wampfler WV0800 Maintenance of Conductor Rails Instructions
General information
These regulations apply to insolated conductor rails from the programs of the 0800 series (0811, 0812, 0813, 0815, 0831, 0842) with rated voltages up to 1000 V and current ratings of 10 A to 2000 A.
Regular and sufficient maintenance is necessary for the designated functioning of the conductor rail. This prevents a jeopardizing of the operating reliability and of the contact safety guard and is the prerequisite for the eligibility of warranty claims. Under certain circumstances, an additional interim maintenance may be necessary.
Safety regulations
The safety regulations detailed in the relevant specification documents are applicable as well as the country-specific regulations for working on electrical devices/systems (e.g. VDE/UVV/VBG4).
Applicable are those safety regulations issued by the particular systems operator with regards to entering the facilities and working on the systems.
Maintenance and repair to the conductor rail must only be performed by appropriately trained expert personnel in accord with the respective technical standards, regulations and laws. Maintenance and repairs on the electrical system of the device must only be performed by qualified electricians in accord with the respective electrical standards (e.g. VDE, IEC) and country-specific regulations and laws. Conductor rails are part of the electrical system and must therefore be regularly and repeatedly checked in accordance ith the accident prevention regulations (e.g. VBG4). Only genuine Conductix-Wampfler spare parts must be used. When using other components, Conductix-Wampfler is unable to assume any responsibility whatsoever for the perfect and hazard-free functioning of the system(s) in question.=
2.1 Safety and hazard information
DANGER!
Danger of injury by electric shock!
→ Prior to inspection, maintenance or repair on the conductor rail, the system must be disconnected from the main power supply and secured against unauthorized, accidental and/or improper reactivation.
→ If, in special situations, there is no main switch, the disconnection from the power supply is to be handled according to specifications.
→ The parts that have been disconnected must first be checked to ensure they are not carrying current, next grounded, and finally short-circuited. Isolate neighboring parts that are carrying current!
→ Before each start-up, an insulation check must be performed in accordance with the local technical standards, specifications and laws.
→ If a conductor rail heater is present, it must also be disconnected from the power supply. Care must be taken to ensure that each individual heater circuit is disconnected from the power supply.
Danger of crushing between stationary and moving parts of the device!
→ Before an inspection, maintenance or repair on the conductor rail, the system must be switched off using the main switch!
Health hazard from carbon dust!
During maintenance tasks, dust deposits can be stirred up and inhaled.
→ A protective dust mask is to be worn!
Tools and materials
Standard tools (metric) and measuring tools are used for maintenance on conductor rails. A caliper is needed to measure the conductor contact height.
Maintenance schedule
A maintenance schedule is recommended in order to regulate the carrying out of maintenance and inspections. Maintenance is carried out by Conductix-Wampfler service personnel or authorized local service partners from Conductix-Wampfler. The advantages of a maintenance contract include increased availability of the system and an economical as well as precise performing of maintenance by trained personnel.
4.1 Current collectors
| Inspection and maintenance tasks | Maintenance interval | Reference to documents |
| Visual inspection of the conductor contact for wear and signs of denting, in particular the brushing surfaces,Replace worn conductor contact if the minimum wear level (hmin) has been reached at least on one part of the running surface. If there is heaving denting, check whether the connection cables are laid so they are free of twists, kinks and directive force. Also ensure there is adequate clearance for movement of the current collector heads. The individual connection cables must not be bundled togethernear the current collector heads (e.g. using cable ties). |
For new systems, every 500 km or 1 month after commissioning at the latest. Under ideal conditions, the mileage of copper-graphite contacts can be up to 8,000 km and of graphite contacts (pure coal) up to 20,000 km. |
Refer to systemspecific documentation. |
| Check that electrical connection is proper and correct. Visual inspection of the connection cables: Kinks, damages to the insulation or the braiding, cabling, connectors, screw connections, cross-sections of the braiding on the screw terminals of the current collector heads. |
Note: Depending on the usage conditions and condition of the unit, the mileage can differ from the above values. The maintenance interval can be broadened depending on experience with the system. |
Refer to systemspecific documentation. |
| Check installation and lateral tolerance of the current collector to the conductor rail (except for 0842 line). For optimum operation, the nominal position is recommended for the installation distance. Installation and lateral tolerances must not be exceeded or undershot during operation. |
½ annually | |
| Check the connector elements (screws, rivets, nuts, bolts), ease of movement of the joints and moving parts, corrosion, and damage. Replace if necessary. Check screw connections and tighten if necessary. |
½ annually |
For wear levels, lift/lateral tolerances and contact pressures for standard current collectors, see following table.
