Conductix-Wampfler ProfiDAT Programm 0514 Mounting Instructions
Mounting Instructions
Programm 0514
ProfiDAT® Data Transmission System
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Mounting Instructions
Programm 0514
ProfiDAT® Data Transmission System
Contents
1 General 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
2 Safety 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
3 Technical Specifications ........................................................................................................................................................... 23
3.1 General Information ................................................................................................................................................... 23
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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
4 Product 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
5 Transport, 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
6 Installation 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
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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
7 Operation .................................................................................................................................................................................. 69
7.1 Safety ........................................................................................................................................................................ 69
8 Maintenance 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
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9 Troubleshooting ........................................................................................................................................................................ 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
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1 General Notes
1.1 About this Document
This document facilitates safe and efficient working with the Conductix-Wampfler ProfiDAT® data-transmission system. The datatransmission 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 components.
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 regulations, 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.
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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!
ProfiDAT® Data Transmission System
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
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.
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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.
ProfiDAT® Data Transmission System
2 Safety 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!
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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.
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.
ProfiDAT® Data Transmission System
2.2 Personnel Requirements
2.2.1 Qualifications
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 employed 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
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Date
Name
Type of training
Training given by
Signature
11/5/2009
John Doe
First safety training for
personnel
Dave Miller
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 produced by the abrasion of carbon brushes and the PVC insulation of the conductor rail.
ProfiDAT® Data Transmission System
2.2.3 Training
Before commissioning the equipment, personnel must be trained by the owner. Log the implementation of training for better traceability.
Example of a training log:
2.3 Personal Protective Equipment
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WARNING!
Hazard due to improper use!
Any application that deviates from or goes beyond the intended use of the devices can result
in hazardous situations.
Strict compliance with the specifications of this installation manual is required.
Refrain from improper use of the system.
Respect the instructions on improper use in chapter 2.4.1.
ProfiDAT® Data Transmission System
2.4 Intended Use
The data-transmission system is designed and built exclusively for the usage described here (intended use).
Intended use
The ProfiDAT® data-transmission system is used for data communication between a base unit and a mobile system component.
In addition to the capacity to transmit data, the ProfiDAT® profile can also be used as a ground conductor rail together with conductor
rails in product ranges 0813/0812 (max. 1000 V/max. 1000 A).
Transmission of electrical power is not permitted.
The system comprises at least one access point and one client transceiver, together with the corresponding infeed and consumer
antennas.
Compliance with these technical conditions is mandatory for the installation:
The maximum permitted traversing speed of the mobile transceiver is 5 m/s.
The profile may only be installed horizontally with the access aperture facing down.
Side access is also feasible after prior technical testing and approval by the manufacturer.
Electrical-engineering operating conditions:
The electrical system must be protected in accordance with local regulations and guidelines.
The system may only be installed on the PE profile (protective conductor, green/yellow).
2.4.1 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 owner bears sole liability for any damage resulting from improper use.
Improper use in particular includes the following forms of use:
Operation that does not comply with the specified operating conditions (see chapter 3.5)
Use of the ProfiDAT
Use where there is a risk of explosion (“Ex”-classified zones)
Use of the transceiver without the profile
Use of transceivers not supplied by Conductix-Wampfler
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
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®
profile for the transmission of power
Mounting Instructions
Programm 0514
ProfiDAT® Data Transmission System
Environmental conditions
The ProfiDAT® data transmission system may only be used under the ambient conditions described in chapter 3.
The ProfiDAT® data transmission system must not be used under the following ambient conditions:
Temperatures below -25°C or above +50°C
Wind speeds above 25 m/s (10 Bft) or 32.7 m/s (12 Bft) if the system is inactive.
Solar irradiance levels greater than 1120 W/m² (for components directly exposed to sunlight)
2.5 Protective Measures to be taken by the Owner/Operator
The data transmission system is used in an industrial setting. The owner of the data transmission system is therefore subject to the
legal obligations concerning workplace safety. In addition to the safety instructions in this document, all safety, accident-prevention
and environmental regulations that apply where the data transmission system is used must also be observed. In particular, pay
attention to the following:
Work on electrical components of the system may only be carried out when disconnected from the power supply.
The owner must become acquainted with the applicable occupational-safety regulations and perform a risk analysis to identify
additional hazards arising from the specific working conditions where the system is used. This knowledge must be
implemented in the form of operating instructions for the data transmission system.
For the entire time that the data transmission system is in use, the owner must check whether the operating instructions it has
produced correspond to the current regulatory situation and adjust them if necessary.
The owner must clearly regulate and define responsibilities for installation, operation, troubleshooting and maintenance.
