Conductix-Wampfler 0813 Series User manual

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 1 of 108
Order Number:
0813xx-...

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 2 of 108
Contents
1General Information ....................................................................................................................................................................5
1.1 About this document....................................................................................................................................................5
1.2 Limitation of liability .....................................................................................................................................................5
1.3 Copyright .....................................................................................................................................................................6
1.4 Replacement 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 persons .................................................................................................................................................9
2.2.3 Training........................................................................................................................................................................9
2.3 Personal protective equipment ....................................................................................................................................9
2.4 Intended use..............................................................................................................................................................10
2.5 Unintended use .........................................................................................................................................................11
2.6 Protective measures by the operator/user.................................................................................................................12
2.7 5 Safety Rules for working on electrical systems ......................................................................................................12
2.8 Special 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 Dangers related to the operational environment .......................................................................................................16
2.9 Conduct in the event of accidents and malfunctions .................................................................................................17
3Technical Data ..........................................................................................................................................................................18
3.1 Installation orientation................................................................................................................................................20
3.2 Tolerances.................................................................................................................................................................20
3.3 Unsuitable ambient conditions...................................................................................................................................21
4Product Description and Functional Principles .........................................................................................................................22
4.1 Brief description.........................................................................................................................................................22
4.2 Interfaces...................................................................................................................................................................25
4.3 Description of the components ..................................................................................................................................26
4.4 Accessories ...............................................................................................................................................................33

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 3 of 108
5Transport, Packaging and Storage ...........................................................................................................................................38
5.1 Safety ........................................................................................................................................................................38
5.2 Transport ...................................................................................................................................................................39
5.3 Packaging..................................................................................................................................................................39
5.4 Storage of packaged parts ........................................................................................................................................40
6Installation.................................................................................................................................................................................41
6.1 Safety ........................................................................................................................................................................41
6.2 Provide additional protection against contact at the conductor rail end. ...................................................................44
6.3 System arrangement .................................................................................................................................................45
6.4 Installation of mechanical components......................................................................................................................46
6.4.1 Required tools ...........................................................................................................................................................46
6.4.2 Trim conductor rail.....................................................................................................................................................46
6.4.3 Install conductor rail system ......................................................................................................................................49
6.4.3.1 50
6.4.3.2 Mount hanger clamps ................................................................................................................................................50
6.4.3.3 Mount conductor rail ..................................................................................................................................................54
6.4.3.4 Connect rails..............................................................................................................................................................57
6.4.3.5 Line feed....................................................................................................................................................................60
6.4.3.6 Mount anchor clamp ..................................................................................................................................................63
6.4.3.7 Mount heating wire (optional) ....................................................................................................................................65
6.4.3.8 Mount expansion unit ................................................................................................................................................67
6.4.3.9 Mount air gap.............................................................................................................................................................69
6.4.3.10 Mount end caps .........................................................................................................................................................72
6.4.3.11 Mount pickup guide ...................................................................................................................................................75
6.4.4 Mount current collector ..............................................................................................................................................78
6.4.4.1 Current collector insertion from the side....................................................................................................................82
6.4.4.2 Typical mounting errors.............................................................................................................................................82
6.5 Electrical installation ..................................................................................................................................................83
6.5.1 Conductor Rail...........................................................................................................................................................83
6.5.2 Current Collector .......................................................................................................................................................83
6.6 Further Documents....................................................................................................................................................83
7Commissioning .........................................................................................................................................................................84
7.1 Safety ........................................................................................................................................................................84
7.2 Testing and initial commissioning..............................................................................................................................86
7.2.1 Test list ......................................................................................................................................................................86
7.2.2 Initial commissioning of the conductor rail system ....................................................................................................88
8Operation ..................................................................................................................................................................................89

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 4 of 108
8.1 Safety ........................................................................................................................................................................89
8.2 Normal operation .......................................................................................................................................................90
8.3 Stopping the system ..................................................................................................................................................90
8.4 Continue operation ....................................................................................................................................................91
9Maintenance and Service .........................................................................................................................................................92
9.1 Safety ........................................................................................................................................................................92
9.2 Tools and materials ...................................................................................................................................................95
9.3 Maintenance plan ......................................................................................................................................................96
10 Troubleshooting ........................................................................................................................................................................97
10.1 Safety ........................................................................................................................................................................97
10.2 Fault correction table ...............................................................................................................................................100
11 Disassembly and Disposal ......................................................................................................................................................102
11.1 Safety ......................................................................................................................................................................102
11.2 Disassembly ............................................................................................................................................................105
11.3 Disposal...................................................................................................................................................................105
12 Further Documents .................................................................................................................................................................106
12.1 Applicable documents .............................................................................................................................................106
12.2 Air gap diagram .......................................................................................................................................................107
13 Index .......................................................................................................................................................................................108

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 5 of 108
1General Information
1.1 About this document
The information provided in this document is designed to enable the Conductor Rail System 0813 to be used safely and efficiently.
