Operating Instructions
Contents
1. DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 12 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 Please fax the filled out form to 49 7621 662 284 For example e changed configuration data e experiences with the festoon system e recurrent errors e difficulties with documentation Your contact data Company Cust No Department Contact Person Address Zip code PO Box Zip code City Phone Fax Email Ihre Erfahrungen und Beobachtungen www wampfler com Seite 37 von 39 Produkt Management Produktbeobachtung Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 www wampfler com Seite 38 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 13 Appendix 13 1 Final handover document Customer no Customer Purchase no Contractor Confirmation no Installation Project designation Site Address Post code Gity2. Contact person Phone no Meeting point Start of installation on site End of installation on site Needed installation time in h Needed travel time in h The installation of above mentioned project has been ended today through the Wampfler AG Germany From today the risk is given over to the contractor The acceptance has been confirmed on the yes L customer specific taking over report Enclosure Maintenance instructions have been handed over yes L CE label is affixed yes E Complaint of the customer Complaint of the supplier Following works included in the order could not be achieved Installation supervisor Wampfler AG Installation supervisor customer Name Name Signature Signature Date Date www wampfler com Seite 39 von 39
3. 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 indicating that the system meets all requirements The commissioning is to be performed based on the Commissioning Checklist document 7 1 Inspections on deactivated system WARNING System damage from wrong action Protect the festoon system from inadvertent activation Safety devices that were removed during inspection of the resting system must be immediately remounted and checked after completion of work Check measuring tools used after clean up collection and inventory The following points are to be checked prior to commissioning the system e The track beam of the festoon system corresponds to the project specific technical documentation e The storage length of the festoon system corresponds to the project specific technical documentation e There are no height differences and that all buffers meet centrally www wampfler com Seite 25 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 e End
4. B www wampfler com Seite 16 von 39 Operating Instructions Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 For applications on which a constant rope loop must be guaranteed even in case of variations in temperature it is essential to always choose type B Towing trolley Towing trolley Fig 3 Types of arrangement for the rope fixation 6 2 2 Steel rope fixation with 2 tensioning screws CAUTION System damage from improper assembly During the assembly of the rope system it is recommended to check the proper operation with one of the supplied cable trolleys Required tools D NOTE 1 Measuring tool Accuracy 0 5 mm Wrench D eg www wampfler com Seite 17 von 39 Operating Instructions owens DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 Screw both support arms to the existing construction Then insert the steel rope into one of the opened tensioning screws and fix it with rope clips Afterwards the premounted tensioning screw is fixed into the support arm Now you place the towing trolley and the cable trolleys onto the steel rope The loose end of the steel rope is now assembled with the remaining tensioning screw placed into the support arm and secured against slipping out Now introduce the towing arm into the towing trolley and screw it to the mobile consumer Install the end cla
5. E ee 33 10 3 Repeat INSPOCtIONS siari aeisi akadai ariaa avian iai ae 35 10 4 Repair sennie ee E 35 www wampfler com Seite 3 von 39 Operating Instructions owens DELACHAUX GROUP Festoon Systems for Steel Ropes BALO200 0004 E Program 0210 0215 11 Spare ANAS TEE 36 KN Mee e EE 37 NS ee E elt EE 39 13 1 Final handover document 22 22 aan eeeinaae 39 www wampfler com Seite 4 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 1 Target audience for operating instructions The operating instructions are intended for qualified specialists 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 Safety and hazard information Safety and hazard information is identified in these operating instructions by symbols Signal words are used to indicate the degree of hazard Always observe safety and hazard information and work carefully to avoid accidents bodily harm or property damage DANGER indicates an immediately hazardous situation which if not avoided may result in death or serious injury WARNING indicates a possibly hazardous situation which if not avoided may result in death or serious injury CAUTION indicates a possibly hazardous situation which if not avoided ma
