Conductix-Wampfler BridgeGuard Plus User manual

BRIDGEGUARD PLUSTM MANUALXA-579411.3 - 08.24.22
www.conductix.us BridgeGuard PlusTM
Installation, Operation & Maintenance
Manual

BRIDGEGUARD PLUSTM MANUAL
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The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE
DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS MANUAL. Conductix Inc. makes no warranty (and assumes
no liability) as to function of equipment or operation of systems built according to customer design or of the ability of any of its products to
interface, operate or function with any portions of customer systems not provided by Conductix Inc.
Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered
and reported to Seller within one year after shipment of such goods to Buyer.
Except where the nature of the defect is such that it is appropriate, in Seller’s judgment, to eect repairs on site, Seller’s obligation
hereunder to remedy defects shall be limited to repairing or replacing (at Seller’s option) FOB point of original shipment by Seller, any part
returned to Seller at the risk and cost of Buyer. Defective parts replaced by Seller shall become the property of Seller.
Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended
by Seller and altered only as authorized by Seller. Seller is not responsible for defects which arise from improper installation, neglect, or
improper use or from normal wear and tear.
Additionally, Seller’s obligation shall be limited by the manufacturer’s warranty (and is not further warranted by Seller) for all parts procured
from others according to published data, specifications or performance information not designed by or for Seller.
Seller further agrees to replace or at Seller’s option to provide a refund of the sales price of any goods that do not conform to applicable
specifications or which dier from that agreed to be supplied which non-conformity is discovered and forthwith reported to Seller within
thirty (30) days after shipment to the Buyer. Seller’s obligation to replace or refund the purchase price for non-conforming goods shall
arise once Buyer returns such goods FOB point of original shipment by Seller at the risk and cost of Buyer. Goods replaced by Seller shall
become the property of Seller.
There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title and freedom
from encumbrances and, except as herein expressly stated and particularly, and without limiting the foregoing, there is no guarantee or
warranty, express or implied, of merchantability or of fitness for any particular purpose or against claim of infringement or the like.
Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyer’s design or of the
ability of any goods to interface, operate or function with any portions of Buyer’s system not provided by Seller.
Seller’s liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of,
connected with, or resulting from the manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in
no case exceed the price paid for the product or services or any part thereof which give rise to the claim. In no event shall Seller be liable
for consequential, special, incidental or other damages, nor shall Seller be liable in respect of personal injury or damage to property not
the subject matter hereof unless attributable to gross misconduct of Seller, which shall mean an act or omission by Seller demonstrating
reckless disregard of the foreseeable consequences thereof.
Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities
and design functions or under abnormal conditions. Seller assumes no liability for loss of time, damage or injuries to property or persons
resulting from the use of Seller’s products. Buyer shall hold Seller harmless from all liability, claims, suits and expenses in connection
with loss or damage resulting from operation of products or utilization of services, respectively, of Seller and shall defend any suit or action
which might arise there from in Buyer’s name - provided that Seller shall have the right to elect to defend any such suit or action for the
account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.
CONDUCTIX INCORPORATED

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CONDUCTIX-WAMPFLER FIELD SERVICE
Need Field Service for our products? We Can Handle It!
Ask us for a quote on expert system installations,inspections, preventative maintenance, and repairs/retrofits.
As the world’s largest single source manufacturer of mobile electrification products, Conductix-Wampfler has the unique ability to oer a
degree of service not found anywhere else. Conductix-Wampfler’s team of highly qualified service technicians and engineers have years of
experience servicing our complete line of products.
We can provide:
• Annual Service contracts
• Installation
• Commissioning
• Installation supervision to ensure your installers avoid common mistakes.
• Troubleshooting to get you up and running.
• Pre-planned inspections to complement your preventive maintenance program.
Call 1-800-521-4888 for further details.

