Festoon, Heavy Duty, 314/315/320/325/330
Contents
1. Operating Instructions Covgugux DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 www conductix com Page 1 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Contents Page 1 Target audience for Operating instructions ccccecceeceeeeeeeeeeeeeeecaeecaeeceeeseeeseeenass 4 2 General MOR At sorisa S EAE Ea 4 2 1 General safety INTOrnmMatON ssnstinin e EE ENTENT end EER 4 21 1 Salety and NaZard INTOMMAHON wiccstcsnccssdermndioradeandeiwneviiuseaecdetuavonmnsieddguansietwantbecensan 4 2 2 General safety regulations and organization ccccseccescecseeceeeeceeeceeeeeeeeeueeseeesaees 5 2 3 opecialsalety NOLES erae e ea ea Ea Eee 5 2 4 Information regarding protection from hazardS cccceecceseceeeceeeceeeceeeeeeeeeeeseeenass 7 2 4 1 M cnanical MAAC Sie ete leks sence eno amconanneeconeneeiaeecnuaecaleeseecnneaunataneetecencemenoateaysesercouanceteaaty T 24 2 TCU AN na a OS eceso naa aa i ra a aa Ea aE a i T 2 5 ToCA SUS ia a E E A E EE EE TE 8 A9 TECNICA Aerenea aaae aA E a A aa a aa A Ra DEERE maS 8 29 2 KOpeat iNSPECHNONS sosisini EAEE E EAA ENEE EEANN ERNES 8 2 6 Mendo SS oe E T E AEE EE E E decedtiecemeneameveee 9 2 6 1 How to use the operating manual ccccecceccecceeeseeeeeceeceeeceeeeeceeesaeeaeeseeseeeseesensaes 9 3 Special iNStUCHoNS se2. 0325 0330 5 Maintenance In order to retain warranty rights and to avoid damage the system operator is responsible for performing the following maintenance tasks Inspection service and repair are to be performed and documented by trained and qualified specialists The following tasks fall under the category Maintenance Maintenance Inspection Senice Exchanging Expanding Adjusting 5 1 Inspection 5 1 1 Inspecting the deactivated system WARNING Bodily harm Before approaching systems with Damping devices these must be released Inspections Interval Description for proper condition for proper function for proper mobility for firm seating for deformations for wear for damages for dirt for corrosion O pu O oO Q 7 5 K2 gt oy _ HE 5 5 6 u c O Q O S O O 28 g Ar Y o G g T gt 0 2 gt LLI Every 14 days 3 and 4 shift operation at the latest after 300 opearational hours www conductix com Page 30 of 37 Operating Instructions Goanaucrix wampfler DELACHAUX GROUP Festoon Systems for I Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 5 1 2 Inspecting the activated system WARNING Bodily harm Observe the safety regulations Inspections Interval Component Descriptio for easy and unobstructed running of the main rollers horizontal guide
3. A d CAUTION System or property damage The horizontal alignment gap between the crane beam and track beam must not exceed 7 5 mm This tolerance should include a possible alignment deviation of the trolley winch NOTE Required tools and materials Crane beam Track beam Sketch 8 Poor vertical alignment between the crane beam and track beam CAUTION System or property damage A The horizontal alignment gap between the crane beam and track beam must not exceed 15 mm This tolerance should include a possible alignment deviation of the main trolley of the crane a th as a eos y e Et i cor 5 a a i ae T aE se a gla le a ma ee ght 2 x r ail x a o a ee ae roe ia eke o 2 Crane beam Track beam www conductix com Page 14 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 3 2 Complete assembly NOTE The use of a pre assembled festoon system with pre attached cables on the cable trolley will save a significant amount of time and money In this case the complete system is delivered on a mounting structure and inserted into the front of the track beam WARNING Danger of bodily harm Lifting of loads may only be performed by qualified specialists Safety regulations must be observed General legal regulations regarding accident prevention and e
4. DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 3 7 Running cables CAUTION System or property damage Only suitable flexible cables may be used 3 7 1 Running round cables CAUTION System or property damage Improper arrangement of cables in the cable package and in loops can damage the cables and the festoon system The projected cable setup for the festoon system is to be maintained The following rules are recommended e Place the cable package into the track beam so that the balance of torque is in the middle e Cables with large copper diameters are to be placed towards the center of the trolley and arranged symmetrically e When using cable trolleys with multiple cable support the heaviest cables are to be placed on the uppermost support e When using cable trolleys with multiple cable support the uppermost cables should be made slightly shorter than the cables below Each layer of cables should be given somewhat less play than the cables below them e When using round cable clamps cables should be run on the outer surface of the supports that are suitable for anchoring the round cable clamps Unshielded cables with a large copper diameter are preferred e The clamping bars of the cable supports are to be screwed on tightly enough that thin cables are not pulled through during operation but that cables are not damaged by being over tightened If necessary clampi
