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Conductix-Wampfler
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0815
Installation Instructions Manual
26 pgs1.22 Mb0
Series Manual
40 pgs5.8 Mb0

Conductix-Wampfler 0815 Series Manual

Conductor Bar
0815 Series Manual
CONDUCTOR BAR 0815 SERIES MANUALMV0815-0007-US | 01.08.19
CONDUCTIX INCORPORATED
of any of its products to interface, operate or function with any portions of customer systems not provided by Conductix.
Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered and reported to Seller within one
year after shipment of such goods to Buyer.
Except where the nature of the defect is such that it is appropriate, in Seller’s judgment, to effect repairs on site, Seller’s obligation hereunder to remedy defects shall
be limited to repairing or replacing (at Seller’s option) FOB point of original shipment by Seller, any part returned to Seller at the risk and cost of Buyer. Defective parts
replaced by Seller shall become the property of Seller.
Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended by Seller and altered only as
authorized by Seller. Seller is not responsible for defects which arise from improper installation, neglect, or improper use or from normal wear and tear.
Additionally, Seller’s obligation shall be limited by the manufacturer’s warranty (and is not further warranted by Seller) for all parts procured from others according to
published data, specifications or performance information not designed by or for Seller.
Seller further agrees to replace or at Seller’s option to provide a refund of the sales price of any goods that do not conform to applicable specifications or which differ from
that agreed to be supplied which non-conformity is discovered and forthwith reported to Seller within thirty (30) days after shipment to the Buyer. Seller’s obligation to
replace or refund the purchase price for non-conforming goods shall arise once Buyer returns such goods FOB point of original shipment by Seller at the risk and cost of
Buyer. Goods replaced by Seller shall become the property of Seller.
There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title and freedom from encumbrances and, except as herein expressly stated and particularly, and without limiting the foregoing, there is no guarantee or warranty, express or implied, of merchantability or of fitness
for any particular purpose or against claim of infringement or the like.
Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyer’s design or of the ability of any goods to interface,
operate or function with any portions of Buyer’s system not provided by Seller.
Seller’s liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of, connected with, or resulting from
the manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in no case exceed the price paid for the product or services or any
part thereof which give rise to the claim. In no event shall Seller be liable for consequential, special, incidental or other damages, nor shall Seller be liable in respect
of personal injury or damage to property not the subject matter hereof unless attributable to gross misconduct of Seller, which shall mean an act or omission by Seller
demonstrating reckless disregard of the foreseeable consequences thereof.
Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities and design functions or under
abnormal conditions. Seller assumes no liability for loss of time, damage or injuries to property or persons resulting from the use of Seller’s products. Buyer shall hold
Seller harmless from all liability, claims, suits and expenses in connection with loss or damage resulting from operation of products or utilization of services, respectively,
of Seller and shall defend any suit or action which might arise there from in Buyer’s name - provided that Seller shall have the right to elect to defend any such suit or
action for the account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.
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CONDUCTIX-WAMPFLER FIELD SERVICE
Need Field Service for our products? We Can Handle It!
Ask us for a quote on expert system installations,inspections, preventative maintenance, and repairs/retrofits. As the world’s largest single source manufacturer of mobile electrification products, Conductix-Wamplfer has the unique ability to offer a degree of service not found anywhere else. Conductix-Wampfler’s team of highly qualified service technicians and engineers have years of experience servicing our complete line of products.
We can provide:
Annual Service contracts Installation Commissioning Installation supervision to ensure your installers avoid common mistakes. Troubleshooting to get you up and running. Pre-planned inspections to complement your preventive maintenance program.
Call 1-800-521-4888 for further details.
MV0815-0007-US | 01.08.19
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CONDUCTOR BAR 0815 SERIES MANUAL
TABLE OF CONTENTS
SECTION 1 - SAFETY 5
Safety Information Responsibility 5 Safety Messages 5
SECTION 2 - SYSTEM DESCRIPTION 6
SECTION 3 - ASSEMBLY 7
Safety 7 Providing additional protection against accidental contact at the conductor-rail end 10 Procedure 11
Required tools 11 Customizing components 11 Assembling the conductor rail system 15 Installing the current collector 29
Additional documents 33
CONDUCTIX-WAMPFLER FIELD SERVICE 38
NOTES 39
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SECTION 1 - SAFETY
Safety Information Responsibility
All owner, operator, and maintenance personnel must read and understand all manuals associated with this product before installation, operation, or maintenance.