This document is a component of the Conductor Rail System 0813 and must be kept accessible to personnel and in close proximity
to the Conductor Rail System 0813 at all times. Personnel must read this document carefully and understand it before starting any
work. Compliance with all safety and handling instructions provided in this document is a basic requirement for safe working.
Local accident protection regulations and general safety guidelines for the area of use of the conductor rail system also apply.
The illustrations in this document are provided for basic understanding and may deviate from the actual implementation of the
product.
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 accepts no liability for damage resulting from:
◼Failure to comply with operating instructions
◼Unintended use
◼Use by untrained personnel
◼Unauthorized modifications
◼Technical changes
◼Use of unauthorized replacement parts or accessories
The actual scope of delivery may differ from the explanations and descriptions provided here if the model in question is a special
one, additional equipment has been ordered or due to recent technical changes.
The obligations agreed upon in the General Terms and Conditions of Business apply, as do the Delivery Conditions of the
manufacturer and the legal regulations applicable at the time the contract was concluded.
All products are subject to technical modifications within the context of improvement of function and further development.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 6 of 108
1.3 Copyright
This document is protected by 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. Our right to further claims remains unaffected.
1.4 Replacement parts
WARNING!
Incorrect replacement parts are a safety hazard!
Incorrect or faulty replacement parts can impair safety and result in damage, malfunctions or
complete failure.
→Always use original replacement parts from the manufacturer!
Order replacement parts from your contracted dealer or directly from the manufacturer.
Contact information: See the last page of this document.
Replacement parts list: See Section 12.1 Applicable documents.
1.5 Material defects
The terms governing material defects can be found in the General Terms and Conditions of Business.
1.6 Technical support
Our Customer Support staff is available for technical support.
We are also always interested in new information, experiences and feedback from the field that can help us improve our products.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 7 of 108
2Safety Instructions
2.1 Explanation of symbols
Safety and hazard information is identified in these operating instructions using symbols. Safety instructions are introduced by signal
words that indicate the degree 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 moderate or
minor injury.
Tips and recommendations:
... refers to useful tips and recommendations as well as information for efficient and trouble-free
operation.
NOTE!
… indicates actions that will help you prevent material damage.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 8 of 108
2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Inadequately trained persons are at risk of injury!
Unintended use can result in serious injury to persons and property.
→All activities must only be performed by qualified personnel.
◼Only persons who can be expected to perform their work reliably are acceptable personnel. People whose reactions are impaired
by drugs, alcohol or medications, for example, are not authorized.
◼When selecting personnel, all age- and occupation-specific regulations applicable at the place of use must be observed.
The following qualifications are specified in the operating instructions for certain fields of activity.
◼Specialist personnel
Consists of persons capable of performing assigned tasks and independently identifying and avoiding potential hazards based
on their specialist training, knowledge and experience as well as their understanding of the applicable regulations.