5. System or property damage Improper positioning or removal of spacers in round cable clamps can cause damage to the cables or the festoon system Sketch 22 Spacer 3 9 1 Flat cable clamp CAUTION System or property damage Improper positioning of the flat cable clamps can lead to damage of the cables and festoon system Improper mounting and arrangement of cables in the flat cable clamp can damage the cables and the festoon system Clamp the uppermost cables in the flat cable clamp The other cables must be freely movable in the flat cable clamp window Sketch 23 inne inn inn i oo yI www conductix com Page 24 of 37 Operating Instructions Covauarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 24 Power cables clamped Control cables with free _ space in the window 3 10 Towing rope CAUTION System or property damage Ensure that the shackles and thimbles can be freely moved after installation Sketch 23 3 10 1 Mounting the towing rope NOTE o Required tools and materials The towing rope is mounted between two cable trolleys Ensure that the shackles can be easily moved after tightening the self locking nut The shackles must be serviced at regular intervals see the section Maintenance If towing ropes are used with retaining bushes the retaining bu
6. 1 Mounting the towing rope cccceccecceeececeeeeeeeteeeeeeseeaeeceesaeeseesaeeaeeseeeeeseeseeenensaees 20 3 10 2 Inspection of towing ropes and criteria for replacement ccccecceeeseeeeeeeeeeeees 26 3 10 3 Maintenance Of towing rOPES cccccceecceeeceeceeecaeecaeecaeeceeeeeeeneeeseeeseeeeeeeeeeeseesaeess 2 3 11 ARTA OLS WNC SS acacia ren rE EEE E umaaie sempeeee 28 4 Commissioning the festoon System ccccsecceeeceeeeseeeceeeeceeecaueceeeeseeeeeueesaeeeseeeeas 29 4 1 Inspections after installing the festoon SYSTEM ccccceecceeeceeeeeeeeeesaeeeeeeeeeseeeees 29 4 2 Functional testing of the festoon system ccccecceseceeeceeceeceeeceeseeeseeeseeeaeeseeeees 29 4 3 Operating the festoon SYSTEM ccccecccseecceeeceneceeeeceeeeceeecaeeeeseecaueesaeeseueeseeesaueeses 29 5 PRU MUMMY LN O enna E E ep E E E 30 5 1 MSDEC UO eea et neers calc tn E E E Ceel ere ote 30 5 1 1 Inspecting the deactivated system cccccsccsecceeeeeceeceeeseeseeeeeeeeeeeeeseeeaeeseeeeeeseneaes 30 5 1 2 Inspecting the activated system cccccceceeceseceeeseeeeeeceesaeeeeesauecessseseesseesenseeenees 31 5 2 SONIO O ee een eee eee Eee on eee ee E ere eee ene en Tee 32 5 2 1 Wenna if 9 c lq seer etter eee ane eee mene se eee Se ee ee eee ee ee eee ee ee eee 33 SA WO UNIS ccd cece faa ct eeescceprnce E T EEEE 33 So gt 92 2 a en ee eee eee ee ee ere 34 5 3 POD a E E E E E E E 34 6 OOO OI
7. girders must not exceed 2 mm Transitions must be ground smooth within about 100 mm of the beginning of the cut All transitions must be beveled and rounded NOTE 8 Required tools and materials Horizontal and vertical p deviation 2 mm Edges beveled and rounded _ e ae Se Edges beveled and rounded Smooth and clean the transitions in all directions up to 100 mm away from the beginning of the cut www conductix com Page 12 of 37 Operating Instructions Covgugux DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 5 Horizontal deviation of track beams CAUTION System or property damage The horizontal deviation over the length of the track beam may not exceed 5 mm For lengths shorter than 2 m deviation may not exceed 2 mm NOTE Required tools and materials Sketch 6 Vertical deviation of track beams CAUTION System or property damage The vertical deviation over the length of the track beam may not exceed 5 mm For lengths shorter than 2 m deviation may not exceed 2 mm www conductix com Page 13 of 37 Operating Instructions Conauarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 7 Poor horizontal alignment between the operator s crane beam and the track
8. 0314 0315 0320 0325 0330 4 Commissioning the festoon system The festoon system is commissioned together with the system operator and is documented All necessary personnel for commissioning including crane operators electricians and installation technicians are to be provided by the system operator for the course of commissioning Free access to the system must be provided After successful commissioning Wampfler AG will receive a final handover document that is authorized by the system operator see the last page of the commissioning checklist indicating that the system meets all requirements The commissioning is to be performed based on the Commissioning Checklist document 4 1 Inspections after installing the festoon system e Check the cable trolley for proper condition function and movement firm seating and for deformations e Check electrical connections and supplies for secure guiding and seating e Check functionality of track beams e Check the steel construction for projecting edges firm seating and mobility 4 2 Functional testing of the festoon system For commissioning the festoon system must be operated with a nominal load 4 3 Operating the festoon system For operation it is mandatory that the safety notices in Chapter 1 are observed www conductix com Page 29 of 37 Operating Instructions Comaugyyx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320