6. be adjusted so that the cables of the block have enough play gt 5 mm in the window The screws are to be lubricated recommendation Kl ber 46 MR 401 www wampfler com Seite 23 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 6 6 Cable trolleys with plastic support and split nuts CAUTION System damage from improper assembly Nominal clamping torque for the plastic split nuts 1 5 Nm Max permissible clamping torque 2 Nm Plastic support Split nut Fig 12 Cable trolley with plastic support and split nuts Required tools D NOTE 1 Torque key Sme www wampfler com Seite 24 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 7 Commissioning the festoon system WARNING System damage from improper mounting or construction of the festoon system Before commissioning perform a visual check The predefined inspection procedure has to be performed Any procedures that could threaten safety are to be avoided The system should only be operated with functional protective gear and safety devices Notify the responsible party immediately in case of damage to the festoon Protect the festoon system from accidental or unauthorized operation Itis forbidden to enter the operating area of the festoon system
7. nae EC 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 3 1 Intended use The machines are designed and constructed for the intended use only The festoon systems for C rails are only used for project specific requirements WARNING Possible injury resulting from improper use Any application that deviates from or goes beyond the intended use of the machine can result in a hazardous situation Any claims against the manufacturer and or its representatives for damages resulting from improper use of the products are excluded Non intended use includes the following e Exceeding projected load capacities e Exceeding projected speeds e Excessive braking deceleration e Use of inappropriate cables e Changing atmospheric conditions including a change to projected physical location e Bridging and or deactivating electrical sensors or switches www wampfler com Seite 8 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 e The presence of projecting edges too close to the surrounding steel framework of the cable trolley Intended use is also considered to be the correct observance of the operating conditions as well as the data and instructions of these operating instructi
8. required horizontal and vertical balancing movements Towing device Function test For functionality of the damping End clamp device especially when the system is in the storage latest after 300 operational hours Steel ropes and the complete installation if degree of pollution and corrosion affect the functionality Steel ropes and installation Every 14 days 3 and 4 shift operation at the latest after 300 operational Every 30 days 2 shift operation at the Should problems be identified during inspection the service work shown in chapter 10 2 should be performed www wampfler com Seite 32 von 39 Operating Instructions Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 10 2 Service WARNING System damage from wrong action Turn off power supply and ensure that no inadvertent activation is possible When installation tasks are carried out above eye level use proper climbing aids and working platforms Do not use machine components as climbing aids Ensure that exhaust collection and disposal of process materials is done in a safe and environmentally friendly manner Safety devices that were removed for installation service or repair must be immediately remounted and inspected after work is completed Observe the inspection and maintenance intervals described in the maintenance instructions Ensure that sufficient space for maintenance wor
9. ELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 10 Maintenance In order to retain the 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 WARNING Bodily harm The intervals indicated for maintenance are dependent for the most part on operational conditions of the festoon system Therefore only mean values can be indicated here The following tasks fall under the category Maintenance MAINTENANCE Inspection Service Repair Checking Cleaning Improving Measuring Cleansing Exchanging Inspecting Conserving Lubricating Expanding Adjusting www wampfler com Seite 29 von 39 Operating Instructions Festoon Systems for Steel Ropes Program 0210 0215 10 1 Inspection 10 1 1 Inspection on deactivated system WARNING System damage from wrong action Conauer x DELACHAUX GROUP BAL0200 0004 E Protect the festoon system from inadvertent activation Safety devices that were removed during inspection of the resting system must be immediately remounted and checked after completion of work Check measuring tools used after clean up collection and inventory Before approaching systems with damping devices these must be
