Conductix-Wampfler ProfiDAT compact User manual

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 1 of 105

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 2 of 105
Contents
1General Information ................................................................................................................................................................. 6
1.1 About this document................................................................................................................................................. 6
1.2 Limitation of liability .................................................................................................................................................. 6
1.3 Copyright .................................................................................................................................................................. 7
1.4 Replacement parts ................................................................................................................................................... 7
1.5 Material defects ........................................................................................................................................................ 7
1.6 Technical support ..................................................................................................................................................... 7
2Safety Instructions ................................................................................................................................................................... 8
2.1 Explanation of symbols............................................................................................................................................. 8
2.2 Personnel requirements ........................................................................................................................................... 9
2.2.1 Qualifications ............................................................................................................................................................ 9
2.3 Unauthorized persons ............................................................................................................................................ 10
2.3.1 Training................................................................................................................................................................... 10
2.4 Personal protective equipment ............................................................................................................................... 10
2.5 Intended use........................................................................................................................................................... 11
2.6 Improper use .......................................................................................................................................................... 12
2.7 Protective measures by the operator / user............................................................................................................ 13
2.8 Special hazards ...................................................................................................................................................... 14
2.9 5 Safety Rules for working on electrical systems ................................................................................................... 14
2.9.1 Electrical hazards and sources of danger in combination with a conductor rail ..................................................... 15
2.9.2 Electrical hazards and sources of danger in combination with a conductor rail ..................................................... 16
2.9.3 Danger from dust and vapors in combination with a conductor rail........................................................................ 17
2.9.4 Danger in connection with the operational environment in combination with a conductor rail ............................... 18
2.9.5 Unexpected start, unexpected overrun in combination with a conductor rail ......................................................... 19
2.9.6 Emergency stop...................................................................................................................................................... 20
2.9.7 Danger zones ......................................................................................................................................................... 20
2.10 Safety systems ....................................................................................................................................................... 21
2.11 Conduct in the event of accidents and malfunctions .............................................................................................. 22

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 3 of 105
3Technical Data ....................................................................................................................................................................... 23
3.1 General................................................................................................................................................................... 23
3.2 Interfaces................................................................................................................................................................ 23
3.2.1 Electrical / Electronic .............................................................................................................................................. 23
3.2.2 Control signal cycle times....................................................................................................................................... 24
3.2.3 Mechanical ............................................................................................................................................................. 25
3.3 Technical data for the transceiver .......................................................................................................................... 25
3.4 Technical data for the data cable (HF cables)........................................................................................................ 26
3.5 Operating conditions............................................................................................................................................... 26
3.6 Unsuitable environmental conditions...................................................................................................................... 27
3.7 Type plate............................................................................................................................................................... 28
4Product Description and Operating Principle ......................................................................................................................... 29
4.1 Overview................................................................................................................................................................. 29
4.2 Brief description...................................................................................................................................................... 30
4.3 Component descriptions......................................................................................................................................... 31
4.3.1 ProfiDAT®compact System..................................................................................................................................... 31
4.3.2 Electrical components ............................................................................................................................................ 33
4.4 Modes of operation................................................................................................................................................. 34
4.4.1 Normal operation .................................................................................................................................................... 34
5Transport, Packaging and Storage ........................................................................................................................................ 35
5.1 Transport ................................................................................................................................................................ 35
5.1.1 Safety instructions for transport.............................................................................................................................. 35
5.1.2 Transporting packaged parts.................................................................................................................................. 35
5.1.3 Transport inspection ............................................................................................................................................... 36
5.2 Packaging............................................................................................................................................................... 36
5.3 Storage of packaged parts ..................................................................................................................................... 37
6Assembly and Commissioning ............................................................................................................................................... 38
6.1 Safety ..................................................................................................................................................................... 38
6.2 Preparation ............................................................................................................................................................. 39
6.3 Grounding............................................................................................................................................................... 40