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TABLE OF CONTENTS
SECTION 1 - SAFETY 5
1.0 Safety Information Responsibility 5
1.1 Safety Messages 5
1.2 Limitation of Liability 5
1.3 Personnel Requirements-Qualifications 6
1.4 Personnel Requirements-Unauthorized Personnel 6
1.5 Personnel Requirements - Training 7
1.6 Personnel Protective Equipment 7
SECTION 2 - PRODUCT DISPOSAL 8
2.0 Product Disposal & Recycling 8
SECTION 3 - OVERVIEW 9-11
3.0 General Product Overview 9
3.1 Specifications 9
3.2 Structure 10
3.3 Status Indicator Lights 10
3.4 Function 11
SECTION 4 - INSTALLATION 12-16
4.0 Reflector Mounting 12
4.1 Sensor Mounting 13
4.2 Sensor Targeting 14
4.3 Controller 15
4.4 Electrical Installation 15
4.5 Sensor Calibration 16
SECTION 5 - MAINTENANCE 17
5.0 Mechanical Maintenance 17
5.1 Electrical Maintenance 17
SECTION 6 - TROUBLESHOOTING 18
NOTES 19

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SECTION 1 - SAFETY
1.0 Safety Information Responsibility
1.0.1 All owner, operator, and maintenance personnel must read and understand all manuals associated with this product before
installation, operation, or maintenance.
1.0.2 The manual provides information on the recommended installation, operation, and maintenance of this product. Failure to read and
follow the information provided could cause harm to yourself or others and/or cause product damage. No one should install, operate,
or attempt maintenance of this product prior to familiarizing themselves with the information in this manual.
1.1 Safety Messages
The following safety messages are used in this manual to alert you to specific and important safety related information.
CAUTION
CAUTION indicates unsafe actions or situations that have the potential to cause injury, and/or minor equipment or property damage.
DANGER
DANGER indicates hazards that have the potential to cause severe personal injury or death.
WARNING
WARNING indicates unsafe actions or situations that have the potential to cause severe injury, death, and/or major equipment or property
damage.
NOTE
NOTE is used to alert you to installation, operation, programming, or maintenance information that is important, but not hazard related.
1.2 Limitation of Liability
1.2.1 All data and information in this mounting instructions have been compiled in compliance with the applicable standards and
regulations, best practice and our many years of experience and knowledge.
1.2.2 The manufacturer accepts no liability for damages resulting from:
• Failure to comply with this document
• Improper use
• Use by untrained personnel
• Unauthorized modifications
• Technical changes
• Use of unauthorized replacement parts and accessories
• The actual scope of delivery may dier 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.
1.2.3 The obligations agreed upon in the delivery agreement and our 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.
1.2.4 All products are subject to technical modifications in the context of improvement of function and further development.

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SECTION 1 - SAFETY
1.3. Personnel Requirements-Qualifications
WARNING
Inadequately trained persons are at risk of injury!
Improper use can result in serious personal injury or material damage. All activities must only be performed by qualified personnel.
1.3.1 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.
1.3.2 When selecting personnel, follow all age- and occupation-specific guidelines applicable at the location of use.
1.3.3 The following qualifications are specified in the operating instructions for certain fields of activity.
1.3.4 Trained personnel and operators
• Will have participated in a training session, given by the owner, on the tasks assigned to them and the potential hazards in case
of improper conduct.
• The owner of the machine or system must document that the appropriate training has taken place.
1.3.5 Specialist personnel
• Will consist 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 knowledge of the applicable regulations. Persons are
deemed to be technically qualified if they have successfully completed training as a master electrician, apprentice electrician,
electrical engineer or electrical technician. Persons are also considered technically qualified if they have been employed in an
appropriate capacity for several years, receiving theoretical and practical training in that line, and their knowledge and skills have
been tested by a specialist in the appropriate field of training.
• The machine or system owner must document that the appropriate certificates or other proofs of qualification have been or are
being provided.
1.4 Personnel Requirements-Unauthorized Personnel
WARNING
Danger due to unauthorized personnel!
Unauthorized persons who do not meet the requirements described here are not acquainted with the dangers in the working area. Keep
unauthorized personnel away from the working area. In case of doubt, address the person and direct them away from the working area.
Stop working, as long as unauthorized persons are in the working area.

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SECTION 1 - SAFETY
1.5 Personnel Requirements-Training
1.5.1 Before commissioning the equipment, personnel must be trained by the owner. Log the implementation of training for better
traceability.
Example of a training log:
Date Name Training Type Training Instructor Signature
11/5/2019 John Doe First safety training for personnel Dave Miller
1.6 Personal Protective Equipment
1.6.1 For every task, always use:
Safety helmet: 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 work 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 failing parts and slipping on slippery floors.
For special tasks, specific protective equipment is required when executing particular tasks:
Safety eye wear: For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather eects.
Hearing protection: For protection against loud noises and to prevent acoustic trauma.
Breathing mask (FFP-3 - according to country-specific requirements): For protection against materials, particles, and organisms. In
this case, for protection against the dust produced by the abrasion of carbon brushes and the PVC insulation of the conductor rail.