10. End clamp 021164 Cable clip 020131 Fig 2 Completely mounted energy supply system with round cables www wampfler com Seite 13 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 5 Transport packaging and storage 5 1 Safety instructions WARNING Possible injury from falling objects During transport or loading and unloading there is a risk of possible injury from falling objects Therefore Do not lift loads over people Unauthorized transport CAUTION Possible damage from unauthorized transport e Transports performed by untrained personnel can result in substantial property damage Therefore Unloading the delivery as well as internal transport may only be performed by trained personnel under the supervision of the manufacturer s employees Improper transport CAUTION Possible damage from improper transport al Improper transports can result in substantial property damage Therefore Act with care when unloading the delivery as well as internal transport and observe the symbols and the hazard information 5 2 Transport inspection Check the delivery for completeness and transport damage immediately upon receipt If there is visible transport damage do not accept the delivery or only accept under reserve Take note of the scope of damage on the transport documents delivery note of the carrier File a com
11. Operating Instructions Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 www wampfler com Seite 1 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BALO0200 0004 E Program 0210 0215 Contents Page 1 Target audience for operating instructions uusnsssrsrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nennen 5 2 General information E 5 2 1 General safety informalion u uuu00uusaeenenn sense nnd 5 2 2 Information on operating INStrUCTIONS nenn 6 2 3 Applicable documents nenn 6 2 4 Limitation of liability 000nnnnsnnssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnn en 6 2 5 Re te LE 7 2 6 lee EC 7 2 7 Neie LE 7 3 le el eld ld ade ads a ee dere a Aa 8 3 1 e ER 8 3 2 Content of the operating instructions unssssnnnnnnnannnannnnnnnnnnnnnnnanennen 9 3 3 Changes and modifications to the machine 2444444444 44H nannnnH Henn 9 3 4 Operator respopnsibiltv cece cee i e a a a aea 9 3 5 Requirements on the personnel 10 3 6 Personal protective equipment 444444444004000R0Rnnnnnnnnn non nn nennen ernennen 11 3 7 Hazards posed by product ccccceee cece teeeteeeeeeeeeeee sees seed eeeeeeeeeeeeeneeeneeeseeeeees 11 4 IS dE 13 Transport packaging and Storage EEN 14 5 1 Safety instructions cccccccccccceecceeeceeeceeeeceeeceeecneeeeeceneceeeeceescen
12. anges without informing the recipient of these documents data Wampfler AG accepts no liability in as much as this is legally permissible for errors in this documentation or for damages that occur in connection with the delivery and use of the documentation 2 6 Spare parts WARNING Injury due to wrong spare parts Wrong or faulty spare parts can result in damages malfunctions or complete failure as well as impair safety Therefore use only original spare parts of the manufacturer The use of unauthorized spare parts renders null and void all warranty service compensation and liability claims against the manufacturer or his agents dealers or representatives 2 7 Disposal Properly disassembled components are to be recycled if no return or disposal agreement has been made e Metal parts are to be scrapped e Plastic elements are to be sent to the plastics recycling e The other components are to be disposed of according to their material composition www wampfler com Seite 7 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 3 Safety This section gives insight into all of the important safety aspects for optimal protection of personnel as well as for safe and trouble free operation The operator must observe the following standards and regulations when operating a festoon system 98 37 EC EC Machinery Directive pene
13. ans or persons under the supervision and direction of an electrician in accordance with electrical rules qualified specialists Mechanical hazards WARNING Loss of consciousness and injury due to crushing shearing cutting wrapping retracting blunt collision stabbing grinding slipping stumbling falling Causes Areas where danger of crushing shearing and wrapping exists Breaking and bursting of parts Ways to protect yourself Keep floors devices and machines clean Repair leaks Observe the required safety distance www wampfler com Seite 12 von 39 Operating Instructions Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 The festoon systems work at heights of more than 2 m WARNING Possible injury from falling parts Avoid standing under the system especially when it is running Always wear a hardhat and safety shoes 4 Construction System sketches NOTE The following images are model illustrations Deviations depending on the type of construction are possible Please observe the respective project specific documentation Cable trolley 021631021632 Towing arm 020531 End clamp Plate 020222 080 020190 End clamp 020222 080 Flat cable Fig 1 Completely mounted energy supply system with flat cables Trolley with Cable collar or Cable clip Towing arm SH 021136 aA AZ ez