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
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6.3.1 TN network ............................................................................................................................................................. 40
6.3.2 Grounding implementation instructions .................................................................................................................. 41
6.4 Mechanical installation ........................................................................................................................................... 43
6.4.1 Mount hanger clamp............................................................................................................................................... 43
6.4.2 Installing the power feed......................................................................................................................................... 44
6.4.3 Mounting the expansion unit................................................................................................................................... 46
6.4.4 Mount the ProfiDAT®compact Rail ......................................................................................................................... 53
6.4.5 Mount connectors ................................................................................................................................................... 54
6.4.6 Mount the PE connector ......................................................................................................................................... 55
6.4.7 Adjust the length of the ProfiDAT®compact Rail..................................................................................................... 56
6.4.8 Transfers ................................................................................................................................................................ 64
6.4.9 Mount the collector ................................................................................................................................................. 64
6.4.10 Mount the positioning system ................................................................................................................................. 65
6.4.11 Connect the PE cable to the PE connector ............................................................................................................ 66
6.4.12 Use of the ProfiDAT®compact Rail without PE function ......................................................................................... 67
6.5 Electrical installation ............................................................................................................................................... 68
6.5.1 Connect stationary transceiver ............................................................................................................................... 68
6.5.2 Connect the mobile transceiver to the vehicle........................................................................................................ 69
6.5.3 Connect the transceiver (Access Point) to the stationary antenna......................................................................... 71
6.5.4 Connect the transceiver (Client) to the mobile antenna ......................................................................................... 73
6.6 Checklist and initial commissioning ........................................................................................................................ 76
7Operation ............................................................................................................................................................................... 80
7.1 Safety ..................................................................................................................................................................... 80
8Service and Maintenance ...................................................................................................................................................... 81
8.1 Safety ..................................................................................................................................................................... 81
8.2 Maintenance schedule............................................................................................................................................ 82
8.2.1 Documentation ....................................................................................................................................................... 83
8.2.2 Maximum wear of the sliding contacts.................................................................................................................... 83
8.2.3 Replacement of the sliding contact......................................................................................................................... 84
8.2.4 Replacement of the collector head ......................................................................................................................... 92

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
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9Troubleshooting ................................................................................................................................................................... 100
10 Disassembly and Disposal................................................................................................................................................... 101
10.1 Safety ................................................................................................................................................................... 101
10.2 Disassembly ......................................................................................................................................................... 101
10.2.1 Disassembly of the components........................................................................................................................... 101
10.3 Disposal................................................................................................................................................................ 102
11 Further Documents .............................................................................................................................................................. 103
11.1 Declaration of Conformity ..................................................................................................................................... 103
11.2 Other applicable documents................................................................................................................................. 103
11.3 Air gap diagram .................................................................................................................................................... 104
12 Index .................................................................................................................................................................................... 105