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SECTION 2 - PRODUCT DISPOSAL
2.0 Product Disposal and Recycling
2.0.1 Once the product has reached it’s end of life it must be disassembled and disposed of in accordance with local and regional
environmental requirements.
2.0.2 In the absence of a return and disposal agreement, disassembled components must be recycled as follows:
• All metallic parts must be sorted and recycled by material type
• All plastic components must be sorted and recycled by material type
• All other components are to be disposed of in accordance with their material composition. Take care with items identified as
Substances of Concern.
2.0.3 Local authorities or special disposal companies can provide information about environmentally appropriate disposal.

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SECTION 3 - OVERVIEW
3.0 General Product Overview
3.0.1 BridgeGuard Plus prevents crane to crane or crane to structure collision during operation, either from human error or from system
malfunction.
3.1 Specifications
• 3-115 foot range
• High Definition Distance Measurement Technology
• Precise time-of-flight measurement
• Visible Laser Red Light
• IP 67 rated for indoor and outdoor use
• 100-240 V AC voltage supply
• Switching Output: Relay
• Relay output max voltage: 240 V AC
• Rated Max Current: 6 A
• Laser Class 1
• Compliant with IEC 60068-2-6:2007
• Each system includes sensor equipped with bracket and 32 ft of cable, and a 12” x 12” reflector
• Optional control panel enclosure for mounting outside and existing control panel.

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SECTION 3 - OVERVIEW
3.2 Structure
CAUTION
• The original equipment manufacturer must assure that the system is properly configured. Safety is ultimately the
responsibility of the user.
3.2.1 Overall features of BridgeGuard Plus can be seen below. See Figure 3-1.
Figure 3-1 1. Optical Axis, Sender 5. LEDs, Teach-In
2. Optical Axis, Receiver 6. LEDs, Status Q1/Q2
3. Zero Level 7. LED, Status Indicator
4. Mounting Hole M4 8. Control Elements
3.3 Status Indicator Lights
3.3.1 The sensor box for BridgeGuard Plus features status indicator LEDs that provide information on the supply voltage activity, signal
strength, and output activity. See Table 3-1.
Status Color Description
Indicator LED 1 Green Operating voltage indicator
Indicator LED 1 Yellow Switching output indicator
Indicator LED 2 Yellow Switching output indicator
Table 3-1
1
2
6 7
4
3
4
5
6
7
8
Q1 Q2 run
Q1 near
Q1 far
Q2 near
Q2 far
slow
ObSB
ObSB
fast
select set

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3.4.3 Window (Wnd) program
1. Push and hold SELECT button for 3-4 seconds to enter TEACH MODE. The top LED (Q1 NEAR) will light up.
2. Place the object and the minimum detection distance to the sensor. Press SET and the distance between the object and the
sensor is saved as a switch point. The LEDs for Q1 and Q2 will flash in sync twice. When the minimum detection distance is
reached, the relay goes from a “1” state (active, green light) to a “0” state (inactive, red light) to a “1” state (active, green light)
and triggers the SLOW feature.
3. Push the SELECT button to switch to Q2 FAR. Place the object at the maximum detection distance to the sensor. Press SET
and distance between the object and the sensor is saved as a switch point. The LEDs for Q1 and Q2 will flash twice. When the
maximum detection distance is reached, the relay goes from a “0” state (inactive, red light) to a “1” state (active, green light) and
triggers the SLOW feature.
4. To close out of the sensor’s function, press and hold SELECT for 5 seconds. Also, not operating the sensor for 5 minutes will
lock-in functions.
3.4.4 Object between Sensor and Background (ObSB) program
1. Remove all objects between the sensor and the background.
2. Push and hold SELECT button for 3-4 seconds to enter TEACH MODE. The top LED (Q1 NEAR) will light up.
3. Push the SELECT button two more times so the Q1 NEAR and Q1 FAR LEDs are both lit.
4. Push the SET button. The Q1 and Q2 LEDs will flash twice, then the Q2 LED stays lit. This means the background is set. When
an object is placed in the path of the sensor, the relay goes from a “0” state (inactive, red light) to a “1” state (active, green light).
When the object is removed from the path of the sensor, relay goes from a “1” state (active, green light) to a “0” (inactive, red
light).
5. To close out of the sensors function, press and hold SELECT for 5 seconds. Also, not operating the sensor for 5 minutes will lock
in functions.
SECTION 3 - OVERVIEW
3.4 Function
3.4.1 Q1 and Q2 are used as switching outputs, the following modes are available.
• Window (Wnd)
• Object between Sensor and Background (ObSB)
3.4.2 To Unlock Sensor
1. Push and hold the Select button for 3-4 seconds to enter TEACH MODE. The top LED (Q1 NEAR) will light up.
2. Press the Select button. This will cycle through the Q1 and Q2 relays.
3. To set up the sensor speed cycle to SLOW. There are 5 speeds, and the LED will blink 1-5 times according to the selected speed.
Push the SET button until the proper speed setting is achieved.
4. To close out of the sensors function, press and hold SELECT for 5 seconds. Also, not operating the sensor for 5 minutes will lock
in functions.

