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
www.conductix.com translated document page 4 of 105
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
www.conductix.com translated document page 5 of 105
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
www.conductix.com translated document page 9 of 105
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.