Please note:
- When using special current collectors, other values may be applicable.
- The contact pressures specified are recommended values and can exhibit deviations of up to
20% (depending on spring tolerances, installation position, soiling, cable routing, etc.). For large deviations, please contact the service partner. The contact pressures apply only to current collectors with vertical rail contact in the stated position and that are equipped with new sliding contacts.
4.1.1 Program 0811 Technical data and test values
| Current collector |
Conductor contact length |
Wear height | Installation distance | Lateral tolerance | Contact force | |||
| L [mm] | hmax [mm] |
hmin [mm] |
Nominal position X [mm] |
Highest position (stroke +) X [mm] |
Lowest position (stroke -) X [mm] |
Y [mm] | F [N] | |
| 081101… | 40 | 5 | 0,5 | 50 | 70 | 30 | 16 | 3 |
| 081101… | 63 | 7,5 | ||||||
| 081102… | 63 | 75 | 105 | 45 | 30 | 5 | ||
| 081106… | 40 | 85 | 65 | 10 | 6 | |||
| 081106… | 63 | |||||||
Illustration of conductor contact length and wear height
Illustration of the installation distance and contact force 081101 and 081102
Illustration of the installation distance and contact force 081106
4.1.2 Program 0812 Technical data and test values
| Current collector | Conductor contact length | Wear height | Installation distance | Lateral tolerance |
Contact force |
|||
|
L [mm] |
hmax [mm] | hmin [mm] | Nominal position X [mm] | Highest position (stroke +) X [mm] | Lowest position (stroke -) X [mm] | Y [mm] | F [N] | |
| 081205… | 90 | 9 | 0,5 | 115 | 165 | 65 | 50 | 20 |
| 081206… | ||||||||
| 081207… | ||||||||
| 081208… | ||||||||
| 081209 1) | 80 | 8 | 10 | |||||
1) Also ProShell-Current collector No. 08-S265-2258 / 08-S265-2259 / 08-S265-2226 / 08-S265-2237 / 08-S265-2403 / 08-S265- 2408.
Illustration of conductor contact length and wear height 081205, 081206, 081207, 081208
Illustration of conductor contact length and wear height 081209
Illustration of the installation distance and contact force 081205, 081206, 081207, 081208
Illustration of the lateral tolerance and contact force 081209
Abbildung zu seitlicher Toleranz 081205, 081206, 081207, 081208
Abbildung zu seitlicher Toleranz 081209
4.1.3 Program 0813 Technical data and test values
| Current collector | Conductor contact length | Wear height | Installation distance | Lateral tolerance |
Contact force |
|||
|
L [mm] |
hmax [mm] | hmin [mm] | Nominal position X [mm] | Highest position (stroke +) X [mm] | Lowest position (stroke -) X [mm] |
Y [mm] |
F [N] |
|
| 081301… | 160 | 15 | 0,5 | 125 | 165 | 85 | 100 | 28 |
| 081302… | 10 | 100 | 140 | 60 | 40 | |||
| 081303… | 15 | 125 | 165 | 85 | 100 | |||
| 081304… | ||||||||
Illustration of conductor contact length and wear height
Illustration of the installation distance
Illustration of the lateral tolerance
4.1.4 Program 0815 Technical data and test values
| Current collector |
Conductor contact length |
Wear height | Installation distance | Lateral tolerance |
Contact force |
|||
| L [mm] | hmax [mm ] |
hmin [mm] |
Nominal position X [mm] |
Highest position (stroke +) X [mm] |
Lowest position (stroke -) X [mm] |
Y [mm] | F [N] | |
| 081506… | 63 | 5 | PE: 2 PH: 1 |
65 | 75 | 55 | 10 | 6 |
| 081507… | ||||||||
| 081508… | 50 | 80 | 90 | 70 | ||||
| 081509… | ||||||||
Illustration of conductor contact length and wear height 081506, 081507
Illustration of conductor contact length and wear height 081508, 081509
Illustration of the installation distance
A = Testing position contact force
Illustration of the lateral tolerance
Conductix-Wampfler recommends for the PE current collectors of types 081506…, 081507…, 081508…, 081509… without cams to use the types 081506…, 081507…, 081508…, 081509… with cams, which are equipped with an interchanging protection. Special towing plates with a slot at the PE position are also provided for the assembly. For old systems replacement against these types should be checked.
