1 General Information about the Operating Instructions Intended Use Safety Rules Symbols used Warnings...

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1 Contents 1 General Information about the Operating Instructions Intended Use Safety Rules Symbols used Warnings Transport, Storage and Preparation for Installation Components of the Cleaning Head Current Collector Housing Control Unit Connector Angle Connector Plate translated document page 1 of 27

2 4.6 Assembly using Connector Angle Assembly using Connector Plate Commissioning and Operation Commissioning Service General Information Safety Rules Warnings Tools and Materials Cleaning General Information Safety Rules Insulation Measurement Description of the individual cleaning Steps/cleaning Agents Environmental Compatibility/Risks Application and Use Packaging/Processing/Sources Error Diagnosis and Repair Troubleshooting Repair Toothed Belt Round Brush Decommissioning, Dismantling and Disposal Dismantling Disposal Spare Parts List Reprinting and copies, even in excerpt, only with our approval. Conductix-Wampfler GmbH/ translated document page 2 of 27

3 1 General Information about the Operating Instructions The is used for extraction and optional brushing out of the EMS support profile. In case of heavy dirt the brush can be used. In using of barcode strips the bristles must be removed from the barcode strip s area (for avoiding damage of the barcode strip). The can be adapted to the EMS hanger and can be supplied and controlled by the EMS hanger (permanent installation). Alternatively, the can be completed by the optional current collector trolley, control unit and it can be used in stand alone use (without EMS hanger) for rail cleaning. By the own carriage with the fast mounting system the stand alone unit can be taken from the rail and inserted again in less than a minute. The has a DN 50 mm pipe socket for connection of an industrial vacuum cleaner or the customer s suction unit with fine dust class H or rather the operator s security request. These operating instructions apply to the following dimensions (EMS support profile): 1.1 Intended Use EMS support profile Components 180 x x x 80 Order no. Cleaning head 08-G G G Current collector housing (optional) 08-G G on request Control unit (optional) 08-S S S Connector plate (optional) 08-B B (08-B ) mounted on current collector housing Wear of the carbon brushes and particles of dirt present in the air cause undesired deposits to be build up in the conductor rail and the EMS support profile over time. These deposits can lead to electrical and mechanical problems in the system and contamination of the products being transported. The (cleaning head) has the task of removing loose and slightly adhesive contaminants from the conductor rail and the EMS support rail. 180 x 60 EMS support profiles are generally used with a 4 to 8 poles and conductor rail models 0811 and 0815 are generally used. s for other EMS support profiles are available upon request. The cleaning head and the current collector housing are guided onto the corresponding EMS support profile during the cleaning process. The non-driven unit is pushed or pulled by the EMS carriage. The coupling uses an auxiliary mechanism designed according to the operational situation (shackles, pusher rod or similar solutions). Appropriate connection points (screw eyes or roller fasteners on the housing) are installed on the housing. A hose installed on the prop (outer diameter 50 mm) leading to an industrial vacuum cleaner (not included in the scope of delivery) is used to generate an appropriate suction flow to vacuum out the particles on the conductor rail and carrier rails. The industrial vacuum cleaner, if used in the EU, must be equipped with a filter and EN compliant dust catcher rated for dust class H. In conveyor segments with gates, expansion points or similar sections, a restriction of the suction power must be assumed. translated document page 3 of 27

4 1.2 Safety Rules The safety rules and country-specific guidelines resulting from applicable directives apply to work carried out on electrical systems (e.g. VDE/UVV/VBG4). The safety rules defined by the system operator apply to entering and working on systems. The system operator must ensure that work on the conductor rail may only be carried out by appropriately trained technicians in compliance with applicable technical standards, guidelines and law. Similarly, work on the electrical components of the system may only be carried out by qualified electricians in compliance with applicable standards of electrical engineering (e.g. VDE, IEC) and country-specific regulations and law. 1.3 Symbols used Warning of general danger of injury and property damage. Warning of injury from electrocution. Warning of a danger of crushing injury. Instructions for proper operation. 1.4 Warnings Danger of injury due to electrocution! Before working on the current collector housing, the system must be disconnected from power using the main switch, and secured against unauthorized, unintentional and/or erroneous activation. In special cases where there is no main switch, the power disconnection must be carried out according to the specifications of the system manufacturer. Check parts disconnected from power, then ground and short-circuit them. Insulate neighboring parts that are connected to power. Before each commissioning, an insulation test must be carried out in accordance with the local technical standards, guidelines and law. Danger of crushing injury between fixed and moving parts of the system! Before working on the conductor rail, the system must be turned off at the main switch. Dust from the carbon brushes collects in the conductor rails and the guide profile. This dust is very fine and is categorized as a health risk: When working on the conductor rail system, particularly during cleaning, the use of personal protective gear (safety glasses, dust mask, safety gloves and disposable overall) is required. Gloves and safety glasses must be worn while inspecting the current collector. Avoid contact with the mucous membranes; do not breathe in dust. Clean skin surfaces with soap and water after work. In case of contact with eyes, rinse with clear water. translated document page 4 of 27