9. A EE A E E A A A A E E 35 Prod ct On Sl AO ING sasiciessidiiobeinisnsninninnaidan inadai naidata irai i aana etnan 35 www conductix com Page 3 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 1 Target audience for operating instructions The operating instructions are intended for qualified personnel who install the festoon systems operate them and who are familiar with the requirements regarding work safety and accident prevention 2 General information 2 1 General safety information 2 1 1 Safety and hazard information The following symbols and designations are used in these operating instructions as safety and or hazard information WARNING Bodily Harm Serious physical injury or fatal accidents may result if work and operating instructions with this symbol are ignored or not followed properly Notices in the Warning category are to be strictly followed ATTENTION Machine Property Damage Serious machine or material damage may result if work and operating instructions with this symbol are ignored or not followed properly Notices in the Attention category are to be exactly followed INFORMATION o Work is facilitated if you follow advice and operational instructions with this symbol INFORMATION Refers to another applicable document y www conductix com Page 4 of 37 Operating Instructions Con
10. auarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 2 2 General safety regulations and organization The operating instructions must always be stored in a readily accessible on site location near the festoon system In addition to the operating instructions general regulations regarding accident prevention and environmental protection are to be observed The operator must observe the following standards and regulations when operating a festoon system 98 37 EG EU Machinery Directive naomi EU Low Voltage Directive DIN EN ISO 12100 Machine Safety IEC 60038 IEC standard voltages IEC 60364 Electrical installations of buildings IEC 60947 Low voltage switchgear and controlgear Accident prevention regulations e Installation set up maintenance and operation of the festoon system must be performed by sufficiently qualified and trained specialists e Before beginning work operation and maintenance personnel must have read and understood the operating instructions and safety guidelines in particular Protective gear for operation and maintenance personnel must be provided and used e The system operator or his her representative is to supervise machine operation to ensure the safety of personnel when working on or with the system 2 3 Special safety notes Transport Installation e Individual parts and larger assembly groups are to be secured on suitable hoisting devices
11. beam are to be protected from corrosion with appropriate measures Sketch 1 Smoothing of welded track beams CAUTION System or property damage Bumps and uneven areas on all sides of the welded track beams are to be sanded smooth for a length of 100 mm NOTE 8 Required tools and materials sanded www conductix com Page 10 of 37 Operating Instructions Conauarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 2 Use of even welded track beams A CAUTION System or property damage Welded joints on the track beams must be even at points that could come into contact with the cable trolleys Fasteners and suspended objects that could come into contact with the cable trolleys are not permitted No uneven areas fasteners suspended N a objects etc Sketch 3 Girder joint for non welded track beams A d CAUTION System or property damage For non welded girder joints the gap between girders must not exceed 5 mm The cut is at a 45 angle NOTE Required tools and materials www conductix com Page 11 of 37 Operating Instructions Conauarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 4 Girder joint for non welded track beams CAUTION System or property damage A For non welded girder joints the horizontal and vertical separation between
12. e observed see Sketch 11 CAUTION System or property damage Height differences greater than 5 mm between the cable trolley and the end clamp buffer must be compensated for by installing a filler plate see Sketch 11 When installing the cable trolley with a buffer on one side ensure that contact is always between buffers or between the buffer and the end stop but that end stops do not collide The end clamp should be installed and adjusted with deviation of no more than 1 see Sketch 13 from the longitudinal and transverse axes of the track beam To take up the buffer energy a shear plate is to be attached see Sketch 13 www conductix com Page 16 of 37 Operating Instructions Conauerx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 11 Height equalization of the end clamp by a steel packing plate Track beam A AN PAn oun js C lt max permissible height offset e H Val N ie Ah 5 mm If Ah is greater than 5 mm use steel packing plate Sketch 12 Permissible deviation between end clamp and track beam Track beam End clamp permitted deviation 1 www conductix com Page 17 of 37 Operating Instructions Covgugux DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 13 Welded shear plate on the track beam NOTE 8 Required