The manual provides information on the recommended installation, operation, and maintenance of this product. Failure to read and follow the information provided could cause harm to yourself or others and/or cause product damage. No one should install, operate, or attempt maintenance of this product prior to familiarizing themselves with the information in this manual.
Safety Messages
The following safety messages are used in this manual to alert you to specific and important safety related information.
CAUTION
CAUTION indicates unsafe actions or situations that have the potential to cause injury, and/or minor equipment or property damage.
DANGER
DANGER indicates hazards that have the potential to cause severe personal injury or death.
WARNING
WARNING indicates unsafe actions or situations that have the potential to cause severe injury, death, and/or major equipment or property
damage.
NOTE
NOTE is used to alert you to installation, operation, programming, or maintenance information that is important, but not hazard related.
MV0815-0007-US | 01.08.19
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CONDUCTOR BAR 0815 SERIES MANUAL
SECTION 2 - SYSTEM DESCRIPTION
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SECTION 3 - ASSEMBLY
Safety
Installation and initial commissioning may only be carried out by specially trained technicians.
Required protective equipment:
WARNING
Risk of death due to suspended loads!
Falling loads can lead to severe injuries or even death.
• Never walk under suspended loads.
• Only move loads under supervision.
• Set down the load when leaving the workplace.
• Use personal protective equipment!
DANGER
Injury due to improper installation and initial commissioning!
Improper installation and initial commissioning can result in serious injury to persons and/or material damage.
• Before starting work, make sure there is sufficient space for assembly.
• Handle open, sharp-edged components carefully.
• Make sure the installation area is tidy and clean! Loosely stacked or scattered components and tools are a source of hazards.
• Install components properly. Comply with the specified screw tightening torques.
DANGER
Poisonous gases in case of fire!
In case of fire in the facility, the plastic parts (PVC) of the conductor-rail system emit poisonous gases (HCL).
• The system operator must take this into account accordingly when planning and take the appropriate protective measures.
• The building must be evacuated immediately.
• The fire brigade must be informed.
MV0815-0007-US | 01.08.19
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CONDUCTOR BAR 0815 SERIES MANUAL
SECTION 3 - ASSEMBLY
DANGER
Risk of injury by crushing skin and limbs!
There is a danger of crushing of skin and limbs due to:
• Spring force/gravity (stored energy).
• Current collector (spring force) during installation, dismantling and maintenance.
• Falling conductor-rail system components if they have not been properly installed or if operated in inappropriate operating conditions (e.g. environment that contains solvents)
• Have installation done only by trained technicians.
• When working on the conductor-rail system, wear safety boots, safety gloves, and a safety helmet
• When changing the collector brush, follow the separate instructions for this task. See chapter 12.1 in BAL0815-0002-EN
• Only install the conductor-rail system where suitable operating conditions prevail. See chapter 3.3 in BAL0815-0002-EN
DANGER
Risk of injury due to grasping or impact!
Grasping and/or impact with moving conductor-rails (slip ring) or current collectors connected to the machine and other components must be prevented.
• Cordon off the work area.
• Caution when working in the vicinity of the danger zone, in particular if protective devices (covers, enclosures, control devices) have been removed or disabled.
• Caution when working in the vicinity of the danger zone, in particular below the conductor-rail.
• Falling conductor-rail system components if they have not been properly installed or if operated in inappropriate operating conditions (e.g. environment that contains solvents).
• Use personal protective equipment!
DANGER
Risk of injury from cuts and cutting!
Cuts and amputations can occur:
• On sharp edges of the general components.
• On sharp edges of the conductor-rails.
• On cut edges when trimming the conductor-rails.
• On packaging materials (cartons, tapes, etc.)
• Use personal protective equipment!
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SECTION 3 - ASSEMBLY
CAUTION
Risk of puncture wounds and cuts!
The packaging material can contain sharp objects such as nails and wood splinters that can cause injury to limbs.