5 2 The, depending on its variant, consists of a cleaning head, a current collector housing, a connector plate that connects the cleaning head with the current collector housing, and a control unit (Dimensions: Approx. 300 x 200 x 155 mm). The control unit represents the electrical interface to the vehicle controller (optional automatic operation) and permits both operation in manual mode (suction ON/OFF and brush ON/OFF ) and connection of an industrial vacuum cleaner using a 3-phase power connection. The industrial vacuum cleaner with a filter can be purchased from various providers. Via the standardized interfaces: 3-phase power connection 50 mm for the suction hose (diameter of the connector) The industrial vacuum cleaner can be freely selected in either compact or modular construction, according to the structural situation, the end customer s plant guidelines and national specifications for suction and cleaning equipment. Before starting work, all relevant sections of these operating instructions must be read completely. Please contact Conductix- Wampfler in case of any lack of clarity. 3 Transport, Storage and Preparation for Installation The cleaning head, current collector housing, and control unit are prepackaged for transport and storage. They must be protected from moisture. Unpack them only directly at the place of installation. Sufficient numbers of all required parts are included in the package! translated document page 5 of 27

6 4 Components of the 4 A 1 A 3 2 Pos. Description 1 2 Current Collector Housing 3 Connector Angle 4 Control Unit (optional) A For stand alone use Installation of the individual components is covered in the installation regulations for the [MV E]! translated document page 6 of 27

7 4.1 Cleaning Head The cleaning head is a housing with a separate carriage. The housing includes a rotating brush for cleaning the conductor rails and the connection for both the power supply of the brush drives as well as a connector for the suction hose of the industrial vacuum cleaner (for installation, see installation regulations MV E). Adaptation using the DIN 444 B eye bolt (di = 8 H9) is possible here. This can be installed on the opposite side, as well. Eye bolt DIN 444 B translated document page 7 of 27

8 4.2 Current Collector Housing The current collector housing is a housing with a separate carriage. The housing has an opening flap for maintenance and replacement of the corresponding current collector units. The current collector units must be ordered additionally depending on the model of conductor rail and the pole layout. The current collector housing is not absolutely necessary if the control unit can be supplied with power from outside (hangers of the EMS system) (for installation, see installation regulations MV E). translated document page 8 of 27

9 4.3 Control Unit The control unit is a terminal box (dimensions: L = 300 mm / W, D = 155 mm / H = 200 mm) that can be installed either on the hangers of the EMS system or between the cleaning head and the current collector housing (installation on connector plate). The control unit takes its power from the current collector housing. The motor of the cleaning head and the industrial vacuum cleaner are supplied with power and controlled by the control unit (for installation, see installation regulations MV E). 4.4 Connector Angle The connector angle (a bracket) connects the cleaning head directly to the current collector housing (for installation, see installation regulations MV E). 4.5 Connector Plate The connector plate, if present, connects the cleaning head with the current collector housing and is simultaneously a holder for the control unit. The control unit is connected to the connector plate with screws (for installation, see installation regulations MV E). translated document page 9 of 27