13. egular inspections are to be performed by the operator www conductix com Page 8 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 2 6 Intended use The festoon system is built in accordance with recognized safety technical regulations using the latest technology and has been checked for safety compliance by the manufacturer Only festoon systems that are in good technical condition may be employed for their intended use These may only be operated by trained personnel aware of safe operating practices and possible hazards Intended use of the system also includes the observance of manufacturer operation service and maintenance requirements See Chapter 4 Non intended use includes the following e Exceeding projected load capacities e Exceeding projected speeds e Excessive braking deceleration e Use of inappropriate cables see also Chap 2 5 e Changing atmospheric conditions including a change to projected physical location e Bridging and or deactivating electrical sensors or switches e Use of technically inappropriate guide systems Such as inappropriate or corroded track beams poorly aligned girder joints etc see Chap 2 1 e The presence of projecting edges on the surrounding steel framework too close to the cable trolley The manufacturer is in no way liable for damages to the system or third parties resulting from non
14. f the cable package to the track beam center e When using layered flat cables give each layer of cables slightly less slack than the layer below e When using cable trolleys with multiple cable supports the uppermost cables should be made slightly shorter than the cables below Each layer of cables should be given somewhat less play than the cables below them e Cables with a large copper diameter are to be placed symmetrically to the center of the cable trolley and at the top of the cable package e When using flat cable clamps only the uppermost cables are clamped The other cables must be freely movable in the flat cable clamp window www conductix com Page 21 of 37 Operating Instructions Covgugux DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 19 CZTDCEITD CETD CZTDCEITD CETD i 1 t l 4 Very good Good Poor 100 clamping 50 clamping Sketch 20 Thicker cables such as 4x50 are to be placed at the top of the cable package This allows for good heat dissipation and solid clamping of smaller cables Traction forces that occur during movement can be taken up by these cables 3 8 Cable clamps 3 8 1 Round cable clamps CAUTION System or property damage Improper positioning of the round cable clamps can lead to damage of the cables and festoon system Improper mounting and arrangement of cables in the ro
15. intended use 2 6 1 How to use the operating manual As a supplement to the operating instructions the operator must observe the following documentation if available e Project specific technical documentation e Installation instructions see Chap 2 e Maintenance instructions see Chap 4 e Drawings e Spare part lists e Sketches www conductix com Page 9 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 3 Special instructions 3 1 Track beam The operator is basically responsible for ensuring that the track beam is securely fastened as well as checking it for wear corrosion or defects The following procedures are to be observed when installing the track beam CATION System or property damage In general track beams are to be protected from corrosion using appropriate measures The running surfaces of the main rollers and the horizontal guide rollers must be clean and free of objects or defects that could damage the rollers scratches cracks holes uneven segments etc If multiple beams are welded together they must all have the same measurements and positional tolerances The beam flanges are to be aligned with particular care in horizontal and vertical planes Track beams that have been damaged during transport or rolling must not be used Modified areas from welding sanding etc on the track
16. ke technical changes without informing the recipient of this document these data Wampfler AG accepts no liability inasmuch as this is legally permissible for errors in this documentation or for damages that occur in connection with delivery and use of the documentation Wampfler AG 2007 7 Product observations We strive to observe our products after delivery in order to further improve them and better meet your needs Please use the form on the following pages to communicate your experiences and issues with us that could be of interest for our improvement process Thank you very much for your help For example e changed configuration data e experiences with the festoon system e recurrent errors e difficulties with documentation www conductix com Page 35 of 37 Product Observation Fax to 49 0 7621 662 284 Prod uct M an agement solutions for a moving world Festoon systems for l Beams Prog 0314 0315 0320 0325 0330 Your contact data Company Cust No Department Contact Person Address Zip code PO Box Zip code City Phone Fax Email Your experiences and observations www wampfler com Page 36 of 37 Product Observation Fax to 49 0 7621 662 284 Prod uct M an agement solutions for a moving world Festoon systems for l Beams Prog 0314 0315 0320 0325 0330 www wampfler com Page 37 of 37
