Conductix-Wampfler ProfiDAT Programm 0514 User manual

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 1 of 82

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 2 of 82
Contents
1General Notes.............................................................................................................................................................................6
1.1 About this Document ...................................................................................................................................................6
1.2 Limitation of Liability ....................................................................................................................................................6
1.3 Copyright .....................................................................................................................................................................7
1.4 Spare 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
2.2.2 Unauthorized Personnel ..............................................................................................................................................9
2.2.3 Training......................................................................................................................................................................10
2.3 Personal Protective Equipment .................................................................................................................................10
2.4 Intended Use .............................................................................................................................................................11
2.4.1 Improper use .............................................................................................................................................................11
2.5 Protective Measures to be taken by the Owner/Operator .........................................................................................12
2.6 Special Hazards ........................................................................................................................................................14
2.6.1 5 Protective Safety Rules when working on Electrical Systems................................................................................14
2.6.2 Electrical Hazards and Sources of Danger................................................................................................................15
2.6.3 Mechanical Hazards and Sources of Danger ............................................................................................................16
2.6.4 Danger due to Dust and Vapors ................................................................................................................................18
2.6.5 Danger related to the Place of Use ...........................................................................................................................19
2.6.6 Unexpected Startup, unexpected Movement ............................................................................................................19
2.6.7 Emergency Stop ........................................................................................................................................................20
2.6.8 Hazard Areas.............................................................................................................................................................20
2.7 Safety Devices...........................................................................................................................................................21
2.8 Conduct in the Event of Accidents and Malfunctions ................................................................................................22
3Technical Specifications ...........................................................................................................................................................23
3.1 General Information...................................................................................................................................................23

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 3 of 82
3.2 Interfaces...................................................................................................................................................................23
3.2.1 Electrical ....................................................................................................................................................................23
3.2.2 Mechanical ................................................................................................................................................................24
3.3 Technical Data for the Transceiver............................................................................................................................25
3.4 Technical Data for HF Cables ...................................................................................................................................25
3.5 Operating Conditions.................................................................................................................................................26
4Product Description and Mode of Operation.............................................................................................................................27
4.1 Overview....................................................................................................................................................................27
4.2 Brief Description ........................................................................................................................................................27
4.3 Description of Assemblies .........................................................................................................................................28
4.3.1 ProfiDAT®System .....................................................................................................................................................28
4.3.2 Electrical Components...............................................................................................................................................30
4.4 Modes of Operation ...................................................................................................................................................32
4.4.1 Normal Operation ......................................................................................................................................................32
5Transport, Packaging and Storage ...........................................................................................................................................33
5.1 Shipment ...................................................................................................................................................................33
5.1.1 Safety Instructions for Transport ...............................................................................................................................33
5.1.2 Transporting packaged Parts ....................................................................................................................................33
5.1.3 Transport Inspection..................................................................................................................................................34
5.2 Packaging..................................................................................................................................................................34
5.3 Storage of packaged Parts ........................................................................................................................................35
6Installation and Commissioning ................................................................................................................................................36
6.1 Safety ........................................................................................................................................................................36
6.2 Preparations ..............................................................................................................................................................37
6.3 Grounding..................................................................................................................................................................38
6.3.1 TN Network................................................................................................................................................................38
6.3.2 Grounding Implementation Instructions.....................................................................................................................38
6.4 Mechanical Installation ..............................................................................................................................................39
6.4.1 Installation of the Expansion Element .......................................................................................................................39
6.4.2 Mounting the ProfiDAT®Profile .................................................................................................................................41
6.4.3 Installing the PE rail connector ..................................................................................................................................43