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 6 of 105
1General Information
1.1 About this document
This document facilitates the safe and efficient handling of the ProfiDAT®compact Data Transmission System.
This document is a component of the system and must be kept accessible to personnel at all times in its immediate vicinity. Personnel
must read this document carefully and understand it before starting any work. Compliance with all safety and handling instructions
given in this document is a basic prerequisite for safe working.
Local accident protection regulations and general safety guidelines for the area of use of the device 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 this mounting instruction, the instructions located in the appendices for the individual assembled components
also apply.
1.2 Limitation of liability
All data and information in this mounting instruction has been compiled while taking the valid standards and regulations as well as
the state-of-the art and our long years of experience and knowledge into consideration.
The manufacturer accepts no liability for damages resulting from:
Failure to follow this mounting instruction
Improper 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, 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 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.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 7 of 105
1.3 Copyright
This document is protected by copyright and is exclusively intended for internal use by customers.
Provision of the mounting instruction to third parties, reproduction in any form —even in part —as well as the reuse and/or disclosure
of its content, except for the customer's internal use, are not permitted without the written approval of the manufacturer.
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.
For further documents, see section 11
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.
Contact information: 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.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 8 of 105
2Safety Instructions
2.1 Explanation of symbols
Safety and hazard information is identified in this mounting instruction by 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.
ATTENTION!
… indicates actions that will help you prevent material damage.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
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2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Inadequately trained persons are at risk of injury!
Improper use can result in serious injury to persons and property.
All activities must only be performed by qualified personnel.
Only 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.
For certain areas of operation, the following qualifications have been prescribed in the mounting instruction:
Trained personnel and 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.
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.
Are deemed to be technically qualified if they have successfully completed training as a master electrician, apprentice electrician,
electrical engineer or electrical technician. 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 machine or system operator must document that the appropriate certifications or other proofs of qualification have been or
are being provided.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 10 of 105
2.3 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 persons 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.
2.3.1 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
05.11.2009
John Doe
First safety training for
personnel
Horst Müller
2.4 Personal protective equipment
Always wear:
For all tasks:
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.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
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To be worn for
special tasks
Specific protective equipment is required when executing particular tasks. Separate reference
to this is made in the individual sections.
Safety 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.
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 sliding contacts and the PVC insulation of the conductor rail.
2.5 Intended use
The equipment is exclusively designed and built for the use described here (its intended use).
Intended use
The ProfiDAT®compact Data Transmission System is used for data communication in indoor industrial applications.
In addition to the ability to transfer data, the ProfiDAT®compact Rail can also be used as a ground conductor rail.
Furthermore, if the positioning option was chosen, a strip or matrix code tape can be attached to the ProfiDAT®compact Rails that
can determine the position of a vehicle with the help of a corresponding reader.
WARNING!
The ProfiDAT®compact Rail must not be used as a phase!
The system includes at least one master and one slave transceiver, as well as a corresponding stationary antenna and a mobile
antenna.
Compliance with these technical conditions is mandatory for the installation:
The permissible maximum travel speed of the collector is 600 m/min.
The rail may only be installed horizontally with the insertion from the side.
Electrical-technical operating conditions:
The electrical system must be protected in accordance with local regulations and guidelines.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 12 of 105
2.6 Improper 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 improper use.
WARNING!
Hazard due to improper use!
Any application that deviates from or goes beyond the intended use of the systems can result
in hazardous situations.
Follow all information in this mounting instruction strictly.
Refrain from improper use of the system
Improper use in particular includes the following forms of use:
Use outside the established operational conditions (see section 3.5)
Use of the rail for the transmission of power
Use where there is a risk of explosion (“Ex” areas)
Use of the transceiver without a rail
Use of the rail without adequate protection
Operation in areas that require a higher protection class than IP 23X
Use of the system parallel to a conductor rail system of a brand/type not approved by Conductix-Wampfler
Use of the system with accessories that are not approved and not authorized by the manufacturer
Use of the system by untrained personnel
Environmental conditions
The ProfiDAT®compact data transmission system may only be operated under the environmental conditions specified in section 3.
The ProfiDAT®compact data transmission system may not be operated under the following environmental conditions:
Ambient temperatures below -20° C and above +55° C
Temperature difference may not exceed 40 K
Outdoor areas (natural/solar UV radiation, wind, humidity)
Installation site higher than 2000 m above sea level

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
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2.7 Protective measures by the operator / user
The system is designed for use in an industrial setting. The operator of the system is therefore subject to compliance with the relevant
legal obligations concerning workplace safety. In addition to the safety instructions in this document, all safety, accident protection
and environmental regulations valid in the place of operation of the system must also be observed. This particularly applies to the
following:
Work on electrical components of the system may only be carried out when disconnected from power.
The operator must inform him/herself of applicable workplace safety guidelines and identify any additional hazards that may
arise under the specific working conditions at the place of use of the system. This knowledge must be expressed in the form of
operating instructions for the operation of the system.
During the entire time the 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 personnel involved with the device have read and understood this mounting instruction. In
addition, the operator must also train the personnel at regular intervals and inform them of hazards.
The operator must provide personnel with the necessary protective equipment.
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 "Qualifications".
The operator must observe the following standards, regulations and directives when operating the unit:
EMC Directive 2014/30/EU,
including
EMC Directive
EN 6100-6-2
Interference immunity in industrial areas
EN 61000-6-4
Interference emissions for industrial areas
EN 61000-3-2
Limit values for harmonic currents
EN 61000-3-3
Limitation of voltage changes, voltage fluctuations and flicker in public low-voltage power
supply networks for systems with a nominal current of 16 A per conductor that are not
subject to special connection requirements
EN 62311
Assessment of electrical and electronic equipment with respect to limiting exposure of
persons to electromagnetic fields (0 Hz - 300 GHz)

