implementation of the
training must be logged as follows:
Example of an instruction log:
Date Name Type of training Training given by Signature
11/5/2009 John Doe First safety training for person-
nel
Horst Müller
2.3 Personal protective equipment
Always wear
For all work
Protective headgear
For protection against falling or flying parts and materials.
Protective gloves
For the protection of hands against friction, scrapes, stabbing or deep wounds, as well as against con-
tact with hot surfaces.
Protective clothing
Primarily for protection against entrapment by moving machine parts. Working clothes must be close
fitting with a low resistance to tearing; they must have close-fitting sleeves and no protruding parts.
Protective footwear
For protection against heavy falling parts and slipping on slippery floors.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 10 of 94
To be worn for spe-
cial tasks
Special personal protective equipment must be used when carrying out certain tasks. The need
for such personal protective equipment will be detailed in the individual chapters of this manual.
Safety goggles
To protect the eyes against harmful influences, such as strong light, chemicals, dust, splinters or effects
of the weather.
Hearing protection
For protection against loud noises and to prevent acoustic trauma.
Respirator (FFP-3 – according to country-specific requirements)
For protection against materials, particles, and organisms. Here: protection against dust caused by the
wear of collector brushes and the PVC insulation of the conductor rail.
2.4 Intended use
The equipment is exclusively designed and built for the use described here (its intended use).
WARNING!
Danger from improper use!
Any application that deviates from or goes beyond the intended use of the devices can re-
sult in hazardous situations.
→Follow all information in these operating instructions strictly.
→Prohibit any use of the system apart from its intended use!
→Observe the information on improper use in chapter 2.5
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 SingleFlexLine 0815 conductor-rail system is an operating resource for customer construction of an electrical energy-supply
system in indoor areas that are not accessible to the public. The conductor rail is an operational resource and thus has no actual
operating mode, since this is determined by the application. Risks are limited only to the failure of mechanical components (e.g.,
falling components) and the danger from electrical current.
The SingleFlexLine 0815 conductor-rail system is used to supply electricity to mobile electrical consumers.
One of its typical applications is, for example, to supply power to logistics shuttles inside a warehouse with horizontal storage racks
or electrical overhead monorail systems (EMS) (in German, Elektrohängebahnen [EHB]).
Use other than in the application approved by the manufacturer must be checked by the system engineer as part of a risk assessment
for the final product and is under the responsibility of the system engineer.
An extended approval by the manufacturer for the application is possible in certain cases and requires written approval after exami-
nation of the use case and ambient conditions.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 11 of 94
The following technical requirements must always be strictly observed for the installation:
The maximum permissible traversing speed of the consumer is up to 600 m/min depending on the system
The conductor-rail must only be fitted horizontally
Electrical engineering operational requirements
The electrical system must be secured in compliance with the locally applicable regulations
2.5 Use other than the intended use
Claims of any kind due to damage incurred during use that deviates from the intended use described above ("use other than the
intended use") are excluded. The operator bears sole liability for all damage that result from improper use.
Uses other than the intended use particularly include the following types of use:
Operating the system outside the specified operating conditions (see Chapter 3.3).
Installation in an area accessible to the public.
Operation within manual reach
Use in non-industrial applications
Overloading of the conductor-rails by excessive current or voltage
Overloading of individual current collectors by excessive current or voltage
Operation at excessively high or low temperatures
Operating under ambient conditions that cause lasting damage to the materials used or drastically reduce insulating properties
(e.g., chemical substances or gases)
Operation under prohibited ambient conditions (see the prescribed ambient conditions depending on the product range)
Operation in areas where flammable or explosive gases or dusts prevail
Operation in areas that require a higher protection class than IP 2X
Use as a walking or climbing aid
Walking on the conductor-rail
Use of unsuitable cleaning agents (e.g., silicone oils or aromatic compounds)
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.
The conductor-rail system must only be operated under the environmental conditions detailed in chapter 3! Unsuitable ambient
conditions are described in chapter 3.3