14. ck cords if necessary oO o gt Tighten mounting screws Lubricate E Steel ropes BEE E fo E e 5 fm End Clam Tighten mounting screws H Possible replacement of wear parts 6 oo L 35 Surface i 5 E SE Refinish hot dip galvanized gt E a EES d surfaces with zinc coating og H Refinish lacquered surfaces gt gt coating ka E o x E gt www wampfler com Seite 34 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 10 3 Repeat inspections WARNING Injury and damage to the festoon system 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 All regular inspections are to be performed by the operator 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 10 4 Repair Request a customer service technician from Wampfler AG for all repairs If qualified service technicians from the system
15. clamp is mounted e All screws have a sufficient length and are secured The projecting ends of the screws are visible at least 2 thread projection e All screw connections are to be secured against loosening e Cables are to be arranged according to specifications in the cable arrangement recommendation see project specific technical documentation e Loop lengths of the cables correspond to the specifications of the project specific technical documentation The permissible length deviation is 50 mm e Cables are arranged free of twists e Cables show no damage caused by transport or assembly e Cables are mounted on the supports in such a way thatthe cable trolley is running horizontally on the steel rope observe torque balance of the cables e Cable clamps firmly tightened so that cables cannot be pulled out manually but still with enough play that the cables are also not crushed e Cable ends installation lengths are arranged with sufficient strain relief and the right length to the end or towing side e Cable clamps round and flat cable clamps are mounted in the loops corresponding to the project specific documentation system sketch with the necessary displacement Special component parts such as spacers additional clamp pieces and guide rings are to be mounted according to the project specific technical documentation e Checking for collision free driveway of the festoon system No catching intertwining of the cables towin
16. e 19 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 6 3 Assembly of the cables trolleys 021111 021112 021115 and 021116 CAUTION System damage from improper assembly Required tools D NOTE 1 Screwdriver een The cable trolleys of this standard have been designed in such a way that they can be mounted if the rope or wire is under tension Remove the screw and the roller first and then force the cable trolley apart figure a now move the cable trolley upwards press it together laterally and install the roller figure b Finally fix the screw figure c On the cable trolleys 021111 and 021112 hook in the cable collars 020111 020114 or the connecting ear 020113 first and finally press the hook together sketch a sketch b sketch c Fig 6 Assembly of the cable trolleys www wampfler com Seite 20 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 6 4 Laying of cables CAUTION System damage from improper assembly Use only appropriate flexible 6 4 1 Laying of round cables CAUTION Damage of the festoon system due to improper assembly Improper arrangement of the cables within the cable package and the loop will cause damage of the cables and the cable trolley technique Depending on the type of cable trolley the instal
17. eached a wave height of 1 3 of the rope 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 e Constrictions Replace in case of severe constrictions in the cable e Curl like deformation discard if the steel rope has been subject to consistent deformations e g because it has been drawn over an edge e Kinks Replace if kinks form after tension is applied to cable loops e Bends discard if bends have occured on the steel rope due to exterior influences www wampfler com Seite 31 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 10 1 3 Inspection on moving system WARNING System damage from wrong action Any procedures that could threaten safety are to be avoided The system should only be commissioned with functional protective gear and safety devices Itis forbidden to enter the operating area of the festoon system Inspections measures Interval Component Measure Description Rollers Visible wear damage Proper running in and running out Cable trolley lof the cable trolleys in the storage area For reliable operation of the towing device based on the
18. ecenseenseeneeeneeeeass 14 5 2 Transport inspection nen 14 5 3 Se e EE 15 5 4 ele Le 15 www wampfler com Seite 2 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BALO200 0004 E Program 0210 0215 6 ee 2 POS BABES NER EEE sects cao ed ions oateaawace asa saa eeingcre EEE AENEIELENEBESERDESIE PRNBURR 16 6 1 Safety INStrUCt ONS EE 16 6 2 Steel rope fixation 2 22 ccecceccccecccecceecceecceeeceecceeeccececececeeeceeceuseeeeeeneesenseetesenes 16 6 2 1 General EE eegene ine esse 16 6 2 2 Steel rope fixation with 2 tensioning SCrewsS REENEN 17 6 2 3 Steel rope fixing with tensioning screws roller trestle and counterweight 19 6 3 Assembly of the cables trolleys 021111 021112 021115 and 021116 20 6 4 El eege E 21 6 4 1 Laying of round We E 21 EE Elle TEE 22 6 5 Flat cableclamps u u anal 23 6 6 Cable trolleys with plastic support and split nts 24 7 COMMISSIONING the festoon sysiem n n ne ea Ate ees 25 7 1 Inspections Gn deactivated system eegener ege a I a a 25 7 2 Inspections on running SyStemS nee ee aaa 26 8 lte TE 27 Faults causes and solution nun en een 28 10 Oe 29 10 1 Inspection EE 30 10 1 1 Inspection on deactivated system cccccccceccsecceeceeecececeeeeeeeeeeeceneeeeeeeeeenees 30 10 1 2 Inspection of towing ropes and criteria for replacement ssssssseenoeeeeeeeeeeen 31 10 1 3 Inspection on moving SyStem EE 32 10 2 SONICO teens ee