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
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Radio Equipment Directive
2014/53/EC, including
Radio equipment
EN 301 489-1 V1.8.1
EN 301 489-17 V2.2.1
Protection requirements with regard to EMC
EN 300 328 V1.8.1
EN 301 893 V1.7.1
Use of the radio frequency spectrum
EN 300 440-1 V1.6.1
Air interface for radio equipment 2.4 - 2.4835 GHz; 5.15 - 6.35 GHz; 5.47 - 5.725 GHz
Low Voltage Directive 2014/35/EU,
including:
Low Voltage Directive
EN 60529
Degrees of protection provided by housings (IP Code)
The operator is furthermore responsible for ensuring that the device is always in perfect working order. The following thus
applies:
The operator must ensure that the service intervals described in this mounting instruction are observed.
The operator must have all safety systems inspected for functionality and completeness on a regular basis (once annually if
possible, but at least as often as required by applicable national regulations).
If the device or system has been modified, the safety systems must be inspected again and adapted to the changed conditions
so that the device or system is safe again.
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 other sections of this mounting instruction in order to reduce health hazards
and avoid dangerous situations.
2.9 5 Safety Rules for working on electrical systems
Work on electrical systems only when they are disconnected from the power supply. Follow the 5 Safety Rules before starting
work (see DIN VDE 0150-100:2009-10/EN 50110-1:2004-11).
1. disconnect the system from the power supply at the main switch
2. secure the main switch against being switched on again
3. verify disconnection from the power supply through measurements
4. ground and short-circuit parts of the system to be worked on
5. cover or block off adjacent energized parts
Only electricians or personnel trained in electrical work may disconnect power or approve reconnection of power after the work
is carried out in the disconnected state!

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 15 of 105
2.9.1 Electrical hazards and sources of danger in combination with a conductor rail
Risk of death by
electrical shock!
Risk of injury from
falling or being thrown
across the room after an
electrical shock!
Burns due to arcing
caused by short circuit!
Contact with energized components can lead to death or severe injury by
electrical shock. There is also a risk of injury from shock reactions, falling or
being thrown across the room as a result of an electrical shock.
Work on the following components is dangerous:
Main power supply
Live parts: Power feed, cables, connections, conductor rail, connectors,
collectors, systems and connections within switching cabinets, control
systems, etc.
Parts that have become live due to a fault
Before working on the parts listed above:
Switch off the power supply of the conductor rail system according to the
5 Safety Rules and secure it against being switched on again. For the 5 Safety
Rules, see section 2.9
During work:
Use insulated tools
Before switching on:
Every time before the device or system is started, test the insulation resistance
according to locally applicable technical standards, directives and legal
regulations.
Carry out locally required electrical tests.
Maintain electrical safety:
Regularly test and maintain electrical equipment.
If dangerous deficiencies are identified, take measures to correct the
deficiencies without delay. Inform the system operator immediately.
If it is not possible to correct the dangerous deficiency, block off the area
involved or turn the equipment off and secure it against being switched on again.
Inform the system operator immediately.
Immediately secure loose cable and replace damaged cables.
Always replace blown fuses with fuses of the same rating.
DANGER!