10 4.6 Assembly using Connector Angle translated document page 10 of 27

11 4.7 Assembly using Connector Plate translated document page 11 of 27

12 5 Commissioning and Operation 5.1 Commissioning CAUTION! System or property damage! Commissioning may only be carried out by trained personnel. Before commissioning, the following points must be checked: Are all components completely assembled? Are damaged components shored up? Proper electrical connection of all components? The round brush will only work if the industrial vacuum cleaner is turned on! Is the industrial vacuum cleaner working? (Turn on industrial vacuum cleaner) Is the lamp of the industrial vacuum cleaner lit? Is the round brush rotating? (Turn on round brush) Is the lamp of the round brush lit? No collision of the cleaning head and/or current collector housing in all operating states? Is the rail cleaner connected to the carriage? In manual or slow operation, observe the movement of the rail cleaner (for installation tolerances) over a longer stretch (curves and joints) and correct any collisions that may occur. After completion of commissioning, the rail cleaner can be operated with the following parameters: Rated voltage: max. 400 V (50 Hz) / 460 V (60 Hz) Permissible ambient temperatures depend on the system (from -10 to +55 C) Maximum speed of travel without cleaning function on a segment: 100 m/min Maximum speed of travel with cleaning function: 10 m/min translated document page 12 of 27

13 6 Service 6.1 General Information CAUTION! System or property damage! Regular, sufficient maintenance is required for the intended function of the rail cleaner. It prevents risk to operational safety and is a requirement for validity of the warranty. In case of particular events, intermediate service may be necessary. Maintenance interval: Scope of maintenance: 3 months (if used continuously, a maintenance interval of 1 or 2 months is recommended) Visual inspection of the pressure rollers (wear/tilt) (replace rollers if necessary). Check connection between the connectors and the industrial vacuum cleaner (hose) (correct if necessary). Inspect the round brush (replace round brush in case of severe wear). [See section 8.2.2] Check screw connections on both housings (tighten screws if necessary). Check electrical connections (correct if necessary). Check toothed belt (tighten if necessary). [See section 8.2.1] 6.2 Safety Rules The safety rules and country-specific guidelines resulting from applicable directives apply to maintenance work (e.g. VDE/UVV/VBG4). The safety rules defined by the system operator apply to entering and working on systems. Maintenance and repair of the rail cleaner may only be carried out by appropriately trained technicians in compliance with applicable technical standards, guidelines and law. Maintenance and repair of the electrical components of the system may only be carried out by qualified electricians in compliance with the applicable standards of electrical engineering (e.g. VDE, IEC) and country-specific guidelines and law. The rail cleaner is part of the electrical system and therefore must be inspected repeatedly and regularly in compliance with accident prevention guidelines (e.g. VBG4). translated document page 13 of 27

14 6.3 Warnings CAUTION! Danger of injury from electrical current! Before inspection, maintenance, repair or disassembly of the rail cleaner, the system must be disconnected from power at the main switch and secured against unauthorized, unintentional and/or erroneous reactivation. In special cases where there is no main switch, the power disconnection must be carried out according to the specifications of the system manufacturer. Check parts disconnected from power, then ground and short-circuit them. Insulate neighboring parts that are connected to power. Before each commissioning, an insulation test must be carried out in accordance with the local technical standards, guidelines and law. CAUTION! Danger of crushing injury between fixed and moving parts of the system! Before inspection, maintenance, repair or disassembly of the rail cleaner, the system must be disconnected from power at the main switch! CAUTION! Risk to health due to carbon dust! Dust from the carbon brushes collects in the conductor rails, the cleaning head, and on the floor. This dust is very fine and is categorized as a health risk. For all work on cleaning hangers, especially while cleaning them, personal protective gear such as safety glasses, dust mask and gloves must be worn. Avoid contact with the mucous membranes. Do not breathe dust. Clean skin surfaces with water and appropriate cleaning agents after work. In case of contact with eyes, rinse with clear water. During maintenance work, accumulated dust may be disturbed and breathed in. It is mandatory to wear a dust mask! 6.4 Tools and Materials For maintenance of the rail cleaner, standard tools (metric) and measurement equipment are used. For maintenance of the current collector, please see the maintenance instructions for conductor rails. translated document page 14 of 27