19. ety devices Itis forbidden to enter the operating area of the festoon system The system is to be checked for changes in running noise and irregularities during operation If irregularities are determined during operation then the system is to be stopped imme diately The cause of the fault is to be determined using the fault table see chapter 10 The fault table includes the causes for the disturbance as well as the recommendations for their remedy If the cause cannot be determined or if there is no way to repair the system with the company s resources then we recommend that you request a service technician from our customer service www wampfler com Seite 27 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 9 Faults causes and solution WARNING Injury due to insufficient qualifications Improper use can result in serious injury to person and property Therefore Elimination of faults may only be performed by qualified specialists St rungen Ursache Beseitigung Roller function impaired EI Exchange roller Wear Noticeable mechanical strain of Exch ze the components bending tear Breakdown nn corresponding component wear D g p If injury to person and property can occur during breakdowns then Wampfler AG is to be immediately informed www wampfler com Seite 28 von 39 Operating Instructions Conauer x D
20. g ropes and shock cords 7 2 Inspections on running systems WARNING System damage from wrong action Any procedures that could threaten safety are to be avoided The system should only be commissioned with functional protective gear and safety devices Itis forbidden to enter the operating area of the festoon system Execution e Inspections on running systems with 10 running speed Forward direction from the trolley storage end clamp side towards the towing side until the cable tow is completely wound up Backward direction from the towing side towards the trolley storage end clamp side up to the end position www wampfler com Seite 26 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 The following items are to be checked e Horizontal alignment gap between the cable trolley and the crane construction is wide enough that no collision can take place with cable trolleys or their components e Check of the loop lengths at the maximum pulled out cable tow corresponds to the project specific technical documentation If no defects are detected then the check is repeated at 50 and 100 running speed The testing time in nominal operation is 30 minutes 8 Operation WARNING Bodily harm Any procedures that could threaten safety are to be avoided The system should only be operated with functional protective gear and saf
21. k is available Ensure that the festoon system is not inadvertently activated during maintenance work Ensure that detached parts do not fall Screw joints that are disconnected during maintenance work are to be reattached and secured as instructed Fasteners and seals that cannot be reused are to be replaced such as self locking nuts disks splints O rings glued or microencapsulated screws Lubrication points that are cleaned or wiped during maintenance and repair work must be re lubricated as instructed After finishing work collect all tools and materials and check that all are present Disassembled parts and components that were exchanged are to be collected stored in a safe place recycled or sent back Before approaching systems with damping devices these must be released www wampfler com Seite 33 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 Service tasks Interval Component Task Description Checking of function respectively damage Possible replacement of cable trolleys Roller mounting Tighten all Fasteners on clamping Cable mounting bars and cable clamps Every 14 days 3 and 4 shift operation at the latest after 300 operational hours Every 30 days 2 shift operation at the latest after 300 operational hours OI Towing device a Tighten all Fasteners D E oO S Damping device S Replace sho
22. lation of the round cables is made by cable collars 020111 or cable clips 020131 Optionally you can mount one tow or three different or equal cable clips one below the other It must be observed that if different cable clips are used the larger one must be fixed on top Fig 7 Cable collar 020111 Fig 8 Cable trolley with cable clips 020131 www wampfler com Seite 21 von 39 Operating Instructions Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 6 4 2 Arrangement of flat cables CAUTION System damage from improper assembly 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 towards the middle of the track beam so that the torque is in balance e When using layered flat cables give each layer of cables slightly less slack than the layer below e Cables with large copper diameters are to be placed symmetrically to the center of the trolley and at the top of the cable package e When using flag cable clamps only the uppermost cables are clamped The other cables must be freely movable in the flat cable clamp window e Tighten the screws of the clamping bar by hand The cables must be sufficiently clamped without causing damage to them The clamping force check is necessary when co