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 12 of 94
2.6 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 instructions in these operating instruction, all safety, accident
protection, and environmental regulations valid in the place of operation of the development must also be observed. This particularly
includes:
Work on electrical components of the system may only be carried out when disconnected from the power supply.
The operator must inform him/herself 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 cur-
rent 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 device have read and understood these operating instructions.
The operator must also train the 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 person-
nel may have access to the keys. The keys may only be issued to technical personnel as described in Chapter 2.2.1.
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 service intervals described in these operating instructions are observed.
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.
2.7 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 the system from power using the main switch,
2. Secure the main switch against being turned back on
3. Verify the absence of a voltage by measuring
4. Ground and short-circuit parts of the system on which work will be done
5. Cover or block off neighboring parts which are still energized.
→Only electricians or personnel trained in electrical work may disconnect power or approve reconnection of power after work
carried out in the disconnected state!

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 13 of 94
2.8 Specific hazards
The following chapter lists residual risks, which were determined on the basis of a risk assessment.
→Follow the safety instructions and the warnings in these operating instructions in order to reduce health hazards and avoid dan-
gerous situations.
→A detailed risk analysis must be prepared for the system in which the conductor rail is integrated. The resulting measures must
be implemented by the system engineer.
→PE and PEplus must always be designed redundantly. It must be monitored that both protective conductor connections are always
engaged. For systems with transitions two current collectors with double heads must be used.
2.8.1 Electrical hazards and sources of danger
WARNING!
Risk of death by electrocution!
Contact with energized components can lead to death by electrocution or severe
injury. There is also a risk of injury from a shock reaction, falling or being thrown
across the room as a result of an electrical shock.
Work on the following components is dangerous:
Main power supply
Parts carrying electricity: Power feed, cables, connections, conductor-
rail, con-
nectors, current collectors, devices and connections within switching c
abinets,
control systems, etc.
Parts that are carrying electricity due to a fault
Before working on the parts listed above:
→Disconnect the conductor-rail system according to the 5 safety rules and se-
cure it against being turned back on. For the 5 safety rules, see chapter 2.5.
During work:
→Use insulated tools
Before switching on:
→Every time before the device or system is started, test the insulation resistance
according to locally applicable technical standards, directives and legal regula-
tions.
→Carry out locally required electrical tests
Maintain electrical safety!
→Regularly test and maintain electrical equipment.
→If dangerous deficiencies are identified, take measures to correct the deficien-
cies immediately. Inform the system operator immediately
→If it is not possible to correct a dangerous deficiency, block off the area in ques-
tion or turn the equipment off, and secure it against being switched back on. In-
form the system operator immediately.
→Immediately secure loose cables and replace damaged cables.
→Always replace blown fuses with fuses of the same rating

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 14 of 94
DANGER!
Fire hazard due to overload or sparking!
A fire hazard can occur due to overloads of the cable, electrical arcing, short circuits or the
generation of sparks. Sparking can occur in poorly serviced, contaminated conductor-rails or if
installation does not comply with the required tolerances.
→Permissible current values must be observed.
→Comply with tolerances during installation
→Design and dimension systems in accordance with the permissible system load capacity and
provide appropriate protection devices
→Do not store inflammable and/or easily ignited materials near to conductor-rails.
→Inspect, service, and clean conductor-rails regularly and in accordance with specifications.
See chapters 8 and 9.
2.8.2 Mechanical hazards and sources of danger
DANGER!
Risk of injury due to grasping or impact!
Grasping and/or impact with moving conductor-rails (slip ring) or current collectors connected
to the machine and other components must be prevented.
→Cordon off the work area
→Caution when working in the vicinity of the danger zone, in particular if protective devices
(covers, enclosures, control devices) have been removed or disabled
→Caution when working in the vicinity of the danger zone, in particular below the conductor-
rail
→Use personal protective equipment!
WARNING!
Secure conductor-rails against falling
→In application areas with personnel traffic and at an installation height of 3 m or more, con-
ductor-rails must be secured against falling.
CAUTION!
Risk of puncture wounds and cuts!
The packaging material can contain sharp objects such as nails and wood splinters that can
cause injury to limbs.
→Use personal protective equipment!
→Cordon off the work area!
→Caution when working in the vicinity, in particular below the conductor-rail