The owner must ensure that all employees involved with the system have read and understood this installation manual. The
owner must also train the personnel at regular intervals and inform them of hazards.
The owner must provide personnel with the necessary protective equipment.
The owner must keep the keys for 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 specialist personnel as described in chapter 2.2.1.
The owner must verify that the operating frequency of the data transmission system is permitted in the place of use.
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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 devices 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)
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 60950-22
Information-technology equipment: Equipment to be installed outdoors
EN 60529
Protection classes due to housings (IP code)
ProfiDAT® Data Transmission System
The owner must observe the following standards, regulations and directives when operating the system:
The owner is also responsible for ensuring that the data transmission system is always in perfect working order. The following thus applies:
The operator must ensure that the service intervals described in this document are observed.
The owner must have all safety systems inspected for functionality and completeness on a regular basis (once yearly if
possible, but at least as often as required by applicable national regulations).
If components or the system have been modified, the safety systems must be re-inspected and adapted to the changed
circumstances such that the system is safe again.
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ProfiDAT® Data Transmission System
2.6 Special Hazards
The following chapter lists residual risks determined on the basis of a risk assessment.
Follow the safety instructions and warnings in this installation manual to reduce health hazards and to avoid dangerous situa-
tions.
2.6.1 5 Protective Safety Rules when working on Electrical Systems
Work on electrical systems only when they are disconnected from the power supply. Follow the 5 safety rules (see DIN VDE
0150-100:2009-10/EN 50110-1:2004-11) before starting work:
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 by 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 work
carried out in the disconnected state!
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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
Electrically live components: Power feed, cables, connections, conductor rail,
connectors, current collectors, devices 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 powers 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 2.6.1.
During work:
Use insulated tools
Before switching on:
Every time before the 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 cables and replace damaged cables.
Always replace blown fuses with fuses of the same rating.
DANGER!
Fire hazard due to overload or sparking!
Fire hazards occur due to overloaded cables, electrical arcs, short circuits or sparking. Sparking
can occur in 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.
Check, service, and clean conductor rails regularly and as prescribed. See the
information in the documents for conductor rail range 0812/0813.
ProfiDAT® Data Transmission System
2.6.2 Electrical Hazards and Sources of Danger
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Risk of crushing injury!
Risk of impact injury!
There is a risk of crushing of skin and limbs due to:
Current collectors (spring force) during installation, dismantling and
maintenance
Falling parts of the data transmission system in case of improper installation or
unsuitable operating conditions (in solvent-containing environments, for
example)
Moving parts (current collectors, mobile equipment) when the system is in op-
eration
Do not enter the hazardous area of the system when in operation, except
for repair and maintenance tasks.
Have installation done only by trained technicians.
Wear safety footwear, protective gloves and a safety helmet when
working on the data transmission system.
When replacing the carbon brushes, follow the instructions in chapter
8.2.4.
Only install the system where suitable operating conditions prevail. See
chapter 3.5
Risk of injury when
cutting and trimming!
The ends of profiles 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.
During installation: Deburr insulating profiles and power rails after sawing.
When dismantling: Handle cut, removed profiles with care and store them
properly (transport or other container).
Be on the lookout for sharp edges near the installation area and avoid
contact.
Danger of injury by
falling objects!
ProfiDAT® profiles, current collectors and other components (e.g., antennas) can
fall off during operation or during any other work on the system. This can cause
severe injuries or fatalities if they fall from great heights.
Wear a safety helmet.
During installation, commissioning, troubleshooting, maintenance: Block
off the entire danger zone.
During decommissioning, dismantling, disposal: Block off the entire
danger zone. Handle cut, removed profiles with care and store them
properly (transport or other container).
ProfiDAT® Data Transmission System
2.6.3 Mechanical Hazards and Sources of Danger
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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. Moving parts include, for
instance, the crane and the current collectors attached to it.
Do not enter the hazardous area of the system when in operation, except
for repair and maintenance tasks.
Traverse at reduced speed!
Before working on the system, switch off the power supply of the
system according to the 5 safety rules and secure it against being
switched on again. For the 5 safety rules, see chapter 2.6.1.
Wear closely fitting work clothing.
ProfiDAT® Data Transmission System
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Danger of sensitization,
irritation of the mucous
membranes, and
respiratory diseases due
to dust!
Abrasion debris from the carbon brushes collects in the ProfiDAT® profiles and the
guide profile. This dust is very fine and is classified as harmful to health. Frequent
exposure can lead to 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 reckoned with if there is a lack of caution in
handling accumulated dust (by blowing out the dust with compressed air, for example).
