Conductix-Wampfler SingleFlexLine Program 0815 User manual

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
www.conductix.us translated document page 1 of 128
Order Number:
0815xx
-…

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
www.conductix.us translated document page 2 of 128
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 personnel ..............................................................................................................................................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 to be taken 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 relating to the operating environment .........................................................................................................16
2.9 Conduct in the event of accidents and malfunctions .................................................................................................17
3Technical Data ..........................................................................................................................................................................18
3.1 Electrical ....................................................................................................................................................................18
3.2 Mechanical ................................................................................................................................................................18
3.2.1 Lengths......................................................................................................................................................................19
3.2.2 Installation orientation................................................................................................................................................19

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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3.2.3 Tolerances.................................................................................................................................................................19
3.3 Unsuitable environmental conditions.........................................................................................................................20
4Product Description and Functional Principles .........................................................................................................................21
4.1 Brief description.........................................................................................................................................................21
4.2 Interfaces...................................................................................................................................................................24
4.3 Description of the components..................................................................................................................................25
4.4 Accessories ...............................................................................................................................................................30
4.4.1 Tools and materials ...................................................................................................................................................30
5Transport, Packaging and Storage ...........................................................................................................................................31
5.1 Safety ........................................................................................................................................................................31
5.2 Transport ...................................................................................................................................................................32
5.3 Packaging..................................................................................................................................................................33
5.4 Storage of packaged parts ........................................................................................................................................33
6Installation.................................................................................................................................................................................34
6.1 Safety ........................................................................................................................................................................34
6.2 Provide additional protection against accidental contact at the conductor rail end ...................................................37
6.3 Procedure..................................................................................................................................................................38
6.3.1 Required tools ...........................................................................................................................................................38
6.3.2 Customizing components ..........................................................................................................................................38
6.3.2.1 Trimming conductor rails ...........................................................................................................................................39
6.3.2.2 Making a notch for the PEplus rail ...............................................................................................................................40
6.3.2.3 Making a bend in the conductor rail...........................................................................................................................42
6.3.3 Installing the conductor rail system ...........................................................................................................................45
6.3.3.1 Mounting the hanger clamps .....................................................................................................................................46
6.3.3.2 Mounting the fixed point ............................................................................................................................................49
6.3.3.3 Mounting conductor rail and connectors (on straight routes) ....................................................................................52
6.3.3.4 Mounting conductor rail and connector (in closed slip ring applications) ..................................................................56
6.3.3.5 Expansion unit and expansion module......................................................................................................................61
6.3.3.5.1 Determine the number of expansion modules........................................................................................................ 64
6.3.3.5.2 Mounting the expansion module with a setting aid................................................................................................. 68
6.3.3.5.3 Mounting the expansion module without a setting aid............................................................................................ 76
6.3.3.6 Mounting air gap insulation section ...........................................................................................................................78

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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6.3.3.7 Mounting a section line feed......................................................................................................................................84
6.3.3.8 Mounting end caps and end line feeds......................................................................................................................86
6.3.4 Mounting the current collector ...................................................................................................................................89
6.4 Additional documents ................................................................................................................................................96
7Commissioning .........................................................................................................................................................................97
7.1 Safety ........................................................................................................................................................................97
7.2 Testing and initial commissioning............................................................................................................................100
7.2.1 Inspection list...........................................................................................................................................................100
7.2.2 Initial commissioning of the conductor rail system ..................................................................................................101
8Operation ................................................................................................................................................................................102
8.1 Safety ......................................................................................................................................................................102
8.2 Normal operation.....................................................................................................................................................104
8.3 Stopping the system................................................................................................................................................105
8.4 Continuing operation ...............................................................................................................................................105
8.5 Perform regular maintenance and servicing............................................................................................................105
9Maintenance and Service .......................................................................................................................................................106
9.1 Safety ......................................................................................................................................................................106
9.2 Tools and materials .................................................................................................................................................110
9.3 Maintenance plan ....................................................................................................................................................111
10 Troubleshooting ......................................................................................................................................................................115
10.1 Fault correction table...............................................................................................................................................119
11 Disassembly and Disposal......................................................................................................................................................121
11.1 Safety ......................................................................................................................................................................121
11.2 Disassembly ............................................................................................................................................................124
11.2.1 Disassemble the conductor rails..............................................................................................................................124
11.3 Disposal...................................................................................................................................................................125
12 Further Documents .................................................................................................................................................................126
12.1 Applicable documents .............................................................................................................................................126
13 Index .......................................................................................................................................................................................127

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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1General Information
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 is a component of the Conductor Rail System 0815 and must be kept accessible to personnel and in close proximity
to the Conductor Rail System 0815 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 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 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 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 equipment has been ordered or due to recent technical changes.
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 all 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
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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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 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 details: 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
For technical support please contact our staff from the Customer Support Department.
Contact details: See the last page of this document.
We are also always interested in new information, experiences and feedback from the field that can help us improve our products.