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 15 of 94
2.8.3 Danger due to dust and vapors
WARNING!
Danger of sensitization, irritation of the mucous membranes, and respiratory
diseases due to dust!
Dust from the collector brushes collects in the conductor-rails and the guide pro-
file. This dust is very fine and is categorized as a health risk. Frequent handling
can result in sensitization. People who frequently spend longer periods of time in
a heavily used plant without protective equipment must expect the following con-
sequences:
Irritations of the mucous membranes
Respiratory diseases
Cancer
These consequences must also be expected if accumulations of dust are handled
without proper care (e.g., removal of dust using compressed air).
→In workplaces with long-term exposure and heavily trafficked plants, take effec-
tive measures to protect employees from the dust.
→During all work on the conductor-rail system in which collected dust can be
stirred up, wear personal protective equipment. In particular wear personal pro-
tective equipment when cleaning the system
Safety goggles
Dust mask class FFP3
Protective gloves
Disposable coverall
→Before starting work, clean the conductor-rail in accordance with regulations.
There are special instructions for this task; see Chapter 9
→Protect the surroundings during cleaning works, for instance by covering or re-
moving warehouse goods and blocking access to those areas, in which dust
could fall down on persons.
→Do not blow out dust with compressed air. Instead, vacuum it up. The vac-
uum cleaner must be equipped with a Class H fine filter.
→Do not eat, drink or smoke during work!
DANGER!
Poisonous gases in case of fire!
In case of fire in the facility, the plastic parts (PVC) of the conductor-rail system emit poisonous
gases (HCL).
→The building must be evacuated immediately.
→The fire brigade must be informed.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 16 of 94
2.8.4 Hazards arising from the operating environment
The following factors can give rise to hazards if the conductor-rail is installed in such an application environment:
Dusts
Gases
Chemical substances
Liquids
Radiation
Major temperature variations
The most important action for protection from these dangers is only to install the conductor-rail system in locations where suitable
operating conditions prevail. See Chapter 2.4.
The system must be designed and operated in accordance with the prevailing ambient conditions.
DANGER!
Risk of components being damaged and losing functionality due to environmental influ-
ences!
Environmental influences (gases, substances, liquids, radiation, etc.) can damage the compo-
nents, particularly the plastic parts. Hanger clamps can break and the conductor-rail system
fall down, for example.
→Check influences depending on temperature, time of action, concentration and interactions.
→Use in chemical works, galvanizing plants, electroplating plants, composting plants or in
warehouses
or installations where chemical substances (e.g., aromatics, benzene) are stored
or processed must be checked in advance by Conductix-Wampfler
The resistance of plastic parts is critical in contact with oils, greases or various cleaning agents.
Major temperature variations can cause large expansions in the conductor-
rail system, particularly
for long systems. Hanger clamps can break and the conductor-rail system fall down, for example.
The system must be designed and operated in accordance with the prevail
ing ambient con-
ditions as part of the permissible operating conditions!
DANGER!
Risk of fire due to sparking!
Highly flammable dusts, substances or gases in the vicinity of the conductor-
rail can be ignited by
sparks! These substances must not be present in the vicinity of the conductor-rail.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 17 of 94
DANGER!
Risk due to energy storage!
If consumers with energy storage are supplied by the conductor-
rail, these must be disconnected
from the conductor-rail or the energy-storage system must be discharged acco
rding to the manu-
facturer’s specifications before starting work and system checked for the absence of a voltage.
2.9 Conduct in the event of accidents and malfunctions
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
Remove persons from the danger zone.
Initiate first-aid measures
Alert the rescue services
Inform responsible parties at the operating site
Make access available for rescue vehicles.
Measures to take in the event of malfunctions:
Shut down the system and secure it against unauthorized, unintentional, and/or erroneous reactivation
Secure the work area against entry
Consult qualified personnel when analyzing the fault
Check for disconnection from power
Remove the device and replace it with a new device.
Determine the cause of error and repair the device.