17. moved for installation service or repair must be remounted and inspected after work is completed e Observe the inspection and maintenance intervals described in the maintenance instructions e Observe the directions in the operating and maintenance instructions for replacing parts e Ensure that sufficient space for maintenance work is available e Ensure that the festoon system is not inadvertently activated during maintenance work e Ensure that detached parts do not fall e Screw joints that are disconnected during maintenance work are to be reattached and secured as instructed e Fasteners and seals that cannot be reused are to be replaced such as self locking nuts disks splints O rings glued or microencapsulated screws e Lubrication points that are cleaned or wiped during maintenance and repair work must be re lubricated as instructed e After finishing work collect all tools and materials and check that all are present e Disassembled parts and components that were replaced are to be collected stored ina safe place recycled or sent back www conductix com Page 6 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 2 4 Information regarding protection from hazards Hazard areas must be identified with warning signs and be protected with barriers Ensure that hazard area notices are observed Hazards can result from e imp
18. ng pieces can be used Sketch 16 Diameter differences If possible the diameter of the round cables should be fairly uniform This helps to prevent them from getting clamped on the cable supports 300909 e278 NENON NTN Reon DD ayo 1 x 120 1 x 120 1 x 120 1 x 120 1 x 120 1 x 120 un cO x 1x 35 1x 25 1x 185 1x 35 1x 25 1x 25 1x 185 www conductix com Page 20 of 37 Operating Instructions Conauarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 17 Using Clamping Pieces For differences in diameter for adjacent O ip A n D 2 cables that are more than 15 mm clamping D x 7 a pieces are to be used for tight clamping M ra BS 027 8 027 8 Clamping piece AEK ASAS ANA Sketch 18 Balance of cable torque Pay attention to the balance of torque when positioning the cables The thicker heavier cables are to be placed in the middle 1 x 185 1 x 150 30 x 2 5 30 x 2 5 1 x 150 1 x 185 N N O x x be oO Oo x lt x lt mM mM Ca 1 x 150 1 x 150 Balenced Unbalanced Very good Inadmissable 3 2 Arrangement of flat cables CAUTION System or property damage Improper arrangement of cables in the cable package and in loops can damage the cables and the festoon system The projected cable setup for the festoon system is to be maintained The following rules are recommended e Balance of torque o
19. nvironmental protection are to be observed Loads are to be carefully secured onto suitable hoists or load carrying devices that are technically intact and have sufficient load capacity The use of a load track may be required depending on the weight of the system Before lifting a mounting structure ensure that the festoon system is firmly installed on the mounting structure Only lift mounting structures in a horizontal position Sketch 9 Complete assembly G PE N Load Track Olie FOLO www conductix com Page 15 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 3 3 Adjusting the running gear of the cable trolleys The horizontal guide rollers of the cable trolley are delivered set to the maximum width tolerance indicated for the track beams stated at the time of ordering with the exception of Prog 0314 Sketch 10 Adjusting the horizontal guide rollers to the actual width of the beam Distance A between both sides of the cable trolley should not exceed the beam width by more than 40 mm After adjusting the side section ensure the screws are properly secured A CAUTION System or property damage A b max 40 Track beam ide shields 3 4 Attaching the end clamp to the beam When attaching the end clamp to the beam the following should b