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 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
qualification, is available or had been submitted previously.
The installation, maintenance and commissioning of electrical equipment may only be conducted by qualified personnel
(electricians) according to local regulations. Work with higher installation positions typically 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
accompaniment of the installation by specialist fitters/supervisors be scheduled.
◼Users
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.
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 according to safety regulations.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 9 of 108
2.2.2 Unauthorized persons
WARNING!
Danger due to unauthorized persons!
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 such persons and direct them away from the working area.
→Stop working as long as unauthorized personnel are in the working area.
2.2.3 Training
Before commissioning the equipment, personnel must be trained by the operator. Log the implementation of training for better
traceability.
Example of instruction log:
Date
Name
Type of Training
Training given by
Signature
11/05/2009
John Doe
First safety training for
personnel
Horst Müller
2.3 Personal protective equipment
Always to be
worn
Depending on local conditions and regulations, the personal protective equipment includes the
following elements:
Protective headgear
For protection against falling or flying parts and materials.
Protective gloves
For the protection of hands against friction, scrapes, puncture or deeper wounds, as well as against
contact with hot surfaces.
Protective clothing
Primarily for protection against entrapment by moving machine parts. Work clothing must be close fitting
with a low resistance to tearing; it must have close-fitting sleeves and no protruding parts.
Protective footwear
For protection against heavy falling parts and slipping on slippery floors.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 10 of 108
To be worn for
special tasks
When carrying out special work, special protective equipment is recommended. Separate
reference to this is made in the individual sections.
Protective eyewear
For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather
effects.
Hearing protection
For protection against loud noises and to prevent acoustic trauma.
Breathing mask (FFP3 —according to country-specific requirements)
For protection against materials, particles and organisms. In this case, for protection against the dust
produced by the sliding contacts and the insulation of the conductor rail.
2.4 Intended use
The product is designed and built exclusively for the usage described here (intended use).
WARNING!
Hazard due to unintended use!
Any application that deviates from or goes beyond the intended use of the product can result in
hazardous situations.
→Strictly follow all information in these operating instructions.
→Refrain from unintended use of the system.
→Respect the instructions on unintended use in Section 2.5.
Claims of any kind due to damages from unintended use are excluded.
The operator bears sole liability for all damage that results from unintended use.
Intended use
The SinglePowerLine 0813 Conductor Rail System is an operating resource for the customer to set up an electrical power supply
system indoors and in protected outdoor areas, in areas that are not accessible to the public. The conductor rail is an operating
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 SinglePowerLine 0813 Conductor Rail System is used to supply electricity to mobile electrical consumers.
A typical use is, for example, in the area of bridge and process cranes.
Use other than in the application approved by the manufacturer must be examined 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
examination of the use case and ambient conditions.
Compliance with these technical conditions is mandatory for the installation:
◼The maximum travel speed is up to 600 m/min depending on the system (straight line without interruption).

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 11 of 108
◼The conductor rail should preferably be installed horizontally with current collector insertion from below. With indoor areas, it is
also possible to insert the current collector from the side (use current collector for lateral insertion).
Electrical engineering operating requirements
◼The electrical system must be secured in compliance with the locally applicable regulations.
2.5 Unintended 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 results from unintended use.
Unintended use particularly includes the following forms of use:
◼Operation in unsuitable environmental conditions (see Section 3.3). The conductor rail system may only be operated under the
environmental conditions described in the Section 3 .
◼Operation 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.
◼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 are not approved and not authorized by the manufacturer.
◼Use of the system by untrained personnel.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 12 of 108
2.6 Protective measures by the operator/user
The product is used in the industrial sector. The operator of the conductor rail system is therefore subject to the legal obligations
concerning workplace safety. In addition to the safety instructions in these operating instructions, all safety, accident protection and
environmental regulations applicable to the use of the conductor rail system must also be observed. This particularly applies to the
following:
◼Work on electrical components of the system may only be conducted when in a de-energized state.
