Installation Instructions for Conductix Wampfler Conductor Bar Program 0811

Quick guide from the manual

This document provides installation and maintenance instructions for the Conductix Wampfler Conductor Bar (Program 0811). Key requirements include using the correct collector height (80 mm for copper-graphite, 75 mm for pure graphite) and ensuring proper alignment to prevent damage to the conductor rail isolation. BMW installations specifically require the use of plate 08-P025-0191-001.

Collector Unit and Polarity Protection

The collector unit is designed for EMS systems. The manual highlights the importance of the PEplus Polarity Protection system. Ensure that all PEplus end caps on the conductor rails are green to correctly identify the system.

Replacing Copper-graphite with Pure Graphite Collectors

When upgrading or replacing collectors, note the following height differences:

• Copper-graphite collector height: 80 mm (when engaged).
• Pure graphite collector height: 75 mm (when engaged).
• Plate requirement: A 5 mm plate must be used when installing pure graphite collectors to maintain the correct distance.
• Alignment: The exact center line of the copper rail and the brush head must be maintained.

Mistakes to Avoid

To ensure system longevity and prevent damage, avoid the following installation errors:

• Improper cable installation: Do not bundle cables or use cable markers, as this creates force on the collector heads. Ensure a parallel cable guide is used.
• Misalignment: If the brush head is aligned too high, it will run at an angle and grind the plastic isolation of the conductor rail.
• Collector heads: Ensure they run parallel to the conductor rail.

Recommendations

• When dismantling EMS trolley doors for collector changes, mark all doors with numbers corresponding to the trolley numbers to maintain the correct combination.
• Check all collector support brackets ('Z'-bracket) for exact angles and parallel surfaces relative to the trolley door and conductor rails.
• Check the position of door hinges.
• Use Conductix-Wampfler high-flexible cables.
• Check the existing brush wear sensor unit, as a new setup may be required.