Mounting Instructions
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Data Transmission System
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MAL0515-0001c-EN
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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 installation does not
comply with the required tolerances.
Compliance with permissible current ratings is mandatory.
Tolerances must be observed during installation.
Install electrical protection as prescribed.
Easily combustible materials may not be stored near to conductor rails.
Check, service and clean conductor rails regularly and as prescribed. See section 8 and 11.
2.9.2 Electrical hazards and sources of danger in combination with a conductor rail
Risk of crushing injury!
Risk of impact injury!
There is a risk of crushing of skin and limbs due to:
Collector (spring force) during assembly, disassembly and maintenance
Falling parts of the conductor rail system after improper installation or in case of
unsuitable operating conditions (for example, in areas containing solvents)
Moving parts, when the system is in operation
Do not enter the hazardous area of the system when in operation. Exception:
Maintenance and Repair tasks.
Allow only trained technicians to carry out the installation.
When working on the conductor rail system, wear safety footwear, safety gloves,
and a safety helmet.
When changing the collectors or sliding contacts, observe section 8.2 in this
mounting instruction.
Only install the conductor rail system where suitable operating conditions prevail.
See section 3.5.
Risk of injury due to
cutting and amputation!
The ends of rails and connectors can have sharp edges, especially if they have
been trimmed at the construction site and have not been deburred.
Use protective gloves and safety footwear.
Deburr the ProfiDAT®compact Rail after sawing.
Sawed through, dissembled ProfiDAT®compact Rails must be handled carefully
and properly stored (container or transport box).
Be on the lookout for sharp edges near the installation area and avoid contact.

Mounting Instructions
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Data Transmission System
Program 0515
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Risk of injury due to
falling objects!
The conductor rails, collectors or other components (e.g., antennas), can fall down
during operations or during any other works on the system. This can cause severe
injuries or fatalities if they fall from great heights.
Wear a safety helmet.
For installation, commissioning, troubleshooting and maintenance: Shut off the
entire danger zone.
For decommissioning, disassembly and disposal: Shut off the entire danger zone.
Sawn through, dissembled conductor rails must be handled carefully and properly
stored (container or transport box).
Danger of injury by
catching and
entanglement!
There is a danger of being entangled in moving parts when the system is in
operation during installation, commissioning, or service. For example, moving
parts are the machine and the attached collectors.
Travel at reduced speed!
Before working on the conductor rail, disconnect the conductor rail system
according to the 5 Safety Rules and secure it against being turned back on. 5
Safety Rules, see section 2.9.
Wear closely fitting work clothing.
2.9.3 Danger from dust and vapors in combination with a conductor rail
Danger of sensitization,
mucous membrane
irritation and respiratory
disease due to dust!
Abrasion from the sliding contacts, rails and plastic collects in the conductor rails,
the ProfiDAT®compact Rail and the support structure (substructure). 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 with compressed air).
In workplaces with long-term exposure and heavily use systems, 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, use personal protective
equipment when cleaning the system.
Safety eyewear
Dust mask, Class FFP3
Gloves
Disposable coveralls