◼The manufacturer/system engineer who installs the electrical equipment from Conductix-Wampfler must inform their self about
the applicable occupational safety regulations and determine additional hazards in a risk assessment that result from the
special working conditions at the place of use of the product. They must implement these in the form of operating instructions
for the operation of the conductor rail system.
◼During the entire time the conductor rail system is in use, the operator must check that these operating instructions still
correspond to the current state of regulations and adapt them 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 conductor rail system have read and understood these
operating instructions. In addition, 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
personnel may have access to the keys. The keys may only be issued to technical personnel as described in Section 2.2.1.
The operator is furthermore responsible for ensuring that the product is always in perfect working order. The following therefore
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 conducted once a year, but at least as often as required under the applicable national regulations.
◼If the conductor rail system or the system has been modified, the safety systems must be inspected again and adapted to the
changed conditions in such a way that the conductor rail system or the system is safe again.
2.7 5 Safety Rules for working on electrical systems
De-energize the entire system and secure against unintentional switching on!
Work on electrical systems must only be conducted when they are in a de-energized state. The 5 Safety
Rules (see DIN VDE 0150-100:2009-10/EN 50110-1:2004-11).
Observe before starting the work:
◼Disconnect the system from power using the main switch.
◼Secure the main switch against being turned back on.
◼Verify the absence of a voltage through measuring.
◼Ground and short-circuit parts of the system on which work will be done.
◼Cover or block off neighboring parts that are still energized.
→Only electricians or personnel trained in electrical work may disconnect power or approve reconnection of power after the
work is conducted in the disconnected state!

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 13 of 108
2.8 Special hazards
The following section lists residual risks 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
dangerous situations.
2.8.1 Electrical hazards and sources of danger
DANGER!
Risk of death due to electrical shock!
Contact with energized components can lead to death or severe injury due to electrical shock.
There is also a risk of injury due 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 under voltage: Line feed, cables, connections, conductor rail, connectors, current
collectors, products and connections within switching cabinets, control systems, etc.
◼Parts that have come under voltage due to a fault
Before working on the parts listed above:
→Disconnect the conductor rail system from the power supply and secure it against
switching on again according to the 5 safety rules (see Section 2.7)
During work:
→Use insulated tools
Before switching on:
→Every time before the product or system is started, test the insulation resistance according to
locally applicable technical standards, directives and legal regulations.
→Conduct locally required electrical tests
Maintain electrical safety:
→Regularly test and maintain electrical equipment.
→If dangerous defects are identified, immediately take measures to correct the defects. Inform
the system operator immediately
→If it is not possible to correct the dangerous defect, block off/secure the area involved or turn
the operating resource off and secure it against switching on again. Inform the system
operator immediately!
→Immediately secure loose cables and replace damaged cables.
→Always replace blown fuses with fuses of the same rating.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 14 of 108
DANGER!
Fire hazard due to overload or sparking!
Fire hazards occur due to overloaded cables, electrical arcs, short circuits or sparking.
Sparking can occur with poorly serviced, contaminated conductor rails or if the installation does
not comply with the required tolerances.
→Permissible current values must be observed.
→Comply with tolerances during installation.
→Design and dimension systems according to the permissible system load capacity and
provide appropriate protection devices.
→Do not store combustible and/or easily ignited materials near conductor rails.
→Check, service and clean conductor rails regularly and as prescribed. See Section 8 and 9
2.8.2 Mechanical hazards and sources of danger
DANGER!
Risk of injury due to ensnarement or impact!
An ensnarement 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.
→Use caution when working in the vicinity of the danger zone, in particular if protective
devices (covers, enclosures, control devices, etc.) have been removed or deactivated.
→Use caution when working in the vicinity of the danger zone, particularly below the
conductor rail.
→Wear personal protective equipment!
WARNING!
Secure components against falling!
Possible falling components must be determined in the customer analysis as part of the operator's
risk and hazard analysis.