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SECTION 4 - INSTALLATION
4.0. Reflector Mounting
NOTE:
• Reflector plate come with 6 pre-drilled holes for mounting See Figure 4-1
• A minimum of 4 fasteners should be used to mount reflector to I-Beam web
4.0.1 Mount reflector to the I-Beam using appropriate hardware. See Figure 4-1
NOTE:
• A spacer must be used between the I-Beam’s web and the reflector back plates.
• A lock washer much be used to prevent loosening.
• The plate can be mounted to other surfaces using the same holes, the beam is only an example.
Figure 4-1
Reflector
5.00
(127)
5.00
(127)
5.00
(127)
6x [ .27
13.00 (330)
Reflector
I-Beam for
Reference

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SECTION 4 - INSTALLATION
4.1 Sensor Mounting
1. Mount sensor in desired location and make adjustments
appropriate to your specific assembly. See Figure 7-2.
WARNING
• Maximum sensor trigger distance should be no more
than 115 feet.
NOTE:
• The sensor can be mounted to the flange of the beam or
other alternative surfaces.
Figure 4-2
4
56
3
1
2
Figure 4-3 Number Description Quantity
6 Washer 8 Screw LK SST 2
5 Washer 8 Flat SST 2
4 Sensor 1
3 Screw 8-32 x 1-1/4 SST PHP 2
2 Nut Hex 8-32 Narrow SST 2
1 Bracket Assembly 1

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SECTION 4 - INSTALLATION
4.2 Sensor Targeting
4.2.1 Included below is a general sensor target installation, your specific installation may vary. See Figure 4-4
Figure 4-4
End of Runway
End of Runway
Reflector
Crane 2
Crane 1
Sensor

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SECTION 4 - INSTALLATION
4.3 Controller
4.3.1 Below is the controller wiring diagram for reference if experiencing issues. See Figure 4-5
NOTE:
• All dashed lines represent wiring that is field installed.
Figure 4-5
4.4 Electrical Installation
4.4.1 Sensor Cable Wiring
4.4.1.1 Use the Sensor Cable Wiring Table for sensor cable installation. See Table 4-1.
Terminal Wire Color Description
4 Brown +24VDC
5-7 Blue -24VDC
8 Black Q1 PNP Out
9 White Q2 PNP Out
10 Gray Teach Input
Table 4-1
L (120V) - BLACK, 18AWG, 6"
N (120V) - WHITE, 18 AWG, 6"
PE - GREEN, 18AWG, 6"
24V - BLACK, 18 AWG, 6",4",4"
24V + RED,
18AWG, 6"
Q2 SIGNAL (SLOW) BLUE, 18 AWG, 4"
Q1 SIGNAL (STOP) BLUE, 18 AWG, 4"
LINE (120)
NEUTRAL (120)
PE
24V + TO SENSOR
24V - TO SENSOR
Q1 SIGNAL FROM SENSOR
Q2 SIGNAL FROM SENSOR
ANALOG SIGNAL FROM SENSOR-PRO
NOT USED-PLUS
N.C. RELAY
RELAY COMMON
RELAY COMMON
N.C. RELAY
ANALOG SIGNAL TO
CONTROL DEVICE-PRO
NOT USED-PLUS
12345 6 7 8 9 10
Q1 Q2