20. or load carrying equipment that are in good working order and have sufficient load capacity For electrical and mechanical connections e Connections are only to be made by personnel specially trained for the given task For commissioning and operation e Before initial commissioning and daily start up a visual check and predefined inspection procedure is to be performed see Chapter 4 e Any procedures that could threaten safety are to be avoided e The system should only be operated with functional protective gear and safety devices www conductix com Page 5 of 37 Operating Instructions Covgugux DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 e Notify the responsible party immediately in case of damage to the festoon system e Protect the festoon system from accidental or unauthorized operation e tis forbidden to enter the operating area of the festoon system See also intended use in Chapter 2 6 For cleaning service repair maintenance reconditioning e Turn off power supply and ensure that no inadvertent activation is possible e When installation tasks are carried out above eye level use proper climbing aids and working platforms e Do not climb on machine components e Check cables for wear or damage e Ensure that exhaust collection and disposal of process materials be done in a safe and environmentally friendly manner e Safety devices that are re
21. rani a a ee es 10 3 1 TACK DO ee E E E E E E 10 3 2 Complete ASSES DIY siccheeh ceaucod napi aE EE aa ene a eae 15 3 3 Adjusting the running gear of the Cable trolleys ccccccseeceeeseeeeeeeeeeeeeeeeeeeaeeees 16 3 4 Attaching the end clamp to the D QM ccccccscceecseceseeeeeeseeeeeseeeaeeseeseasseeeaeeneesans 16 3 5 Attaching the towing clamp to the crane towing arm s ssesssssssnnerenrnnnnrennernnnnnnne 18 3 6 Festoon systems with towing trolley Crane interface cccccceccseeceeeceeeeeeeeeeees 19 3 PTI A Se sacteeteetucnattoeanisen E E E E E 20 3 7 1 RUNNING YOUNG CAC Se si ecesiececcetecs ccsersshcucqusnedadoertaerdecsecssdadebeat an seceiauaeueiauss iesca 20 3 2 Arrangement of flat cables ce ccecceecceeeceeeceeeceeeceeceeeceeecaeeeagecaseseeeseeeseeeseeesaees 21 www conductix com Page 2 of 37 Operating Instructions Conauarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 3 8 caca D ae E O E A ee ers 22 3 8 1 ROUNA CADIE CAMPS ssrin ria a a rar 22 3 8 2 Mounting the round ClAMPs ccccccceccecceseeeceseceecseeesessesoeeceeseeeeeeseeeeuesseseeeseesenes 22 3 9 Sl anger aa pacer Fed geri de aie tie Haas T E T 24 3 9 1 PAT CGI CIAD ings toss cus seectuareateameawamesamseupateuauau tesaieontancvedecatseueasaseutanede seasiuatansuees 24 3 10 MOVIN TODO esecrceactie son seeatainct en corttereateceanceeubensuasast E 20 3 10
22. rollers and anti lift rollers on the track beam running surfaces for proper entry and exit of the cable trolleys in the storage area for reliable operation of the towin devices based on the required horizontal and vertical balancing movements for functionality of the towing ropes and damping devices especially when the system is completely extended of the track beam and the entire system for dirt and corrosion that influence functionality Rollers Cable trolleys 4 gt O C E cC Q 0b Q O Q O ap B g Towing ropes w Damping devices n V Oo amp 0b ke c 2 _ 0b Q O O i N a gt gt LLI Track beams and Every 14 days 3 and 4 shift operation at the latest after 300 opearational hours system Function Test Should problems be identified during inspection the service work shown in Point 5 2 should be performed www conductix com Page 31 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 5 2 Service WARNING Bodily harm Before approaching systems with Damping devices these must be released Service tasks Interval Description Roller mounting Tighten all Fasteners Tighten all Fasteners on clamping Cable mounting bars and cable clamps Towing device Replace worn parts if necessa
23. roper use e failure to adequately observe safety notices e inadequate inspection and maintenance work 2 4 1 Mechanical hazards WARNING Bodily harm Unconsciousness and injury due to crushing pinching cutting wrapping retracting blunt collision stabbing grinding slipping stumbling falling Causes Areas where danger of crushing pinching and wrapping exists Part failure or explosion Ways to protect yourself Keep floors devices and machines clean Repair leaks Observe the required safety distance 2 4 2 Electrical hazards All errors must be analyzed before remedying the problem Work on electrical systems or production equipment may only be performed by specialized electricians or persons under the supervision and direction of an electrician in accordance with electrical rules qualified personnel WARNING Bodily harm Death due to electric shock injury and burns due to Touching live sources Faulty insulation Inadequate maintenance and repair Short circuits Causes Touching or coming too close to uninsulated current bearing parts Using uninsulated tools Current bearing parts that are laid bare due to insulation failure Inadequate safety checks after maintenance work Use of improper fuses www conductix com Page 7 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Ways