4.1.5 Program 0831 Technical data and test values
| Current collector |
Conductor contact length |
Wear height | Installation distance | Lateral tolerance |
Contact force |
|||
| L [mm] | hmax [mm] |
hmin [mm] |
Nominal position X [mm] |
Highest position (stroke +) X [mm] |
Lowest position (stroke -) X [mm] |
Y [mm] | F [N] | |
| 083102… | 68 | 10 | 5 | 80 | 110 | 50 | 30 | 5 |
| 083103… | ||||||||
| 083104… | ||||||||
| 083106… | 80 | 8 | 0,5 | 100 | 150 | 50 | 50 | 10 |
| 083107… | ||||||||
Illustration of conductor contact length and wear height 083102, 083103, 083104
Illustration of conductor contact length and wear height 083106, 083107
4.1.6 Program 0842 Technical data and test values
| Current collector | Conductor | Wear height | |
| Conductor contact length | |||
| L [mm] | hmax [mm] | hmin [mm] | |
| 084201… | 25 | 5 | 0 |
| 084203… | 28 | ||
Illustration of conductor contact length and wear height 084201
Illustration of conductor contact length and wear height 084203
4.2 Conductor rails
| Inspection and maintenance tasks | Maintenance interval |
Reference to documents |
| Visual inspection of the brush surfaces for wear, damage, filth or burn spots. Replace rails if necessary. Ensure that the sliding surfaces are completely burr-free. Particularly on the junctions of the rails,burrs can result in increased carbon wear. Dirty sliding surfaces can be mechanically removed using a cleaning brush. Consult your local service partner for information on cleaning brushes. |
½ annually | |
| Visual inspection of the insulation for wear, damage, filth or burn spots. Replace rails if necessary. Ensure that there are no constrictions in the insulation profile (e.g. constrictions due to dirt in the rails or constrictions that were not removed after assembly and still remain), on which the current collector heads get stuck and can get stood upright (cause for contact problems).Manually check free movement of the rails with loose current collectors.Ensure that the insulation is not affected by foreign bodies (chippings, liquids, dirt, etc.) as this poses a short circuit hazard.Clean if necessary |
½ annually |
WV0800-0001-E Cleaning conductor rails |
4.3 Rail connectors
| Inspection and maintenance tasks | Maintenance interval |
Reference to documents |
| Visual check for damages, dirt, burn spots or corrosion. Replace if necessary. Check for proper electrical connection.Check position of connector caps. Check screw connections and tighten if necessary. Clean if necessary | ½ annually |
4.4 Anchor clamps
| Inspection and maintenance tasks | Maintenance interval | Reference to documents |
| Visual check for damages, cracking, dirt, or corrosion. Replace if necessary. Check whether the fixing of the conductor rail is ensured.Check screw connections and tighten if necessary.Check that there are no constrictions in the rails near the anchor clamps. Check free movement with current collectors (see chapter “Conductor rail”).Clean if necessary | ½ annually |
4.5 Hanger clamps
| Inspection and maintenance tasks | Maintenance interval |
Reference to documents |
| Visual check for damages, cracking, dirt, or corrosion. Replace if necessary. Check screw connections and tighten if necessary. Check that there are no constrictions in the rails near the anger clamps. Check free movement with current collectors (see chapter “Conductor rail”).For outdoor systems: Check whether damage (tears, cracks, etc.) has resulted due to weathering (UV radiation, storms, hale, snow, etc.). Replace affected component if necessary.Clean if necessary | ½ annually |
4.6 Power feeds
| Inspection and maintenance tasks | Maintenance interval |
Reference to documents |
| Visual check for wear, damage, dirt, burn spots or corrosion. Replace if necessary.Check that electrical connection is proper and correct. Visual inspection of the connection cables: kinks, damage to the insulation or braiding, cable routing, connector/screw connections).Check screw connections and tighten if necessary. Clean if necessary | ½ annually |