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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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 minor or moder-
ate injury.
Tips and recommendations:
... indicates 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
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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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 guidelines 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 qualifica-
tion, is available or had been submitted previously.
The installation, maintenance and commissioning of electrical equipment may only be conducted by qualified personnel (electri-
cians) according to local regulations. Work with higher installation positions typically requires additional qualifications and certif-
icates 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.
Operators
Have been instructed in a training session by the operator with respect to the tasks assigned to them and the potential dangers
arising from improper actions.
The operator of the machine or facility must document that the corresponding training has taken place.
Transport personnel
Trained persons with appropriate training in transporting goods safely, who transport the material indoors and outdoors accord-
ing to safety regulations.

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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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. Log the implementation of training for better trace-
ability.
Example of 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 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, punctures 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
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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To be worn for spe-
cial tasks
When carrying out special work, special protective equipment is recommended. Separate refer-
ence to this is made in the individual sections.
Protective eyewear
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.
Protective mask Class FFP3 (observe local regulations)
For protection against materials, particles, and organisms. Here: protection against dust from the current
collector head and the PVC insulation of the conductor rail.
2.4 Intended use
The product is exclusively designed and built for the use described here (intended use).
WARNING!
Hazard due to unintended use!
Any application that deviates from or goes beyond the intended use of the devices can re-
sult in hazardous situations.
→Strictly follow all information in these operating instructions.
→Refrain from unintended use of the system! Prohibit any use of the system apart from its
intended use!
→Observe the information 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 SingleFlexLine 0815 Conductor Rail System is an operating resource for customer construction of an electrical power 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 hazard due to 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 examined by the system engineer as part of a risk assess-
ment 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
BAL0815-0002g-US
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Compliance with these technical conditions is mandatory for the installation:
The maximum permissible travel speed of the consumer is up to 600 m/min depending on the system.
The conductor rail must only be installed horizontally.
Electrical engineering operational 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 result from unintended use.
Unintended use particularly includes the following types of use:
Operation in unsuitable/unauthorized environmental conditions (see Section 3.3).
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.
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 specified 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 are not approved and not authorized by the manufacturer.
Operation of the system by untrained personnel.
The conductor rail system must only be operated under the environmental conditions detailed in Section 3! Unsuitable environ-
mental conditions are described in Section 3.3.

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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2.6 Protective measures to be taken 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 distances and inform them of hazards.
The operator must provide personnel with all required protective equipment (work clothes, safety shoes, hearing protection,
protective gloves, protective headgear, 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 in a de-energized state. See
Section 2.2.1.
The operator is furthermore responsible for ensuring that the device is always in perfect working order. The following therefore
applies:
The operator must ensure that the service distances described in these operating instructions are observed.
The operator must have 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 has been modified, the safety systems must be inspected again and adapted to the changed condi-
tions in such a way that the conductor rail system is safe again.
2.7 5 Safety Rules for working on electrical systems
Requirement:
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) must always be observed 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 through measuring.
4. Ground and short-circuit parts of the system on which work will be done.
5. 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
work carried out in the disconnected state!

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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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 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. Continual engagement of both protective conductor connections must be
monitored. For systems with transfers, two current collectors with double heads must be used.
2.8.1 Electrical hazards and sources of danger
WARNING!
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 from a shock reaction, falling or be-
ing 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 are 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 2.5).
During work:
→Use insulated tools
Before switching on:
→Each time before the product 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 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 in-
volved 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
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SingleFlexLine Program 0815
BAL0815-0002g-US
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DANGER!
Fire hazard due to overload or sparking!
Fire hazards occur due to overloaded cables, electrical arcs, short circuits or sparking. Spark-
ing 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 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 Sections 8 and 9.
2.8.2 Mechanical hazards and sources of danger
DANGER!
Risk of injury due to ensnarement or impact!
Ensnarement and/or impact with moving conductor rails (slip ring) or current collectors con-
nected 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, particularly if protective devices
(covers, enclosures, control devices) have been removed or disabled.
→Use caution when working in the vicinity of the danger zone, particularly below the conduc-
tor rail.
→Wear 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, struts, steel bands and wood
splinters that can cause injury to limbs.
→Wear personal protective equipment!
→Cordon off the work area!
→Use caution when working in the vicinity, particularly below the conductor rail!