23. lia New Zealand sudden temperature fluctuations no uncontrolled except for temperate areas ventilation no aggressive vapors Protect against insect feeding www wampfler com Seite 15 von 39 Operating Instructions Festoon Systems for Steel Ropes Program 0210 0215 6 Installation Conauer x DELACHAUX GROUP BAL0200 0004 E 6 1 Safety instructions WARNING Injury due to improper installation Improper installation can result in serious injury to person and property Therefore The operation and maintenance personnel must have read and understood the operating instructions and in particular the guidelines on safety Installation of the festoon system must be performed by sufficiently qualified and trained specialists Protective gear for operation and maintenance personnel must be provided and used 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 6 2 Steel rope fixation 6 2 1 General information Usually there are two types of arrangement for the steel rope fixation A Steel rope fixation with 2 end straining screws B Steel rope fixation with end straining screw and deviating roller Rope loop h Recommended design of the tensile length I Prog 210 Prog 215 0 63 B 0 80 B 1 00 Not recommended B 1 25 B 1 60 A A and B 2 00 A A and B 2 50 A A and B 3 20 A A and
24. mental regulations are to be observed and adhered to www wampfler com Seite 9 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 e The operator and personnel authorized by him are responsible for the trouble free operation as well as for determination of responsibilities with regard to installation and maintenance of the products 3 5 Requirements on the personnel WARNING Injury due to insufficient qualifications Improper use can result in serious injury to person and property Therefore Only have special activities performed by persons mentioned in the respective chapters of these operating instructions The following qualifications have been mentioned in these operating instructions for different areas of operation e Instructed persons have been instructed by the operator about the tasks assigned to him her and the possible hazards resulting from improper use e Qualified specialists can assess the tasks assigned to them and recognize possible hazards based upon their specialized training knowledge and experiences as well as Knowledge about applicable conditions The responsibilities for the work on and with the products installation maintenance must be clearly defined and observed so that there is no unclear allocation of responsibilities and duties under the safety aspect Only persons capable of reliable work may work on or wi
25. mmissioning the system and must be inspected on a regular basis L IL tt 4x6 Luxe EEN Very good Good 100 clamping 50 clamping Fig 9 Arrangement of flat cables Thicker cables such as 4 x 50 are to be placed at the top of the cable package This allows for good heat dissipation and tight clamping of smaller cables Traction forces that occur during movement can be taken up by these cables Fig 10 Cable arrangement www wampfler com Seite 22 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 6 5 Flat cable clamps CAUTION System damage from improper assembly Improper positioning of the flat cable clamps can lead to damage of the cables and festoon system An improper fixation and arrangement of the cables in the flat cable clamp will cause damage of the cables and the cable trolley technique Clamp the uppermost cables in the flat cable clamp The other cables must be freely movable in the flat cable clamp window Required tools D NOTE 1 Hexagon wrench Allen wrench a A WS 5 Lubricant for screws Recommendation Kl ber 46 MR 401 Play gt 2 mm Main electrical line lt clamped Spacer Fig 11 Flat cable clamp The arrangement of the spacers allows for the height of the flat cable clamp to be adapted to the cable package The window for the control cable is to
26. mp on the feeding side and begin to lay on the cables As soon as the cables have been clamped in the festoon tension the rope by tightening the nuts at the tensioning screws End clamp Fig 4 Example of a complete energy supply system with 2 tensioning screws www wampfler com Seite 18 von 39 Operating Instructions Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 6 2 3 Steel rope fixing with tensioning screws roller trestle and counterweight CAUTION System damage from improper assembly During the assembly of the rope system it is recommended to check the proper operation by means of one of the supplied cable trolleys Required tools e NOTE 1 Measuring tool Accuracy 0 5 mm Wrench a The steel rope is introduced into the opened tensioning screw and fixed by rope clips After that install the premounted tensioning screw into the support arm and tighten it The towing trolley and the cable trolleys are now placed on the steel rope The loose end of the steel rope is now led over the deviating roller and tensioned with the counterweight Now introduce the towing arm into the towing trolley and screw it to the mobile consumer Install the end clamp on the feeding side and start to lay on the cables Roller trestle 021550 Tensioning screw 020188 Fig 5 Example of a bracing on two mats with counterweight www wampfler com Seit