15 7 Cleaning 7.1 General Information Cleaning is a part of the maintenance of the rail cleaner. Cleaning prevents both hazards to operational safety as well as risk to personnel. The purpose of cleaning is to: Remove dust on the carbon brushes Remove dust adhering in the current collector housing Remove dust adhering in the cleaning head 7.2 Safety Rules CAUTION! Danger of injury from electrical current! The safety rules for working on electrical systems listed in the applicable regulations apply. The safety rules defined by the system operator apply to entering and working on systems apply. The safety data sheets and processing guidelines associated with the use of cleaning agents apply. 7.3 Insulation Measurement Not required. 7.4 Description of the individual cleaning Steps/cleaning Agents Vacuum and remove coarse residue. Use a damp cloth without cleaning agents. Cleaning concentrate Rivolta B.W.R Weakly alkaline, biodegradable, non-flammable, physiologically harmless cleaning concentrate, pleasant odor and insulating residue. High-performance cleaner Rivolta S.L.X. Top. Penetration resistant, evaporates without residue, free of halogen hydrocarbons, odorless, no hazards according to GefStoffV, versatile cleaning concentrate. Rivolta O.X.X. Oxide remover : Dissolves layers of oxides and sulfide, resinified oils, greases and mineral dust; must always be recleaned with S.L.X. Top. translated document page 15 of 27

16 7.5 Environmental Compatibility/Risks B.W.R 210 S.L.X- Top O.C.X. Oxide remover Biodegradable By more than 97 % - - Burning point Non-flammable > 55 C - Class A III > 65 C - Class A III Warnings according to GefStoffV (Regulations about hazardous substances) Storage Not required Not required Not required In plastic containers at room temperature. In sufficiently well-ventilated rooms at room temperature; seal containers well. In sufficiently well-ventilated rooms at room temperature; seal containers well. 7.6 Application and Use Each cleaning must first start with the weakest possible cleaning agent for the contamination found (see table below, left column). Only if no satisfactory result is obtained should the cleaning agent in the next column be used. Cleaning agent/ contamination Moist cloth B.W.R 210 S.L.X- Top O.C.X. Oxide remover Dust, carbon dust, or mild dirt Housing inside and out Housing inside and out Greasy, oily, rusty, or other contamination Housing inside and out Housing inside and out, carbon brushes Corrosion Housing inside and out Other Approval for food industry; Use cold only! Attacks plastics! Only for the cleaning of metallic parts. Attacks plastics! Only for the cleaning of metallic parts. translated document page 16 of 27

17 7.7 Packaging/Processing/Sources B.W.R 210 S.L.X- Top O.C.X. Oxide remover Packing Loose goods Loose goods/spray bottle Loose goods / spray bottle Processing Source Mix at 1:50 / use with sprayer or high-pressure cleaner (lance distance > 0.7 m). Rinse cleaned area with water Undiluted with air-free, electrical spray gun/ Airless high-pressure cleaner Bremer & Leguil GmbH; Am Burgacker 30-42; Duisburg / Germany Phone: +49 (0) Fax.: +49 (0) Spray using aerosol cans/ Undiluted with air-free, electrical spray gun / minutes to work Caution: Always reclean with S.L.X. Top. translated document page 17 of 27

18 8 Error Diagnosis and Repair 8.1 Troubleshooting Errors that may occur in practice, if known, are listed in the table below with their corrective measures. Repairs may only be carried out by qualified technicians. Fault Troubleshooting Repair Movement of the rail cleaner on the rails not ideal Vibration noises from rail cleaner Pressure rollers crooked Pressure force of the pressure rollers too low Some screw connections may be loose Imbalance on the brush drive - Motor with gear off-center Imbalance on the brush drive - Gear under the round brush off-center Replace damaged rollers Replace tension springs Tighten loose screw connections Contact manufacturer Contact manufacturer Round brush worn Replace round brush (see ) Reconnect connector and hose. Rail cleaner no longer cleaning Air flow from the suction fan is too weak or nonexistent. Electrical power disconnected Check electrical connection to the suction fan. Service suction fan according to manufacturer instructions; contact the manufacturer of the suction fan if necessary. Reconnect the electrical components Round brush not turning Toothed belt skipping teeth - Tension in toothed belt too low Toothed belt skipping teeth - Toothed belt defective Toothed belt broken Retension the toothed belt (see 8.2.1) Replace toothed belt Replace toothed belt translated document page 18 of 27

19 8.2 Repair Toothed Belt Retensioning the toothed belt: The toothed belt can be tightened or loosened using a countered cylindrical screw [5] with an interior hex head. a) Remove safety guard [1] (cylinder screws [M4] with interior hex head). To do this: 1. Slightly loosen screw [2] and 2. Remove screws [3]. [2] [3] [1] [3] b) Loosen counter nut (M8) [4] [4] [5] translated document page 19 of 27

20 c) By turning the cylindrical screw (M8) [5], tighten or loosen the toothed belt. [5] d) Tighten the counter nut [4]. [4] translated document page 20 of 27