In workplaces with long-term exposure and heavily use systems, take
effective measures to protect employees from the dust.
Use personal protective equipment during all work performed on the data
transmission system where accumulated dust can be stirred up. Use
personal protective equipment particularly when cleaning the system.
Safety eyewear
Dust mask, class FFP3
Gloves
Disposable coverall
Clean the profiles as prescribed before starting work. There are special
instructions for this task; see chapter 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 onto people.
Do not blow out dust with compressed air. Instead, vacuum it up. The
vacuum cleaner must be equipped with a Class H fine filter.
Do not eat, do not drink, do not smoke during the work!
Poisonous gases in case
of fire!
In the case of a fire in the system, the plastic parts of the conductor rail system (PVC) will emit
toxic gases (HCl).
Leave the system immediately.
Notify the fire brigade.
ProfiDAT® Data Transmission System
2.6.4 Danger due to Dust and Vapors
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Danger by slipping and
falling!
When entering the system, there is a danger of slipping and falling due to
environmental conditions such as moisture, snow, water, contamination and wind.
Wear personal protective equipment when entering the system and during
all work on the ProfiDAT® system.
Suspend work on the ProfiDAT
®
system in strong wind: Risk of falling!
Clean severely contaminated system parts before entering.
Failure/fault of the control system, software error!
Failure of the data transmission system or a software error can result in unexpected system
movements.
A plausibility check of signals must be carried out by the customer's higher-level control
system. We recommend the use of PROFIsafe controllers.
Complete the start-up checklist, see chapter 6.6
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.
Use only shielded aluminum profiles made by the manufacturer.
A plausibility check of signals must be carried out by the customer's higher-level control
system.
ProfiDAT® Data Transmission System
2.6.5 Danger related to the Place of Use
The following characteristics of the ProfiDAT® system can cause hazards when the ProfiDAT® system is installed in its
operational environment:
Electrical energy
Sparking
Dust caused by abrasion (of the carbon brushes)
Material composition of the insulating profiles, which releases toxic vapors if burned
The most important measure to provide protection from these dangers is to install the ProfiDAT® system only in locations where
suitable operating conditions prevail. See chapter 3.5
2.6.6 Unexpected Startup, unexpected Movement
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WARNING!
Risk of injury due to moving components!
When the system is operating, severe injuries can result if persons or objects are within the
movement range (hazard area!).
Do not start the system if there are persons or objects within the movement range
(hazard area!).
Exception: Repair and maintenance work. Traversing is only permitted at
reduced speed.
Make sure that the system cannot start up in an uncontrolled manner.
Do not reach into moving parts.
Block off the hazard area around the entire system.
WARNING!
Risk of injury due to moving components!
Serious injuries may occur if the system is moved in an uncontrolled manner.
Block off working and hazard areas.
Do not reach into moving parts. The interfaces between current collectors and rail-
fastening equipment are particularly dangerous.
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.
The spring force must be taken into consideration, during all works on the current
collector. Do not reach between profiles and current collectors (see Fig. 1).
During installation, maintenance and repair works: Check the spring force with
caution.
ProfiDAT® Data Transmission System
2.6.7 Emergency Stop
The ProfiDAT® data transmission system is used for transparent transmission of safety-relevant signals. These signals must be
generated by a higher-level component. Suitable safety components must be used to guarantee the emergency-stop function. The
emergency stop must be implemented using safety equipment provided by the customer and depends on the nature of the power
supply.
We recommend the use of a PROFIsafe system.
2.6.8 Hazard Areas
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Fig. 1: Sketch of the hazard area at the current collector
WARNING!
Risk of death due to inoperative safety devices!
Safety is only guaranteed if the safety devices are intact.
Before starting work, check that the safety systems are serviceable and properly
installed.
Never disable or deactivate safety systems.
Danger area
ProfiDAT® Data Transmission System
2.7 Safety Devices
The data transmission system has no safety devices. The system is always operated in conjunction with the plant in which the data
transmission system is installed. Therefore pay attention to the safety equipment of the plant!
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Conductix-Wampfler GmbH
Rheinstrasse 27 + 33
79576 Weil am Rhein – Märkt
Germany
Phone: +49 (0) 7621 662-0
Fax: +49 (0) 7621 662-144
info.de@conductix.com
www.conductix.com
ProfiDAT® Data Transmission System
2.8 Conduct in the Event of Accidents and Malfunctions
Measures to take in the event of accidents:
Shut down the system and secure it against unauthorized, unintentional and/or erroneous activation.
Secure the danger zone
Remove persons from the danger zone.