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 4 of 82
6.4.4 Installing the rail connector (without PE) ...................................................................................................................44
6.4.5 Installing the Anchor Point.........................................................................................................................................44
6.4.6 Installing the Entry Funnel .........................................................................................................................................47
6.4.7 Adjusting the length of the ProfiDAT®Profile ............................................................................................................47
6.4.8 Installing the Infeed ...................................................................................................................................................49
6.4.9 Connecting the ProfiDAT®Profile to the Entry Funnel ..............................................................................................50
6.4.10 Installing the Terminating Unit ...................................................................................................................................51
6.4.11 Installing the Current Collector ..................................................................................................................................52
6.4.12 Installing the PE Cable on the ProfiDAT®Profile.......................................................................................................54
6.4.13 Use of the ProfiDAT®profile without PE function ......................................................................................................55
6.4.14 Installing Trace Heating (optional).............................................................................................................................55
6.4.15 Mounting a Temperature Sensor (optional)...............................................................................................................56
6.4.16 Retrofitting of a PE Rail Connector (Ground) ............................................................................................................56
6.5 Electrical Installation..................................................................................................................................................59
6.5.1 Installing the ProfiDAT®Infeed Switching Cabinet ....................................................................................................60
6.5.2 Installing a ProfiDAT®Transceiver on a Mobile System Component ........................................................................61
6.5.3 Installing the Connecting Cable (HF cable) on the Infeed Antenna...........................................................................62
6.5.4 Installing the Connection Cable (HS Cable) on the Transceiver ...............................................................................62
6.6 Profile-heating (optional) ...........................................................................................................................................63
6.6.1 Profile-heating Controller...........................................................................................................................................64
6.6.2 Profile-heating Components ......................................................................................................................................65
6.7 Checklist and Initial Commissioning ..........................................................................................................................66
7Operation ..................................................................................................................................................................................69
7.1 Safety ........................................................................................................................................................................69
8Maintenance and Servicing.......................................................................................................................................................70
8.1 Safety ........................................................................................................................................................................70
8.2 Maintenance Plan......................................................................................................................................................71
8.2.1 Documentation ..........................................................................................................................................................72
8.2.2 Replacement of the ProfiDAT®Antenna....................................................................................................................72
8.2.3 Maximum Wear of the Carbon Brushes ....................................................................................................................74
8.2.4 Replacement of Carbon Brushes on the ProfiDAT®Current Collector ......................................................................75

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 5 of 82
9Troubleshooting ........................................................................................................................................................................78
10 Dismantling and Disposal .........................................................................................................................................................79
10.1 Safety ........................................................................................................................................................................79
10.2 Dismantling................................................................................................................................................................79
10.2.1 Dismantling the Assembly .........................................................................................................................................79
10.3 Disposal.....................................................................................................................................................................80
11 Additional Documents ...............................................................................................................................................................81
11.1 Conformity Declaration ..............................................................................................................................................81
11.2 Other applicable Documents .....................................................................................................................................81
12 Index .........................................................................................................................................................................................82

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 6 of 82
1General Notes
1.1 About this Document
This document facilitates safe and efficient working with the Conductix-Wampfler ProfiDAT®data-transmission system. The data-
transmission system consists of components integrated into a conductor rail system by the system engineer for the transmission of
data between a base unit and a mobile system component.
This document is a part of the data transmission system, and must be kept in its immediate vicinity and accessible to personnel at
all times. 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 data-transmission system also apply.
Illustrations in this document are provided for basic understanding and may deviate from the actual versions of individual compo-
nents.
In addition to these instructions, the instructions in the appendices for the individual installed components also apply.
1.2 Limitation of Liability
All data and information in this mounting instructions have been compiled in compliance with the applicable standards and regula-
tions, best practice and our many years of experience and knowledge.
The manufacturer accepts no liability for damages resulting from:
Failure to comply with this document
Improper use
Use by untrained personnel
Unauthorized modifications
Technical changes
Use of unauthorized replacement parts and accessories
The actual scope of delivery may differ from the explanations and descriptions provided here if the model in question is a spe-
cial one, if additional equipped 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 in the context of improvement of function and further development.