21 8.2.2 Round Brush Replacing the round brush: a) 1. Remove knurled screws [1] (2 screws). 2. Remove cover with holding bolts for the round brush [2]. [2] [1] [1] b) Take out round brush. c) Remove adapter plate [3] (top and bottom on the round brush) from the worn round brush [4] and mount them on the new round brush [5]. [3] [4] [5] [3] translated document page 21 of 27

22 d) Insert new round brush. Round brush must be lightly placed on the bolts and then turned into the proper orientation. e) 1. Replace cover with holding bolts for the round brush [6]. 2. Secure cover with both knurled screws [7]. [6] [7] [7] translated document page 22 of 27

23 9 Decommissioning, Dismantling and Disposal Temporary decommissioning If the rail cleaner will not be used for a period of up to 3 weeks, no measures are required. The system is ready to use. 9.1 Dismantling Before dismantling, thorough cleaning of all components of the rail cleaner is recommended (carbon dust). CAUTION! Risk to health due to carbon dust! Dust from the carbon brushes collects in the conductor rails, the cleaning head, and on the floor. This dust is very fine and is categorized as a health risk. For all work on cleaning hangers, especially while cleaning them, personal protective gear such as safety glasses, dust mask and gloves must be worn. Avoid contact with the mucous membranes. Do not breathe dust. Clean skin surfaces with water and appropriate cleaning agents after work. In case of contact with eyes, rinse with clear water. During maintenance work, accumulated dust may be disturbed and breathed in. It is mandatory to wear a dust mask! It is recommended that dismantling be carried out in the following order: 1. Disconnect the industrial vacuum cleaner (connectors with outer diameter 50 mm) and the cleaning head. 2. Disconnect all electrical components. 3. Dismount the control unit. 4. Dismount the connector plate (between the cleaning head and the current collector housing) (if present). 5. Remove the current collector housing from the EMS support profile. a) Open the flap with the current collectors. translated document page 23 of 27

24 b) Grip the housing underneath and pull it away from the support profile against the spring force [1.] and simultaneously attach the strap on the lower pressure roller [2.]. [2.] [1.] c) Open the lower flap of the housing using both clamp connectors (right and left of housing). d) Pull the housing up off the EMS support profile. To do this, pull against the spring force of the pressure roller [1.] and simultaneously tip the housing around the EMS support profile [2.]. [1.] EMS support profile [2.] translated document page 24 of 27

25 6. Remove the cleaning head from the EMS support profile. a) Grip the cleaning head underneath and pull it away from the support profile against the spring force [1.] and simultaneously attach the strap on the lower pressure roller [2.]. [2.] [1.] b) Open the lower flap of the cleaning head using both clamp connectors (right and left of housing). c) Pull the housing up off the EMS support profile. To do this, pull against the spring force of the pressure roller [1.] and simultaneously tip the housing around the EMS support profile [2.]. [1.] EMS support profile [2.] translated document page 25 of 27

26 9.2 Disposal The disposal of packaging and the rail cleaner is the responsibility of the operator and must be carried out according to valid national or regional law of the place of installation. Most components can be dismantled and reused (recycled). Component Material Disposal Components (steel) Steel Steel scrap recycling Component (aluminum) Aluminum Bright metal recycling Round brush with carbon dust Plastic and carbon dust Hazardous waste Strip brush with carbon dust Aluminum, plastic, carbon dust Hazardous waste Current collector (arm) Plastic Plastic recycling Current collector (head) Composite Hazardous waste Motor - Electrical scrap recycling Toothed belt Plastic Plastic recycling Roller with ball bearing Plastic, steel Residual waste Terminal box Plastic and electrical components Electrical scrap recycling Electrical components - Electrical scrap recycling 10 Spare Parts List Name Material number Round brush (D = 100 mm) Pressure roller Toothed belt Side brush set (system with rotating optical fiber transmitter) Side brush set (system without rotating optical fiber transmitter) Ball roller Pressure spring VD-207J DC Motor (24V) Clamp connector Comment: All figures are intended as visualization aids. They may not correspond to the current condition of a component or assembly! translated document page 26 of 27

27 Conductix-Wampfler GmbH Rheinstraße Weil am Rhein - Märkt Germany Phone: +49 (0) Fax: +49 (0) info.de@conductix.com translated document page 27 of 27