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SECTION 4 - INSTALLATION
4.5 Sensor Calibration
4.5.1 STOP and SLOWDOWN Distance Detection Settings
4.5.1.1 Make sure that the sensor and the reflector are properly mounted and make sure the visible laser light can be seen on the
reflector before setting range detection.
4.5.1.2 Setting the range detection distances will require movement of the crane to the desired STOP and SLOWDOWN distances.
4.5.2 Setting up STOP distance detection
1. With the sensor mounted to the crane, move crane to the STOP distance point.
2. Press and hold (it will take approximately 5 seconds) the “SELECT” pushbutton until “Q1 Near” LED turns ON.
3. Press “SET” pushbutton; “Q1” and “Q2” LEDs should flash twice simultaneously indicating that the setup was successful. If “Q1”
and “Q2” LED’s do NOT flash, repeat this step.
4. Press and hold “SELECT” pushbutton for at least 6 seconds to exit setting up STOP distance setup mode. “Q1” and “RUN” LEDs
should stay on with the crane at the STOP distance.
4.5.3 Setting up SLOWDOWN distance detection
1. With the sensor mounted to the crane, move crane to the SLOWDOWN distance point.
2. Press and hold (it will take approximately 5 seconds) the “SELECT” pushbutton until “Q1 Near” LED turns ON.
3. Press select until “Q2 Near” LED light turns ON (Hint: press “SELECT” 3 times).
4. Press “SET” pushbutton “Q1” and “Q2” LEDs should flash twice simultaneously indicating that the setup was successful. If “Q1”
and “Q2” LED’s do NOT flash, repeat this step.
5. Press and hold the “SELECT” pushbutton for at least 6 seconds to exit setting up SLOWDOWN distance setup mode. “Q2” and
“RUN” LEDs should stay on with the crane at the SLOWDOWN distance.
6. Move the crane back and forth a couple of times to verify relays are triggering at the correct distances.
Figure 4-6 1. Q1 Indicator Light 6. Q2 near Indicator Light 11. Q1 Indicator Light
2. Q2 Indicator Light 7. Q2 far Indicator Light 12. Q2 Indicator Light
3. Run Indicator Light 8. Slow Indicator Light 13. Run light/Satus Indicator Light
4. Q1 near Indicator Light 9. Select Push Button
5. Q1 far Indicator Light 10. Set Push Button
11
2
10
7
12
3
4
5
6
9
8
Q1 Q2 run
Q1 near
Q1 far
Q2 near
Q2 far
slow
ObSB
ObSB
fast
select set
13
1

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SECTION 5 - MAINTENANCE
5.0 Mechanical Maintenance
5.0.1 Reflector
• Ensure the reflector is clean and clear of dirt and debris at all times.
5.0.2 Sensor
• Ensure the sensor is clean and clear of dirt and debris at all times.
• Ensure sensor target path is clear of obstructions.
5.1 Electrical Maintenance
WARNING
• Equipment damage due to improper cleaning!
• Never use cleaning agents containing aggressive substance
• Never use pointed objects for cleaning
Interval Maintenance Work To be Performed by
Cleaning interval depends on ambient
conditions and climate
Clean housing Specialist
Every 3 months depending on the
application conditions with regard to shock
and vibration
Check the screw connection and plug
connections
Specialist
Table 5-1
NOTE:
• Compressed air should be used to clean

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SECTION 6 - TROUBLESHOOTING
6.0 Potential issues and solutions are shown below. Contact the factory for additional support. See Table 14-1.
Issue Potential Cause Solution
Loss of signals Electrical Connections Inspect the electrical connections to the
sensors and to the control box.
Unable to read output signals Electric Connection Inspect the connection to terminal blocks in
control box and to the sensor.
Laser is not on reflector plate Realign sensor and reflector plate
Sensor not working even when plugged in Sensor-target misalignment Check to see if sensor is working by holding
the reflector close to the sensor.
Sensor-target misalignment If the sensor is working check sensor-target
alignment and make adjustments.
Table 6-1

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NOTES

BRIDGEGUARD PLUSTM MANUAL XA-579411.3 - 08.24.22
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