27. nowledge into consideration The manufacturer is in no way liable for damages resulting from e Non observance of the operating instructions e Improper use e Subsequent changes and modifications to the system The written and visual illustrations do not necessarily correspond to the scope of delivery The illustrations do not correspond to a scale of 1 1 The actual scope of delivery may vary from the data and information described here as well as the visual representations due to special models the utilization of additional order options or recent technical changes For more information please contact the manufacturer All products are subject to technical modifications www wampfler com Seite 6 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 2 5 Copyright These operating instructions are to be considered as confidential They are intended solely for persons working with the product It is forbidden to pass on these operating instructions to third parties without the manufacturer s prior written consent amp NOTE 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 make technical ch
28. ons 3 2 Content of the operating instructions Before beginning work operation and maintenance personnel must have read and understood the operating instructions This also applies if the aforementioned personnel has already worked with this type or similar machines or has been trained by the manufacturer Reading the content of the operating instructions is a precondition to protect personnel from hazards as well as to prevent errors and therefore to operate the product safely and in a trouble free manner It is recommended that the operator have this acknowledgement of the content of the operating instructions confirmed by the personnel 3 3 Changes and modifications to the machine To avoid hazards and to ensure optimal performance no changes or modifications may be made to the machines that have not been expressly approved by the manufacturer 3 4 Operator responsibility e These operating instructions must be stored on site and always be kept readily available in a location near the festoon system e The festoon system may only be operated in good technical condition Before initial commissioning a visual inspection and predefined inspection is to be performed e The instructions in this manual are to be followed completely and precisely e In addition to the safety instructions and valid accident prevention regulations the general regulations regarding accident prevention and general safety regulations as well as the valid environ
29. 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 wampfler com Seite 35 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 11 Spare parts WARNING Injury due to wrong spare parts The installation and or use of unauthorized spare parts or accessories can have a negative impact on the structural properties of the festoon system and therefore affect active and passive safety No liability is accepted or warranty given for damages that occur from the use of unauthorized spare parts and accessories NOTE 1 Keeping a stock of the most essential spare and wear parts at the place of installation ensures constant operational readiness of the system For spare part orders please indicate the following data Part no see spare part list project documentation Description Piece number Desired mode of shipping postal freight sea air express Shipping address www wampfler com Seite 36 von 39 Operating Instructions Conauer x
30. plaint NOTE Complain about hidden defects as soon as they are detected since claims for compensation can only be made within the valid complaint period www wampfler com Seite 14 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 5 3 Packaging If no agreement regarding the return of the packaging has been made the materials are to be separated according to type and size and are to be reused or recycled CAUTION Always dispose of packaging material in an environmentally friendly manner and according to the local disposal regulations Hire a recycling company if necessary NOTE Good for the environment Packaging material is a valuable resource and can be reused processed or recycled in many cases 5 4 Storage Store package pieces closed until installation and observe the stacking and storage identification Observe the storage conditions listed in the following table Climate zone Storage location Temperate Covered and closed with constant temperature and Europe USA Canada China and humidity 5 C 50 C lt 50 relative humidity No Russia except for tropical areas sudden temperature fluctuations no uncontrolled ventilation no aggressive vapors Tropical Covered and closed with constant temperature and Asia Africa Middle and South humidity 5 C 50 C lt 50 relative humidity No America Austra