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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2.8.3 Danger due to dust and vapors
WARNING!
Danger of sensitization, irritation of the mucous membranes and respiratory
diseases due to dust and vapors!
Abrasions from the sliding contact carbon brushes collect in the conductor rails
and the guideway. This dust is very fine and is a health hazard. Frequent han-
dling 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 facilities, take ef-
fective 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.
Protective eyewear
Protective dust mask Class FFP3 (observe local regulations)
Protective gloves
Disposable coveralls
→Before starting work, clean the conductor rail in accordance with regulations.
There are special instructions for this task; see Section 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; vacuum it up instead. The vac-
uum cleaner must be equipped with a Class H fine filter.
→Do not eat, drink or smoke during work!
DANGER!
Poisonous vapors/gases in case of fire!
The standard insulation materials contain PVC. Poisonous vapors/gases (HCL) can be pro-
duced during fires.
→The building must be evacuated immediately.
→Notify the fire department.

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
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2.8.4 Dangers relating to the operating environment
The following factors can give rise to hazards if the conductor rail is installed in this operational environment:
Dusts
Vapors/Gases
Fog
Chemical substances
Moisture
Liquids
Radiation
Temperature
Contaminants
The most important measure to protect against these hazards is to only install the conductor rail system in locations where appro-
priate operating conditions prevail. See Section 2.4.
The system must be designed and operated in accordance with the prevailing ambient conditions.
DANGER!
Risk of materials and components being damaged and losing functionality due to envi-
ronmental influences!
Environmental influences (dust/gases, chemical substances, liquids, radiation, etc.) can dam-
age the materials and components, particularly the plastic parts, which can then pose dangers
(breakage, loss of function). For example, hanger clamps can break and the conductor rail sys-
tem can fall down.
→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 wher
e chemical substances (e.g., aromatics, benzene) are stored
or processed must be checked in advance by Conductix-Wampfler.
The chemical resistance of plastic parts is critical in contact with oils, greases or various clean-
ing agents.
Major temperature vari
ations 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 prevailing 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.

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SingleFlexLine Program 0815
BAL0815-0002g-US
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DANGER!
Risk of injury 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 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 product and replace it with a new product.
Determine the cause of error and repair the product.

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
www.conductix.us translated document page 18 of 128
3Technical Data
3.1 Electrical
Rated current for the overall system 10–54 A as an overall system with expansion units; (conductor rails:
10–100 A)
Rated current for current
collectors*
Single current collector Pure carbon: max. 16 A
Copper–graphite: max. 35 A
Double current collector Pure carbon: 2 x 16 A
Copper–graphite: max. 2 x 25 A
Rated 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 pole spacing
0.748 Ω/1000 m
Number of poles
Any (2-pole to 8-pole EMS system support)
Assignment
Protective earth (PE) 4. Pole from above
Conductor rail cross-section
25 mm
2
Conductor material
Copper
Protection class
Protection against contact according to IP 23 insertion from below
Protection against contact according to IP 21 insertion from the side
*Current collector capacity depending on the current collector type! The current collector capacity is defined by the connected cable
and is generally lower (see catalog)! Ambient temperatures and operating modes result in reduced current collector capacity (e.g.,
operating at a standstill, operating at elevated temperatures).
3.2 Mechanical
Max. travel speed
Uninterrupted straight line 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 Forward and backward (reversing)
Insertion of the current collector from below or from the side
Pole spacing
14 mm

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
www.conductix.us translated document page 19 of 128
3.2.1 Lengths
Max. length of the installed conductor rail
Any, depending on the line feed design
Conductor bars
Max. 4000 mm (standard), 6000 mm and short lengths on request
Min. permissible conductor bar length
300 mm
Supplementary length per connection point
10 mm
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 of injury due to loss of contact or increased heating if the current collector is operated outside the
permissible 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: Conductor bar 0815 coordinate system
Y
X
Z
Y
X
Z

Operating Instructions
Single-pole Conductor Rail System
SingleFlexLine Program 0815
BAL0815-0002g-US
www.conductix.us translated document page 20 of 128
3.3 Unsuitable environmental conditions
The conductor rail must not be installed and not be operated under these environmental conditions (see also Section 2.5, Section
2.8.4 and Section 3):
Direct UV radiation (direct sunlight).
In environments containing chemical substances or gases that can potentially permanently damage the conductor rail's materials
(corrosion) or drastically impact 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.
Outdoors with free weathering.
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 soiled. Clean or dry as specified.
→Take the relevant measures to restore suitable operating conditions.