Mounting Instructions
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Data Transmission System
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MAL0515-0001c-EN
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Before starting work, clean the conductor rail in accordance with requirements.
There is a special maintenance instruction for this task, see section 11.
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
cleaner must be equipped with a Class H fine filter.
Do not eat, drink or smoke during the work!
Poisonous gases during fire!
In case of fire in the facility, the plastic parts (PVC) of the conductor rail system emit poisonous
gases (HCL).
The building must be evacuated immediately.
Notify the fire department.
2.9.4 Danger in connection with the operational environment in combination with a conductor rail
Danger as a result of
environmental
influences!
Due to environmental conditions such as flammable dusts / gases, chemical
substances, radiation, temperature and contaminants can damage components
and cause breakage and falling off. Flammable dusts can cause fires by
sparking.
Check influences depending on temperature, time of action, concentration and
interactions.
Use in chemical works, galvanizing plants, electroplating plants, composting
plants or in warehouses or installations where chemical substances (e.g.,
aromatics, benzene) are stored or processed must be checked in advance
through Conductix-Wampfler.
Secure conductor rails against falling down at a height of 3 m in areas with
persons moving about (safety gear).
Install and operate the system according to the environmental conditions within
the permissible operating conditions.
DANGER!
These characteristics of the conductor rail can cause danger if the conductor rail is installed in an operational
environment with:
Electrical power
Sparking
Dust due to abrasion
Material composition of the insulating profiles, which releases toxic vapors if burned
The most important measure to protect against these hazards is to only install the conductor rail system where the appropriate
operating conditions prevail. See section 3.5.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 19 of 105
The environment of the
conductor rail may be
exposed to electrical
current!
The environment of the conductor rail may be exposed to electrical current under the following
circumstances:
If the conductor rail is severely contaminated or wet.
If electrically live parts are exposed (insulating profile or the insulation of the connection cable
are damaged)
When the hanger clamps or the insulating profile fail, or if the conductor bar falls down and
touches a conductive material.
Secure the electrical system according to specifications.
Install the conductor rail in accordance with the relevant documentation (see section11), follow
environmental conditions requirements and inspect, carefully service and clean the system
Regularly clean the conductor rail and repair if necessary
Danger of sensitization,
mucous membrane irritation
and respiratory disease due
to dust!
Abrasion from the sliding contacts collects in the conductor rails, the ProfiDAT®compact Rail
and the support structure (substructure). This dust is very fine and is a health hazard. Possible
consequences:
Irritations of the mucous membranes
Respiratory diseases
Cancer
For protective measures, see section 2.9.3.
2.9.5 Unexpected start, unexpected overrun in combination with a conductor rail
Failure/fault of the control
system, software error!
The failure of the data transmission system or a software error can lead to uncontrolled
movement of the vehicle.
A plausibility check of the signals must be carried out through the customer's superordinate
control system.
Fill out the Test and Commissioning List; see section 6.
Restore the energy feed
after failure of the power
feed!
Failure of the power feed can lead to uncontrolled movements of the system.
Initialization of the RAM memory (carried out automatically).
External influences on
electrical equipment due to
external sources of
interference!
External sources of interference, such as radio or radar, can cause malfunctions of the
components and the WiFi network.
Only use the manufacturer's ProfiDAT®compact Rail (*slotted waveguide).
A plausibility check of the signals must be carried out through the customer's superordinate
control system.

Mounting Instructions
ProfiDAT®compact
Data Transmission System
Program 0515
MAL0515-0001c-EN
www.conductix.com translated document page 20 of 105
2.9.6 Emergency stop
The ProfiDAT®compact does not have a built-in emergency stop Suitable safety components must be incorporated to ensure an
emergency stop function.
Conductix-Wampfler recommends the use of a PROFIsafe system.
2.9.7 Danger zones
WARNING!
Danger of injury from moving components!
When the system is operating, severe injuries can result if persons or objects are within the
movement range (danger zone!).
Do not run the machine if persons or objects are within the range of motion (danger zone!).
Exception: Repair and Maintenance work. The machine may only be run at a reduced
speed and with extreme care.
Make sure that the machine cannot move in an uncontrolled manner.
Do not reach into moving parts.
Block off the danger zone around the entire system.
WARNING!
Risk of death due to suspended loads!
Falling parts or uncontrolled swinging loads can lead to severe injury or even death.
Never walk under suspended loads.
Use only authorized lifting gear and lashing components with sufficient load capacity.
Be sure the lashing elements are firmly seated.
Do not use torn or worn ropes or straps.
Do not attach ropes or straps at sharp corners and edges and do not knot or twist them.
Only move loads under supervision.
Set down the load when leaving the workplace.
CAUTION!
Crushing hazard due to stored energy!
When working on the current collector, there is the risk of crushing extremities due to
uncontrolled movements as a result of the energy stored in the spring.
Pay attention to spring force during all work on the collector. Do not reach between the
ProfiDAT®compact Rail and the collector.
For installation, maintenance and repair: Carefully check the spring force.