4.7 End caps
| Inspection and maintenance tasks | Maintenance interval | Reference to documents |
| Visual check for wear, damage, dirt, burn spots or corrosion. Replace if necessary. Check screw connections and tighten if necessary.Clean if necessary | ½ annually |
4.8 Pickup-, Transfer-, Tangential guides / Transfer point cap / Insulating sections
| Inspection and maintenance tasks | Maintenance interval |
Reference to documents |
| Visual check for wear, damage, dirt, burn spots or corrosion. Replace if necessary.Check the rossing tolerances (current collector relative to the pick-up guide/crossing cap).heck the orientation to the conductor rail and to the conductor rail. Note: All current collectors in the system have to be adjusted to each pick-up guide/crossing cap (tolerance 1:n).For several of the pick-up guides that are used by a vehicle, it can be necessary to face the ick-up guides to each other.In general, check the stability of the pick-up guide! Check screw and rivet joints, and tighten/replace as necessary.Clean if necessary | monthly |
See system-specific ocumentation for tolerance |
4.9 Expansion units
| Inspection and maintenance tasks | Maintenance interval |
Reference to documents |
|
Visual check for wear, damage, dirt, burn spots or corrosion. Replace if necessary. Check the stretching gap as depends on temperature Check screw connections and tighten if necessary.Clean if necessary |
½ annually |
See system-specific documentation for information on stretching gap |
4.10 Heating wires
| Inspection and maintenance works | Maintenance interval |
Reference to documents |
| Check all fuses, replace if necessary. Check all heating wires for electrical continuity. Replace heating wire if damaged. | Half-yearly | |
| Measure insulation resistance | 3-6 months | MV0800-0018Insulation measurement Heating wire |
4.11 Cleaning
| Inspection and maintenance tasks | Maintenance interval |
Reference to documents |
| Cleaning the conductor rail Brush out, vacuum out, and clean with cleaning agents. | As necessary. | WV0800-0001 Cleaning conductor rails |
VORSICHT!
Only use solvent-free cleaning agents!
When cleaning rails and power consumers, it must be ensured that only solvent-free cleaning agents are used that do not have an aggressive action on or destroy plastics such as PVC, PC and PBTP (see WV0800-0001).
4.12 Electrical inspection
| Inspection and maintenance tasks | Maintenance interval | Reference to documents |
| PE conductor: Visual check, free movement check inside the system and on the interfaces, measurement of the grounding resistance. Inspection of the safety guards Measure insulation resistance per phase. See “Reference to documents”. Observe additional specifications from system manufacturer! Visual inspection of areas with localized overheating. | After each maintenance | VBG4 Insulation measurements: see WV0800-0001Cleaning conductor rails |
Commissioning after maintenance
Before re-commissioning, ensure that…
- all work was completed.
- any possible self-start of machines is prevented.
- the system was inspected, and the personnel was informed.
- the specifications of the system manufacturer were observed.
A test run of the entire system is to be performed.
The system has to be observed during the first hour of operation.
Conductix-Wampfler GmbH
Rheinstraße 27 + 33
79576 Weil am Rhein – Märkt Germany
Importer for the United Kingdom:
Conductix-Wampfler Ltd.
1, Michigan Avenue
Salford
M50 2GY
United Kingdom
Phone: +49 (0) 7621 662-0
Fax: +49 (0) 7621 662-144
info.de@conductix.com
www.conductix.com
Phone: +44 161 8480161
Fax: +44 161 8737017
info.uk@conductix.com
www.conductix.com
WV0800-0002g-EN
www.conductix.com
Documents / Resources
 |
CONDUCTIX wampfler WV0800 Maintenance of Conductor Rails [pdf] Instructions WV0800 Maintenance of Conductor Rails, WV0800, Maintenance of Conductor Rails, Conductor Rails |