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 7 of 82
1.3 Copyright
This document is subject to 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 are not permitted without the written approval of the manufacturer, except for the customer's internal use.
Infringements will result in liability for damages. Our right to further claims remains unaffected.
1.4 Spare Parts
WARNING!
Incorrect spare parts are a safety hazard!
Incorrect or faulty spare parts can impair safety as well as resulting in damage, malfunctions
or complete failure.
Always use original spare parts from the manufacturer!
Order spare parts from your contracted dealer or directly from the manufacturer.
Contact details: See the last page of this document.
Spare parts: see Section 11.2
1.5 Material defects
The regulations about material defects are listed 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.
Our employees are also always interested in new information and experience from the field that can be valuable for the improvement
of our products.

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 8 of 82
2Safety Instructions
2.1 Explanation of Symbols
Safety and hazard information is identified by symbols in this mounting instruction. Safety instructions are introduced by signal words
that signal the scale 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 that will result in death or serious injury if not
avoided.
DANGER!
…indicates an immediately hazardous situation due to electricity that will result in death or se-
rious injury if not avoided.
WARNING!
…indicates a potentially hazardous situation that can result in death or serious injury if not
avoided.
WARNING!
…indicates a potentially hazardous situation due to electricity that can result in death or seri-
ous injury if not avoided.
CAUTION!
…indicates a potentially hazardous situation that can result in moderate or minor injury if not
avoided.
Tips and recommendations:
…highlights useful tips and information for efficient, problem-free operation.
CAUTION!
…indicates measures that will help you avoid material damage.

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 9 of 82
2.2 Personnel Requirements
2.2.1 Qualifications
WARNING!
Inadequately trained persons are at risk of injury!
Improper use can result in serious personal injury or material damage.
All activities must only be performed by qualified personnel.
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, follow all age- and occupation-specific guidelines applicable at the location of use.
The following qualifications are specified in the operating instructions for certain fields of activity.
Trained personnel and operators
have participated in a training session, given by the owner, on the tasks assigned to them and the potential hazards in case of
improper conduct.
The owner of the machine or system must document that the appropriate training has taken place.
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 knowledge of the applicable regulations.
Persons are deemed to be technically qualified if they have successfully completed training as a master electrician, apprentice
electrician, electrical engineer or electrical technician. Persons are also considered technically qualified if they have been em-
ployed in an appropriate capacity for several years, receiving theoretical and practical training in that time, and their
knowledge and skills have been tested by a specialist in the appropriate field of training.
The machine or system owner must document that the appropriate certificates or other proofs of qualification have been or are
being provided.
2.2.2 Unauthorized Personnel
WARNING!
Danger due to unauthorized personnel!
Unauthorized persons who do not meet the requirements described here are not acquainted
with the dangers in the working area.
Keep unauthorized personnel away from the working area.
In case of doubt, address the person and direct them away from the working area.
Stop working, as long as unauthorized persons are in the working area.

Mounting Instructions
ProfiDAT®Data Transmission System
Programm 0514
MAL0514-0005b-EN
www.conductix.com translated document page 10 of 82
2.2.3 Training
Before commissioning the equipment, personnel must be trained by the owner. Log the implementation of training for better tracea-
bility.
Example of a training log:
Date
Name
Type of training
Training given by
Signature
11/5/2009
John Doe
First safety training for
personnel
Dave Miller
2.3 Personal Protective Equipment
Always use:
For all tasks:
Safety helmet
For protection against falling or flying parts and materials.
Protective gloves
For the protection of hands against friction, scrapes, puncture or deeper wounds, as well as against
contact with hot surfaces.
Protective work clothing
Primarily for protection against entrapment by moving machine parts. Work clothing must be close fitting
with a low resistance to tearing; it must have close-fitting sleeves and no protruding parts.
Protective footwear
For protection against heavy falling parts and slipping on slippery floors.
Used for special
tasks:
Specific protective equipment is required when executing particular tasks. Separate reference to this is
made in the individual sections.
Safety eyewear
For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather
effects.
Hearing protection
For protection against loud noises and to prevent acoustic trauma.
Breathing mask (FFP-3 —according to country-specific requirements)
For protection against materials, particles, and organisms. In this case, for protection against the dust pro-
duced by the abrasion of carbon brushes and the PVC insulation of the conductor rail.