24. ry Every 14 days 3 and 4 shift operation at the latest after 300 opearational hours lataest after 300 operational hours Damping device Replace shock cords if necessary Every 30 days 2 shift ooperation at the Maintenance measure Tighten mounting screws Lubricate shackles Towing rope Every 3 monts Surface corrosion Refinish hot dip galvanized surfaces with zinc coating Refinish lacquered surfaces protection Corrosion protective coating influences Improve replace Varies dependent on external The bearings of the trolley rollers do not require service www conductix com Page 32 of 37 Operating Instructions Festoon Systems for I Beams Conauarx DELACHAUX GROUP BAL0300 0007 E Program 0314 0315 0320 0325 0330 5 2 1 Wearing parts Wearing parts are excluded from the warranty This includes e All trolley rollers including main rollers horizontal guide rollers counter pressure rollers e Shock cords on damping devices e Special damping devices in the towing trolley window e Rubber or cellular buffers e Other definitions require written documentation 5 2 2 Wear Limits Component Rollers Buffers Center plates and side shields Cable supports Fasteners Cables Cable clamps Towing ropes Towing devices www conductix com Wear limit has been reached if the diameter of the roller has been reduced from the nominal diameter by 2 mm sharp impre
25. shes must be pressed or hammered into the drill hole in the center plate of the cable trolley www conductix com Page 25 of 37 Operating Instructions Conauerx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 25 Towing rope grease Shackle must be able to move 7 freely after mounting TE 3 10 2 Inspection of towing ropes and criteria for replacement In case of defects towing ropes are to be taken out of operation immediately and replaced A towing rope must be replaced if one or more of the following criteria are fulfilled 1 Wire breakage 2 Structural changes 3 Corrosion 4 Abrasion CAUTION System or property damage A Towing ropes must be inspected at regular intervals The inspections must be performed at least every 12 months The following cable deformations are grounds for replacement e Corkscrew like deformation A towing rope must be replaced if it has corkscrew deformations with waves that measure more than a third of the cable diameter e Fraying Replace the cable if it starts to fray e Loop formation Replace the cable if loop formation has led to significant changes in the cable structure e Loosening Replace if wires are loosened due to rust or abrasion e Node formation Replace if nodes points where the cable is widened form in the steel cable w
26. ssions can be seen cracks broken off pieces or embrittlements have formed on Vulkollan or Adiprene rollers or if initial signs that the outer section is disengaging from the core appear increased bearing play occurs due to worn ball bearings significant lubrication leakage is seen the rollers do not run smoothly cracks breaks or embrittlements are seen corrosion protection has failed corrosion protection has failed initial signs of cracks in the supports are seen corrosion protection has failed connection integrity screw joints clamp connections glued connections is no longer ensured wire shielding or jacket breakage is seen corkscrews have formed corrosion protection has failed cracks and embrittlements are seen in the clamp rubber the clamp does not hold cables sufficiently see Chap 3 10 2 wires break structural changes occur corrosion and abrasion see chapter 3 10 2 if there are broken wires structural changes corrosion and wear and tear Page 33 of 37 Operating Instructions Conauarx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Component Wear limit has been reached if End clamp corrosion protection has failed attachment to the track beam is no longer secure Damping devices and corrosion protection has failed shock cords severe constrictions in the shock cords occur the mantle of the shock cordis even partially torn fraying s
27. to protect yourself Ensure that current to machines and system parts that are to undergo maintenance work is turned off and protected against reactivation Check parts to ensure that they are free of current Cover and isolate nearby live parts Check electrical equipment regularly Immediately replace loose or damaged cable or lines Always replace blown fuses with identical fuses Avoid touching live parts Use insulated tools 2 5 Technical status These operating instructions were prepared in May 2007 2 5 1 Technical Data INFORMATION See project specific technical documentation such as system sketches cable running suggestions and round or flat cable clamp layout 2 5 2 Repeat inspections Every operator is to record all inspection service and maintenance tasks in a machine book in an orderly manner This is to be confirmed by a technical expert In case of inaccurate or missing entries the warranty is rendered null and void Devices and systems are to be periodically inspected by an expert In general visual and functional checks are to be performed The condition of components with regard to damage wear corrosion or other damage is to be determined Generally speaking the completeness and functionality of the safety equipment is evaluated To better evaluate the wear and tear of parts disassembly may be required A CAUTION System or property damage CAUTION System or property damage All r