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 18 of 94
3Technical specifications
3.1 Electrical
Rated current for the overall system 10–54 A as an overall system with expansion elements; (conductor-
rails: 10–100 A)
Rated current for current
collectors*
Single current collector Pure carbon: max. 16 A
Copper–graphite: max. 35 A
Dual current collector Pure carbon: 2 x 16 A
Copper–graphite: max. 2 x 25 A
Nominal voltage
without protective earth
max. 48 V AC/DC
with protective earth (PE)
max. 500 V AC
Ohmic resistance at 35°C
0.745 Ω/1000 m
Impedance at 14 mm pin spacing
0.748 Ω/1000 m
Number of pins
Any (EMS system holder 2, 4, 6, 8, 10 pin)
Assignment
Protective earth (PE) 4. Pin from above
Conductor-rail cross chapter
25 mm
2
Conductor material
Copper
Protection class
IP 2X contact protected to IEC 60529
*Current-carrying capacity depending on the current-collector type! The current-carrying capacity is defined by the connected cable
and is generally lower (see catalog)! Ambient temperatures and operating modes result in reduced current-carrying capacity (e.g.,
operating at a standstill, operating at elevated temperature).
3.2 Mechanical
Max. travel speed
Uninterrupted linear track 400 m/min
Ambient temperature
–5°C to +55°C
Maximum air humidity at +40°C
50 % RH
Max. operating temperature difference
40 K (in the ambient temperature range)
Altitude above sea level
≤ 2000 m
Installation situation/environment
Horizontal rail alignment/ interior (not vertical)
Direction of travel Forwards and backwards (reversing)
Engagement of the current collector from the bottom or from the side
Pin spacing
14 mm
3.2.1 Lengths
Max. length of the installed conductor-rail
Any, depending on the power feed design
Power rails
max. 4000 mm (standard), 6000 mm and short lengths on request
Min. permissible power rail length
300 mm
Supplementary length per connection point
10 mm

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 19 of 94
3.2.2 Installation orientation
WARNING!
Danger due to increased wear or damage!
→Install the current collector with its central axis exactly on the central axis of the conductor-rail
→The mean distance between the outrigger axis and the contact surface must be precisely complied
with
WARNING!
Loss of contact or increased heating!
Risk due to loss of contact or increased warming if the current collector is operated outside the permis-
sible installation position.
3.2.3 Tolerances
The conductor-rail must be installed within the following tolerances. Conductix-Wampfler does not accept any responsibility for the
conductor-rail's correct functioning if these tolerances are not observed. In such a case, Conductix-Wampfler does not accept any
liability for problems that arise if the conductor-rail system is not functioning correctly.
Conductor-rails
X: ±3 mm; Y: ±1 mm (see Fig. 1)
Current collector*
X: ±10 mm; Y: ±10 mm (X: ± 15 mm, Y: ± 15 mm)
Force with which the current collector contacts the rail
approx. 9 N
*depending on the current-collector type
Fig. 1: Power rail 0815 coordinate system
Y
X
Z
Y
X
Z

Operating Instructions
Single-pole conductor-rail system
SingleFlexLine Program 0815
BAL0815-0002d-US
www.conductix.us translated document page 20 of 94
3.3 Unsuitable environmental conditions
The conductor-rail must not be installed and not be operated under these environmental conditions (see also Chapter 2.5, Chapter
2.8.4 and Chapter 3):
In environments containing chemical substances or gases that can potentially permanently damage the conductor-rail's materials
(corrosion) or drastically impact on the insulation
In ambient air that contains solvent vapors or aromatic compounds
In ambient air that contains flammable or explosive gases or dusts
In dusty environments
Outside closed rooms
In environments with relative humidity of more than 85%
In close proximity to splashing water
In environments that require a higher protection class than IP 2X
WARNING!
Faults due to incorrect operating conditions!
If the operating conditions change or are no longer within the specified range, the conductor-rails
can malfunction due to short circuits, premature aging and damage to electrical and mechanical
components.
→The conductor-rail must be switched off if the operating conditions are no longer within the permis-
sible range described above.
→The conductor-rail must be switched off if it gets wet or is dirty. Cleaning or drying as prescribed
→Take the relevant measures to restore suitable operating conditions.