→The operator must take appropriate measures.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 15 of 108
2.8.3 Danger due to dust and vapors
WARNING!
Danger of sensitization, mucous membrane irritation and respiratory disease due to dust!
Abrasion from the sliding contacts collects in the conductor rails and the guideway. This dust is
very fine and is a health hazard. Frequent handling can result in sensitization. Persons who
frequently spend longer periods in a heavily used system without protective equipment must
reckon with the following consequences:
◼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 effective 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 protective equipment when
cleaning the system:
◼Protective eyewear
◼Dust mask Class FFP3 (observe local regulations)
◼Protective gloves
◼Disposable coveralls
→For soiled and dusty conductor rails, clean them as prescribed before starting work. There are
special instructions for this task; see Section 9.
→During cleaning operations, protect the surrounding area, for example by covering or
removing stored materials and blocking off areas in which dust could fall down on persons.
→Do not blow out dust with compressed air, but rather vacuum it away. The vacuum must
be equipped with a Class H fine filter
→Do not eat, drink or smoke during work!
DANGER!
Poisonous gases during fire!
In case of fire in the facility, the plastic parts of the conductor rail system will emit poisonous
gases (HCL).
→The building must be evacuated immediately.
→Notify the fire department.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 16 of 108
2.8.4 Dangers related to the operational environment
The following factors can give rise to hazards if the conductor rail is installed in this operational environment:
◼Dusts
◼Gases
◼Chemical substances
◼Liquids
◼Radiation
◼Major temperature variations
The most important measure to protect against these hazards is to only install the conductor rail system in locations where
appropriate operating conditions prevail (see Section 3.3).
The system must be designed and operated according to the prevailing ambient conditions.
DANGER!
Risk of components being damaged and losing functionality due to environmental
influences!
Environmental influences (gases, substances, liquids, radiation, etc.) can damage the
components, particularly the plastic parts. For example, hanger clamps can break and the
conductor rail system can fall down.
→Check the influencing factors of temperature, exposure time, concentration and
interactions.
→Use in chemical works, galvanizing plants, electroplating plants, composting plants or in
warehouses or installations where chemical substances (e.g., aromatic compounds,
benzene) are stored or processed must be verified in advance by Conductix-Wampfler.
The resistance of plastic parts is critical when 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. For example, hanger clamps can break and the conductor rail system can fall
down.
The system must be designed and operated according to the prevailing ambient conditions
within the framework of the permissible operating conditions!
DANGER!
Fire hazard 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
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 17 of 108
DANGER!
Hazard 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 according to the
manufacturer's specifications before starting work and the system must be checked for the absence
of voltage.
2.9 Conduct in the event of accidents and malfunctions
Measures in the event of accidents:
◼Shut down the system and secure it against unauthorized, unintentional and/or erroneous reactivation.
◼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 to rescue vehicles.
Actions 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 product and replace it with a new product.
◼Determine the cause of the fault and repair the product.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 18 of 108
3Technical Data
System
Insulated conductor rail system for use in supplying energy to crane systems, the
construction of larger slip ring arrangements, transfer carriages, cable tracks or similar
moving consumers mounted in non-publicly accessible areas, out of hands' reach in
indoor areas and weather-protected outdoor areas (IP2x).
Installation orientation
Current collector insertion from below; current collector insertion from the side is also
possible in indoor areas.
Rail length
5000 mm (nominal size at 20° C/tolerance ± 3 mm)
Phase offset
80 mm (standard)/70 mm (reduced with offset current collector arrangement)
Suspension interval
2.5 m/typically 2.4 to 2.5 m
Maximum system length
Unlimited
Travel speed
Maximum 600 m/min (straight line without interruption)
Permitted ambient temperature *
-15°C to +55°C (85°C in heat-resistant version/PPE + SB) [Lower temperatures on
request. At lower temperatures, flexible lines should be used.]
