Conductor Bar Series 812

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Cecil Hudson
5 years ago
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1 Conductor Bar Series 812

Contents Page 1 Completeness of the delivered parts... 1 2 Hints... 2 3 Installation... 2 4 Maintenance... 6 5 Photos of relevant system parts.

2 Contents Page 1 Completeness of the delivered parts Hints Installation Maintenance Photos of relevant system parts... 8 In addition to other advantages, the Conductix-Wampfler single pole insulated conductor rail, program 0812, 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 chapter 5), 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 Hanger clamp End cap Current collector PE (green stripe) Towing arm 2

The maximal 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.

3 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 maximal 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 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 hanger clamp. Rail clipped into the track 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 Conductix-Wampfler conductive grease 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.. 3

Notch Rail joint Conductor rail with screwed connector. Placing the connector cover halves into the conductor rails. Completely mounted rail connector.

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.

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.

Diagonal cutting pliers are similar Anchor point: Anchor clamps positioned right and left, next to the hanger clamps.

The power feed can be installed within a conductor rail section or at every rail joint instead of the rail connector.

4 Notch Rail joint Conductor rail with screwed connector. Placing the connector cover halves into the conductor rails. Completely mounted rail connector. 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 left, next to the hanger clamps. Completely mounted anchor point: the support stripes 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 Conductix-Wampfler conductive grease 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. 4

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

The cover halves are clipped together enclosing the power feed clamp and screwed together with the already fitted cable sleeves and nuts.

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 2 nd cover halves!

5 Cable sleeve Cable lug Rail joint Feeding: completely mounted connections. The axle centre of the cable must be in alignment with the cable sleeve. Feeding equipped with power feed covers. 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 2 nd 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. 5

6 Air gap allowance on expansion joints Both air gaps in an expansion joint must be identical! Ambient temperature during assembly [ C] Instructions tmin = lowest temperature that occurs in the respective area of application. tmax = highest operational temperature that occurs in the respective area of application. Draw a connection line from tmin to tmax. Mark the ambient temperature during operation horizontally. Draw a line from the intersection vertically down and read the air gap to be set. Examples = Temperature range from -30 C up to +110 C (ambient temperature during installation: +20 C) Air gap (read): 16 mm Air gap [mm] = Temperature range from -0 C up to +60 C (ambient temperature during installation: 0 C). Air gap (read): 25 mm On conductor rail systems > 200 m it is required to install expansion joints at certain intervals: Number of expansion joints Intermediate length a Material St Al Cu Δt ges DV (expansion joint) FP (anchor clamp) a (intermediate length for an expansion joint) L (total length of conductor rail installation) 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. 6

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.

7 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 a 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. 4 Maintenance Im Abstand von einem halben Jahr sind folgende Prüfungen nach Inbetriebnahme der Anlage vorzunehmen: Hanger clamp 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 and Power feed 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. 7

8 Expansion joint 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 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. Stromabnehmer bis a) Check the installation dimensions according to Catalogue KAT 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 ). 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. If you use the current collector type strip the cable 15 mm on one side, enter it into the connector up to the end position and fix it with the screw. 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 ). 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 WV E). For additional information see our catalogue KAT E. 8

9 5 Photos of relevant system parts ; Hanger clamp with steel nut ; Hanger clamp for C-rail support arm ; Anchor clamp ; Rail connector ; Air gap insulating section ; Power feed ; End cap ; Insulating section ; Pick-up guide (4 poles) ; Expansion joint 9

10 / ; Support arm / ; Weld-on bracked for support arm ; Girder clip ; Towing arm ; Cable lug for feeder cable / 02- / ; Insulator ; Current collector ; Double current collector ; Collector shoe (spare part) / 06- / 07- / ; Current collector / 06- / 07- / ; Double current collector ; Collector shoe (spare part) 10

11 Notes 11

12 Conductix-Wampfler 2013 Subject to Technical Modifications Without Prior Notice USA / LATIN AMERICA F Street Omaha, NE Customer Support Phone Fax Phone Fax info.us@conductix.com latinamerica@conductix.com CANADA J.A. Bombardier Mirabel, QC J7J 0H5 Customer Support Phone Fax Phone Fax info.ca@conductix.com MÉXICO Calle Treviño 983-C Zona Centro Apodaca, NL México Customer Support Phone (+52 81) (+52 81) (+52 81) Fax (+52 81) info.mx@conductix.com BRAZIL Rua Luiz Pionti, LT 05, QD. L - Vila Progresso Itu, São Paulo, Brasil CEP: Customer Support Phone (+55 11) Fax (+55 11) info.br@conductix.com Contact us for our Global Sales Offices

1 Product Description System Layout Safety Instructions Intended Use Installation... 3

1 Product Description System Layout Safety Instructions Intended Use Installation... 3 Part Number 0812xx- Contents 1 Product Description... 2 2 System Layout... 2 3 Safety Instructions... 3 4 Intended Use... 3 5 Installation... 3 5.1 Hanger Clamp... 3 5.2 Cutting of Conductor Rail... 4