Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

Order number
0812xx-...

TABLE OF CONTENT
Page

1. Completeness of the delivered parts 1

2. Hints 2

3. Installation 2

4. Maintenance 6

5. Photos of relevant parts 8

In addition to other advantages, the Wampfler Single Pole Insulated Conductor Rail,
programme 812, excels by ist easiness of assembly. To ensure the easiness of assembly
the following points are to consider:

1. Completeness of the delivered parts

Please check first, if the individual parts are completely delivered (see Photos on page 8
and 9), if they comply with the shipping papers and if they are free of damage.

System arrangement:

Support arm Power feed

Conductor rail

Rail connector

Anchor clamp

PE (green stripe)
Hanger clamp

End cap Current collector Towing arm

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

2. Hints
The insulated conductor rail system will be installed onto the existing support structure.
The mechanical correct installation of the support arm must be checked before the start
of conductor rail installation. The max. horizontal and vertical tolerance between the
crane rail and rail holder support bracket is ± 5 mm. It has to be ensured, that the
support construction is rectangular to the crane rail.
The conductor rail components for the different bays are arranged as shown in the
conductor layout drawing with the respective connection diagrams and part lists.

3. Installation
First the hanger clamps are fitted to the support brackets with nut tightening torque
Mt = 7 Nm. No aligning of the hanger clamp is necessary because the clamp is self-
aligning. An exception is the compact hanger clamp. This one is only suited for indoor
use and horizontal conductor rail arrangement. It can be fixed by pushing in a C-rail (size
30 mm) and fixing by square nuts or it can be directly mounted on a support plate (Mt =
7 Nm). Now we can clip the conductor rail and expansion joints into the rail holders.
Centre distance between hanger clamp and rail connector: ≥ 200 mm!

Support arm

Introduce conductor rail below approx. 45° into track Rail clipped into the track hanger clamp
hanger clamp

The rail connector is now fitted. It joins together adjacent lengths of conductor rail. To
guarantee proper current transfer at the joints, all contact surfaces should be cleaned
and covered with a thin layer of Wampfler conductive grease 080021. The conductor rails
will now slided into the rail joints. The rail ends and the rail joint marking should be in
accordance. By tightening the bolts (Mt = 11,3 Nm with galvanized and 9,75 Nm with
stainless steel) the rails will be mechanically fixed. When preparing conductor rail
sections it must be noted that the insulation cover is always 80 mm shorter than the rail.
Both halves of the connector cover are hooked below the rail and closed up above the
joint. That will electrically insulate the rail joint.
notch Rail joint

Conductor rail with screwed Placing the connector cover halves into Completely mounted rail
connector the conductor rails connector

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

The 2 rail connector cover halves can be screwed additionally at the lateral cover plates
with enclosed self-tapping screws.

The anchor clamps must be positioned on the conductor rail as indicated (usually in the
middle of the system), before the rail connector is fitted. For each anchor point one
anchor clamp must be positioned on either side of a hanger clamp, as shown. The
anchor clamp screws are only tightened after final adjustment to the expansion joints are
completed.
Note: On systems with L ≤ 200 m expansion joints are not required. For systems with
L > 200 m see separate item of these installation instruction.
Observe accessibility of the screws! Diagonal cutting pliers are similar

Anchor point: Anchor clamps positioned right and Completely mounted anchor point: the support stripes
left, next to the hanger clamps can be removed (after the assembly) if required

The current from the supply is connected to the rail by the power feed. The power feed
can be installed within a conductor rail section or at every rail joint instead of the rail
connector. The power feed should be installed as near as possible to the source of the
incoming power. If the power feed is required within a conductor rail section, the
insulation cover must be separated and 40 mm must be cut off on either side. Please
note that a space (centre distance ≥ 300 mm) must be available between power feed and
hanger clamp for the expansion of the conductor rail due to the temperature variation.
Also a cable loop has to be provided (about 300 mm), so that a system-expansion can
not pull off the cable.
To quarantee proper current transfer the contact surfaces should be cleaned and
covered with a thin layer of Wampfler conductive grease 080021.
The power feed clamp is pushed on to the conductor rail. The feeder cables are fastened
to the power feed clamps and by tightening the screws (Mt = 11,3 Nm with galvanized
and 9,75 Nm with stainless steel) an electrical connection of the power feed clamp with
the conductor rail is achieved.
Cable sleeve Cable lug

Rail joint
Feeding: completely The axle centre of the cable must be Feeding equipped with power feed
mounted connections in alignment with the cable sleeve covers

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

Both halves of the power feed cover are hooked under the rail and the inner snap
fastener of the insulation cover must be placed between the two clamping bolts. The
cover halves are clipped together enclosing the power feed clamp and screwed together
with the already fitted cable sleeves and nuts.
If the power feed is installed of the rail connector the installation must be made
according to the installation hint for the rail connector with regard to the above
mentioned feeder cable installation.
The expansion joints are supplied pre-assembled. A rail holder must be positioned on
the center of the section.
Illustration shows the
expansion joint without the
2nd cover halves!

Standard for setting: 0-25 mm

A hanger clamp has to be placed in the centre part of the expansion joint!