28. tools and materials Track beam Welded shear plate End clamp 3 5 Attaching the towing clamp to the crane towing arm CAUTION System or property damage Height differences between the cable trolley buffer and the towing clamp buffer or towing clamp deflector must be equalized using a filler plate When installing the cable trolley with a buffer on one side ensure that contact is always between buffers or between the buffer and the end stop but that end stops do not collide The towing clamp should be installed and adjusted with a deviation of no more than 1 from the longitudinal and transverse axes of the track beam The free space h between the towing arm and the lower border of the track beam must be at least 12 mm www conductix com Page 18 of 37 Operating Instructions Conauerx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 14 Permissible deviation between towing clamp and track beam permissable deviation max 1 3 6 Festoon systems with towing trolley crane interface CAUTION System or property damage A The towing arm must have enough play in the opening towing window in all directions The towing arm is to be aligned to the center of the towing window Sketch 15 Aligning the towing arm in the towing window Towing Arm Towing unit www conductix com Page 19 of 37 Operating Instructions Conauerx
29. trands on the shock cord appear mechanical deformations on the shock cord consoles appear Track beam corrosion protection has failed significant tracks from the rollers of the cable trolley unit appear 5 2 3 Spare parts The following spare parts are available e cable support complete with clamping bar and fasteners e side shield complete with trolley rollers 5 3 Repair Request a customer service technician from Wampfler AG for all repairs If qualified service technicians from the system operator perform the repairs themselves all information contained in these operating instructions must be observed Wampfler AG accepts no liability or responsibility for damages and production faults that result from failure to follow these operating instructions For maintenance and repair only use e suitable tools in good working order e original spare parts from Wampfler AG or spare parts that have been explicitly approved by Wampfler AG www conductix com Page 34 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 6 Copyright This documentation is protected by copyright law The rights established herein including translation reprinting the use of figures radio transmission reproduction using photographic or similar methods or saving in electronic format remain reserved even for partial use Wampfler AG reserves the right to ma
30. und cable clamp can damage the cables and the festoon system 3 8 2 Mounting the round clamps NOTE o Required tools and materials www conductix com Page 22 of 37 Operating Instructions Comaugyyx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 Sketch 21 Mounting the round cable clamps mounted Inner cable loose ie Not mounted Outer cable ra damped Clamp round cable with Profile side Spacer It is recommended that the round cable clamps be preassembled as shown in this diagram in order to maintain two identical halves Diagram for round cable clamp subassembly Clamped Loos Clamped The outer left and right cables are firmly clamped between the rubber profiles Ensure that the inner cables can move freely in the round cable clamp window If spacers need to be used in order to prevent turning and superimposition of cables insert them before closing the cable clamp The use of spacers depends on the diameter of the cables The cable clamp screws must be lubricated Screws must be tightened crosswise www conductix com Page 23 of 37 Operating Instructions Comaugyyx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 3 9 Spacers CAUTION
31. ww conductix com Page 26 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 e Constriction Replace in case of severe constrictions in the cable e Curling Replace the towing rope if permanent deformations are present such as those caused by being pulled over a corner e Kinks Replace if kinks form after tension is applied to cable loops e Bends Replace the towing rope if it has been bent by an external force 3 10 3 Maintenance of towing ropes NOTE o Towing ropes and the accompanying connection elements and stops are to be serviced We recommend regular maintenance using cable spray every four weeks www conductix com Page 27 of 37 Operating Instructions Conauanx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program 0314 0315 0320 0325 0330 3 11 Damping devices The damping device is to be mounted in accordance with installation instructions WARNING Bodily harm Before performing maintenance or approaching a system with Damping devices release the Damping devices A CAUTION System or property damage Ensure that the mounting eyes and Shackle for the towing rope can be freely moved after installation NOTE Required tools and materials www conductix com Page 28 of 37 Operating Instructions Conaucrx DELACHAUX GROUP Festoon Systems for l Beams BAL0300 0007 E Program
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