Maximum temperature difference
∆ K 40° C
Maximum conductor temperature
+85°C (115°C for heat-resistant version/PPE + SB, briefly 125°C)
Protection type
With current collector insertion from below: IP23 (DIN EN 60529, VDE 0470-1); with
current collector insertion from the side: IP21
Storage temperature
-30°C to +40°C (store in a dry place dry, avoid condensation)
Minimum installation temperature
-10°C (recommended installation temperature: Above 0°C)
Local approvals
UL/CSA/EAC
Max. Air humidity at +40° C
85% rel. H/non-condensing
Altitude above sea level
≤ 2000 m
Travel direction
Forward and backward (reversing)
* Note: At temperatures below -10°C, the mechanical load must be limited through physically limiting the breaking strength.
Conductor bar material
Aluminum with stainless
steel sliding surface
CopperECO
Copper
Type
081313
081314
081319
08131C
08131D
08131I
081315
081316
081317
Current load [A] at 100% DC
and 35°C (rated value)
at 60% DC
500
510
800
810
1000
1050
500
510
800
810
1000
1050
500
520
800
880
1250
1400
Rated voltage [V]
690 (UL 600 V) - min. 24 V/1 A (minimum load)
Ohmic resistance at
+35°C [Ω/1000 m]
+ 20°C [Ω/1000 m]
0.097
0.092
0.074
0.071
0.051
0.049
0.097
0.092
0.074
0.071
0.051
0.049
0.104
0.097
0.057
0.054
0.033
0.031
Impedance at +20°C [Ω/1000 m]
Impedance at +20°C [Ω/1000 m]
0.157
0.152
0.144
0.140
0.137
0.134
0.157
0.152
0.144
0.140
0.137
0.134
0.161
0.156
0.136
0.134
0.127
0.126

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 19 of 108
NOTE!
Current collector capacity:
The current collector capacity is defined by the connected cable as well as sliding contacts used and is
typically lower (see catalog)! Ambient temperatures and operating modes result in reduced current
collector capacity (e.g., operating at a standstill, operating at elevated temperatures).
Chemical resistance
Insulating material
PVC: Good general chemical resistance
PPE: Average chemical resistance, critical when in direct contact with oils, not suitable
for outdoor use in direct sunlight.
Installation material
PC, PA, PBT: Good general chemical resistance, partly limited
Conductor bar material
Aluminum with stainless steel sliding surface
CopperECO
Copper
Information regarding resistances are general notes and depend on the temperature, exposure time, concentration and interactions and must be
verified in individual cases. Before usage in critical environmental conditions such as chemical operations, galvanizing plants, compost works and
warehouses and locations with high concentrations of aromatic compounds, benzene and other substances from these material groups, we ask
that you please contact us for the purpose of alternative installation positions and materials and possibly necessary additional components.
Insulating profile
Material
Stabilized rigid PVC (standard material) and PPE + SB (heat-resistant version for indoor
applications)
Flammability
Compliant with requirements for insulating materials according to UL94 V-1; flame-
retardant and self-extinguishing (IEC60695-11-10 ); PPE + SB halogen free
Note: Under certain framework conditions, individual data is only valid to a limited extent.

Operating Instructions
Insulated Conductor Rail System
SinglePowerLine Program 0813
BAL0813-0007-EN
www.conductix.com translated document page 20 of 108
3.1 Installation orientation
WARNING!
Danger due to increased wear or damage!
→Align the current collector with its central axis exactly on the central axis of the conductor rail
→The mean distance between the bracket axis and the contact surface must be precisely complied
with.
WARNING!
Loss of contact or increased heating!
Hazard due to loss of contact or increased heating if the current collector is operated outside the
permissible installation position.
3.2 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: ± 5 mm
Current collector*
X: ± 100 mm; Y: ± 40 mm
Pressure with which the current collector contacts the rail
28 N (with double current collector: 2x28 N)
*Depending on the current collector type
Fig. 1: Conductor bar 0813 coordinate system
X
Z
Y