• Use personal protective equipment!
• Cordon off the work area!
• Caution when working in the vicinity, in particular below the conductor-rail.
DANGER
Risk of injury due to conductor-rails sliding out!
Risk of injury due to conductor-rails sliding out when the packaging units are held at an angle or carelessness with long loads.
• Use personal protective equipment!
• Cordon off the work area!
DANGER
Risk of death by electrocution!
Contact with components carrying electrical power can lead to death by electrocution or severe injury. Danger of injury due to shock reactions, falling, or being thrown across the room due to electrical shock.
• The main power supply (from the building) must be disconnected in the installation area and secured against switching on again.
• Disconnect all electricity-supply power feeds.
• Check whether a voltage is still present in the components and take measures where necessary.
• Install the conductor-rail out of manual reach.
• Attach a sign saying “Risk of death by electrocution” with the relevant hazard symbol in all areas with live components.
• The customer must ground metallic components.
• The customer must provide protective devices.
• Make sure there is sufficient stability in the area.
WARNING
The system must be designed and operated in accordance with the prevailing ambient conditions!
WARNING
Secure conductor-rails against falling
• In application areas with personnel traffic and at an installation height of 3 m or more, conductor-rails must be secured against falling!
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CONDUCTOR BAR 0815 SERIES MANUAL
SECTION 3 - ASSEMBLY
ATTENTION
To the side of the conductor-rail there must, a clearance of at least 4 mm from metal components must be maintained (see Figure 3-1) to prevent mechanical collisions and guarantee sufficient electrical insulation distances!
Figure 3-1: Conductor side rail clearance
Providing additional protection against accidental contact at the conductor-rail end
An end cap is attached to the conductor-rail end as protection against accidental contact. When using dual current collectors, one of the collector brushes, which will be live, might protrude from the end of the conductor-rail. Touching this collector brush might cause injury from an electric shock, as a result of falling or being thrown across the room. The system operator must ensure that the current collector does not project, instead remaining within the conductor-rails, or must make the danger area inaccessible (e.g. by providing protection against accidental contact).
CAUTION
Take structural protective measures!
• Use control technology to ensure that the current collector never travels beyond the end of the conductor-rail.
• Also fit a contact guard that will safely cover the collector brush if it leaves the conductor rail!
CAUTION
Alert personnel to the hazard!
• Attach a sign saying “Risk of death by electrocution” with the relevant hazard symbol in all areas with live components.
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SECTION 3 - ASSEMBLY
Procedure
Required tools
Standard tool:
• Measuring tape
• Calipers
• Scribe
• Allen key (3 mm)
• Cutting tool (e.g. cordless angle grinder). For producing short lengths.
• File for deburring cut edges after trimming
• Cordless drill and countersink bit
• Screwdriver set
Special tool:
• Bending device (081091)
• Rail-dismantling tool
• Drilling jig for transition units
• Torque wrench (2 Nm) with 3 mm Allen key for rail connector
Personnel:
• Installation by technical personnel only
• At least two people
Customizing components
The customization of components is limited to the bending and trimming of the conductor-rail.
ATTENTION
The trimming of the conductor-rail must be done away from the installation area!
Trimming conductor-rail
The conductor-rails have a standard length of 4000 mm. Shorter lengths can be supplied but are generally produced at the building site. Required tools:
• Cutting tool, preferably a battery angle grinder with 1 mm cutting disc
• Print cutter
Work steps:
• Cut the conductor material and insulation to the same length.
• Saw off the metal rail and PVC insulation away from the contact area using a cutting tool.
• Deburr the sawed end with a smooth file. Chamfer the contact surface in the whole rail base by 0.3–0.4 mm by 15° to guarantee a problem-free passage of the collector brushes over the rail joint.
CAUTION
Sharp edges and burrs result in increased wear of the collector brushes!
A sharp edge and/or burr can rapidly wear away the carbon of the collector brushes.
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CONDUCTOR BAR 0815 SERIES MANUAL
SECTION 3 - ASSEMBLY
• Clean the profile well and remove sawing debris
Figure 3-2: Deburr the conductor rail with smooth file
Figure 3-3: PEplus rail without end machining
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