31. released first Inspection measures Interval Component Measure Rollers Center plate Cable supports Fasteners Cables Cable clamps Fixed installation length Installation connections latest after 300 operational hours3 shift latest after 300 operational hours Towing devices Every 14 days 3 and 4 shift operation at the Every 30 days 2 shift operation at the Steel ropes Visual inspection Description for proper condition for proper function for proper mobility for firm seating for deformations for wear for damages for dirt for corrosion www wampfler com Seite 30 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 10 1 2 Inspection of towing ropes and criteria for replacement WARNING Injury and damage to the festoon system Towing ropes must be inspected at regular intervals The inspections must be performed at least every 12 months If any defects have occurred the steel ropes must be immediately withdrawn from further use They must be discarded replaced A steel rope must be discarded if one or several of the following criteria have been fulfilled 1 Wire breakage 2 Structural changes 3 Corrosion 4 Abrasion The following cable deformations are grounds for replacement e Corkscrew like deformation A steel rope must be discarded if a corkscrew like deformation has r
32. th the products No work methods may be performed that affect the safety of persons the environment or the described product Persons who are under the influence of drugs alcohol or medication that affects the reaction time may not work on or with the products At the place of installation of the product personnel are selected on the basis of the valid age and professional qualifications related regulations The personnel are obligated to immediately report to the operator any changes occurring on the products which could have an effect on safety www wampfler com Seite 10 von 39 Operating Instructions Conguarx DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 3 6 Personal protective equipment When working on and with the products personal protective equipment must be worn in order to minimize health hazard Protective work clothing is close fitting work clothing that has a low tearing strength with tight arms and no parts that protrude It is mostly used as protection from getting caught by moving machine parts Do not wear any rings chains or any other jewelry Safety shoes used to protect from falling heavy parts and slipping on slippery floors Hard hat to protect from falling and flying parts and materials Protective gloves used to protect the skin from touching hazardous substances Protective goggles for eye protection 3 7 Hazards posed by product The produc
33. ts have undergone a hazard analysis The construction and design are based on the latest technology The products are safe when used properly However an element of risk still remains www wampfler com Seite 11 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 The product operates using high voltage current WARNING Death due to electric shock The electrical current could cause serious bodily harm Faulty insulation or individual components could lead to personal injury through electrical shock 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 Ways 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 cables or lines Always replace blown fuses with identical fuses Avoid touching live parts Use insulated tools All errors must be analyzed before remedying the problem Work on electrical systems or production equipment may only be performed by specialized electrici
34. y result in moderate or minor injury CAUTION indicates a possibly hazardous situation which if not avoided may result in property damage PBB Tips and recommendations 3 NOTE refers to useful tips and recommendations as well as information for efficient and trouble free operation www wampfler com Seite 5 von 39 Operating Instructions Conauer x DELACHAUX GROUP Festoon Systems for Steel Ropes BAL0200 0004 E Program 0210 0215 2 2 Information on operating instructions These operating instructions describe the safe and proper handling of the device The safety instructions and the valid accident prevention regulations and the general regulations regarding accident prevention for the area of application are to be observed Before beginning any work on the components operation and maintenance personnel must have read and understood the operating instructions and the Safety chapter in particular 2 3 Applicable documents The operator must consider the following documents as supplements of the operating instructions if applicable e Project specific technical documentation e Installation instructions e Maintenance instructions e Drawings e Spare part lists e Sketches 2 4 Limitation of liability All data and information in these operating instructions has been compiled while taking the valid standards and regulations as well as the state of the art and our long years of experience and k
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