Initiate first-aid measures
Alert the rescue services
Inform responsible parties at the operating site
Clear access routes for emergency vehicles
Measures to take in the event of malfunction:
Shut down the system and secure it against unauthorized, unintentional and/or erroneous reactivation.
Secure the work area against entry
Consult qualified personnel when analyzing the fault
Involve authorized personnel for maintenance and repair
Check for disconnection from power
Remove the component and replace with a new component
Determine the cause of the fault and repair the component
Conductix-Wampfler must be informed immediately if personal injury or material damage can occur during breakdowns.
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Designation
Value, unit
System length (without segmentation)
500 m
Profile length
5000 mm
External profile dimensions (width x height)
50 mm x 56 mm
Power supply:
ProfiDAT® transceiver
ProfiDAT® infeed cabinet
24 V DC*
120–500 V AC / 50–60 Hz
Maximum data transmission rate
100 Mbit/s
Maximum travel speed of the mobile transceiver
(connection trolley)
5 m/s
Interface
Ethernet (RJ45 as standard)
System service life (except wear parts and
electrical components)
10 years
ProfiDAT® Data Transmission System
3 Technical Specifications
3.1 General Information
* Deviations may occur, see the manufacturer’s documentation (chapter 11.2 “Other applicable Documents”)
3.2 Interfaces
3.2.1 Electrical
The interfaces to the customer system are:
Data interface
Power supply/control voltage
PE
Data interface: ProfiDAT Ethernet, RJ45 connection.
The customer has to connect the ProfiDAT® system with its own system at both ends of the ProfiDAT® system with a RJ45 connector
or an optional LC (fiber-optic) connector. The interface is located on both the mobile and the stationary transceivers.
The customer system must provide the data using the Ethernet protocol. If the customer control system is not Ethernet capable, the
appropriate conversions must be made.
PE interface:
The interface for the customer's grounding cable is located at the PE rail connector (see chapter 4.3.1). At the flap (M10 drilled hole),
the PE cable must be connected according to the applicable standards.
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Description
Voltage/frequency
AC power supply
Infeed switching cabinet
120–500 V, 50/60 Hz
DC control voltage
Transceiver
24 V DC*
WARNING!
Danger of injury by current collector!
Failure to comply with the prescribed supply voltages for the controller can cause a controller
failure and electrical components may be destroyed. As a result, the current collector may run
jerkily and hit persons or objects.
Observe and comply with the prescribed supply voltages.
Keep persons and objects out of the hazard area (see chapter 2.6.6).
ProfiDAT® Data Transmission System
Power supply/control voltage:
The controller of the ProfiDAT® data transmission system requires the following power supply:
* Deviations may occur, see the manufacturer’s documentation (chapter 11.2 “Other applicable Documents”)
On commissioning of the transceiver devices, please observe that the cycle periods for the ProfiDAT® communication distances must
be adapted.
The cycle period must be at least 32 ms (but can differ depending on the application) and must be adjusted accordingly in the superior
control assembly group.
3.2.2 Mechanical
The interface between the data transmission system and the system is:
Current collector
The current collector on the ProfiDAT® profile performs a dual function. Two divided carbon brushes guide the current collector on
the ProfiDAT® profile. The carbon brushes secure the connection to the ground conductor rail (ProfiDAT® profile) while data
transmission occurs via the two built-in antennas. The antennas are inserted into the slot in the ProfiDAT® profile and are electrically
isolated from the carbon brushes.
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Designation
Value, unit
Ethernet
1 x 100 Mbit/s RJ45*
Supply voltage:
24 V DC*
Data rate
up to 100 Mbit/sec
Operating frequency
4.9–5.8 GHz**
Energy consumption
See the data sheet for the transceiver
Temperature range
See the data sheet for the transceiver
Dimensions (width x height x depth)
See the data sheet for the transceiver
Weight
See the data sheet for the transceiver
Designation
Value, unit
Temperature range
-25°C to +50°C
Min. bending radius
40 mm
Tension force
50 N
Recommended coupling torques:
N connector
SMA/R-SMA
4–6 Nm
79–113 Ncm
CAUTION!
The HF cables may not be squeezed (for instance through firm pulling at the cable binder).
Observe the bending radius of the HF cables.
Maintain the recommended coupling torque.
ProfiDAT® Data Transmission System
3.3 Technical Data for the Transceiver
* Deviations may occur, see the manufacturer’s documentation (chapter 11.2 “Other applicable Documents”)
** Country-specific deviations may occur
Please note the information in the documentation of the transceiver, see chapter 11.2. “Other applicable documents”.
3.4 Technical Data for HF Cables
The following values must not be exceeded:
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