If the rail installation is completed to the next anchor point, both air gaps of the
expansion sections must be set as per following diagramme, corresponding to the
ambient temperature during assembly.
Air gap allowance on expansion joints
Both air gaps in an expansion joint must be identical.
Instructions:
tmin = lowest temperature that occurs in the respective
area of application.

tmax = highest operational temperature that occurs in the

respective area of application.

1. Draw a connection line from tmin to tmax.

2. Mark the ambient temperature during operation
horizonally.
3. Draw a line from the intersection vertically down
and read the air gap to be set.

Examples:
c = Temperature range from –30°C up to +110°C
(ambient temperature during installation: +20°C).
Air gap (read): 16 mm

d = Temperature range from –0°C up to +60°C

(ambient temperature during installation: 0°C).
Air gap (read): 25 mm

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

On conductor rail systems > 200 m it is required to install expansion joints at certain
intervals:

Then the anchor clamps are moved close to the rail holder and positioned with the
locking screws. Thereafter the expansion section is checked to have the correct air gap
and smoth operation of the collector shoe passing through.

Each rail end is protected by an end cap which is

pushed onto (the final end has to be burred) the
end of the conductor rail with gentle blows of a
hammer and tightening by the clamping screw.
The distance measured from the end of the end cap
to the centre of the hanger clamp is max. 250 mm.

End cap Hanger clamp Support arm

To determine the distances between the track

support brackets for the support arm assembly it is
required to use an mounting jig. The standard
distance between the centre lines of the conductor
rails is 50 mm.
Standard distance 50 mm Special distance 40 mm

Distances between the poles < 40 mm

require a stagged position of the feed
lines and expansion joints!

After completion of the installation the system must be mechnically and electrically
tested before the power is switched on. The correct position of the collector and
operation must be checked by driving the crane in slow speed over the complete system.

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

4. Maintenance

The following points must be inspected at 6 month intervals after commissioning:

Hanger clamp 081241-...

a) Correct tightening of the nuts.
b) Correct position of the rail within the hanger clamps.
c) Free movement of conductor rail within the hanger clamps. Free movement for
expansion.

Rail connector 081221-... and Power feed 081251-...

a) The correct position of the rail in the rail joint to be checked, max. distance between
rail ends 2 mm. If the distance is more than 2 mm reconnect the rail joint or power
feed.
b) Check that the rail ends are smooth and do not protrude beyond the contact surface.
c) Check the correct tightening of the cable connection.

Expansion joint 081261-...

On the expansion joint we have to check the correct tightening of the cable connection.
The distance of the 2 air gaps must be checked according to the setting instructions
described in the “Instruction for the installation of conductor rail system”. If the difference
is more than 5 mm to the actual setting expansion section has to be reset to the correct
air gap distance.

Anchor clamp 081231-...

The anchor clamp must be checked of the correct and rigid position. If the anchor clamp
is not close to the rail holder it must be repositioned but in accordance with the correct
adjustment to the expansion joint.

Conductor rail 0812XX-...

a) The rail insulation must be checked for visual damage, cuts or deformations due to
external interferences like mechanical damage or extensive ambient temperature. If
required insulation cover to be replaced.
b) Further it must be checked that the insulation lips located left and right of the rail
opening are not subject to exessive wear. Normally there is no wear on this lips but
should there be wear detected the collectors must be adjusted. If the damage is
excessive the insulation cover must be replaced.

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

Current collector 081205-... to 081209-...

a) Check the installation dimensions according to Catalogue KAT0812-0001-E and re-
adjust them if necessary.
b) Check the contact pressure of the collector shoe with a spring scale. The contact
pressure must be 20 N (10 N for 081209). The spring is to be replaced if the contact
pressure is less than 20 N (10 N).
c) Check the position and the fastening of the connecting cable. The connecting cable
may not handicap the current collector head.
d) The collector shoes have to be replaced if the carbon is worn down to 2 mm up to the
insulation of the collector shoe.
e) Hinges resp. bolts have to be oiled slightly (except 081209).

Heating system
a) Check all the safety fuses. Replace them if necessary.
b) Check all the heating wires on electrical continuity.

Please note:

On cleaning the runway and the mobile equipment etc. take care that only solvent free
cleaning agents are used, which don’t react aggressive and destructive to plastic
material such as PVC, PC and PBTP (see also WV0800-0001-E).

For additional information see our catalogue KAT0812-0001-E.

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

5. Photos of relevant system parts

081241-...; 081243-...; 081231-...;

Hanger clamp with steel nut Hanger clamp for C-rail support arm Anchor clamp

081221-...; 081294-...; 081251-...;

Rail connector Air gap insulating section Power feed

081271-...; 081296-...;
End cap Insulating section

081281-...; 081261-...;
Pick-up guide (4 poles) Expansion joint

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Installation Instruction

MV0812-0009a-E
Single Pole Insulated Conductor Rail
Programme 812

020185-... / 020186-...; 020285-... / 020286-...; 020180-...;

Support arm Weld-on bracked for support arm Girder clip

020195-...; 080051-...; 080401-... / 02- / 03-...;

Towing arm Cable lug for feeder cable Insulator

081209-...; 081209-...; 081001-...;

Current collector Double current collector Collector shoe (spare part)

081205-... / 06- / 07- / 08-...; 081205-... / 06- / 07- / 08-...; 081001-...;

Current collector Double current collector Collector shoe (spare part)

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