POWER BAR SYSTEM ECONOMICAL ENCLOSED CONDUCTOR SYSTEM FOR MOBILE EQUIPMENT M O B I L E E L E C T R I F I C A T I O N

Transcription

1 A e r o B A R POWER BAR SYSTEM ECONOMICAL ENCLOSED CONDUCTOR SYSTEM FOR MOBILE EQUIPMENT M O B I L E E L E C T R I F I C A T I O N

2 AeroBAR Enclosed Conductor Bar System AeroBAR provides many of the advantages of Aero-Motive s standard Pow-R- Feed system at a cost competitive with single hard bar systems.the continuous contact, totally enclosed, multi-conductor system is designed for use in many mobile electrification applications including hoists and overhead cranes. Continuous Conductor Strips Flexible copper conductors deliver reliable, trouble-free power to mobile equipment with up to 1700 feet without joints. Joint free design ensures longer brush life, reduced signal interference and minimal voltage drop. Safety No exposed live electrical parts which can be accidentally touched or bumped with a ladder or tool. No thermal expansion problems "Free Floating" design allows for the various expansion rates of the conductors, housing and mounting. Each element moves independently of each other, eliminating the distortion and/or open joints experienced with conventional fixed bar systems. Typical AeroBAR Systems Joints in single bar systems (right) can corrode due to moisture and capillary action. End Feed Box Page 5 Fixed Point Clamp Page 3 Joint Clamp Page 3 Sliding Hanger Page 4 Housing Page 3 End Cap Page 4 Trolley Page 7 Line Feed/ Splice Box Page 5 Compact design & interchangeability It can fit almost anywhere. Get up to 5 conductors in a space half as wide as 3 single bars. The system can be mounted to existing support brackets at 5 ft. intervals. Multiple trolleys can be used to meet higher amp requirements or to power additional equipment. Travel speed up to 329 ft/min. Optional ball bearing wheels are available. Top wheels can also be added to the trolley. Indoor and outdoor application Galvanized and zinc plated hardware make the system suitable for outdoor use. Optional sealing strips protect the contacts from dust and humidity. Stainless steel components are also available for tough environments Simple installation and flexibility The single housing makes it possible to install AeroBAR in less than half the time required of single bar systems. If power requirements change in the future, higher capacity conductor strips can be substituted without removing the existing housing. (see page 8 for installation tools) etc. End Feed System Line Feed System 5 etc etc

3 5 ABH10 STANDARD HOUSING The ABH10 housing is available for operating temperatures ranging from -30 C to 60 C (-22 F to 140 F) and standard lengths of 10 feet. An anti-reversing rib A is incorporated in the profile, which ensures that the collector trolley can only be installed in one direction, preventing accidental cross-phasing. The housing is bright orange in color for high visibility and has a black stripe B on one side to ensure proper alignment of the anti-reversing rib. T E C H N I C A L D A T A Properties Test Method Typical Values Flammability UL94 V-0 Flexural Strength, psi ASTM D Tensile Strength, psi ASTM D Notched Izod Impact, ft-lb/in ASTM D Heat Deflection Temperature at 264 psi, F ASTM D Coefficient of Thermal Expansion in/in F ASTM D x105 Voltage Rating 600 V Chemical Resistance Resistant to grease, caustic soda solution up to 50%, gasoline, mineral oils, sulfuric acid up to 50% and concentrated hydrochloric acid (the Aero-Motive supplier should be consulted regarding the use of AeroBAR under chemically aggressive conditions, since the above mentioned resistivities do not apply to the copper conductors). Optional sealing strips provide a high degree of protection. 2 AB400K FIXED POINT CLAMP Each system should be secured to the support structure adjacent to the electrical feed point via a fixed point clamp. The system is allowed to expand freely from this position. When a line feed is used, a fixed point clamp is positioned on each side of the feed box. One is required for End Feed system, and two are required for Line Feed systems. AB400K Galvanized steel ABS400K Stainless steel (AISI 304) for corrosive environments AB300K JOINT CLAMP The housing sections are connected by means of the joint clamp. The joint clamps are provided with angle returns which grip the housing while aligning the clamp halves, thus providing a quick means of ensuring a secure joint. AT50 insulating tape must be used with joint clamps. AB300K Galvanized steel for corrosion protection. ABS300K Stainless steel (AISI 304) for corrosive environments. All brackets and clamps are suitable for high temperature systems AT50 INSULATING TAPE Ensures a permanent seal around the housing joints prior to installation of the joint clamps. This tape is required on all installations, both indoor and outdoor. Each No. AT50 roll of tape is 10 meters long and is enough to seal 40 joints. See page 8 for system installation tools. Page 3

4 4 AB500K SLIDING HANGER BRACKET Sliding hangers are used to support the conductor housings. The hangers are designed with rounded edges and sufficient clearance to allow the free expansion of the system due to temperature changes. The hanger is suspended via a mm bolt. The bolt is provided with additional locking nuts for simple vertical alignment of the system. Two required for each 50 or 80 amp housing section. Three required 3.04 for each 125 amp sections. AB500K for standard galvanized or ABS500K for stainless steel ABHEC END CAP End cap is used to seal off the open ends of an AeroBAR system. NOTE: A joint clamp AB300K is required to attach the end cap to the conductor housing. One is required for end feed systems and two are required for line feed systems USB UNIVERSAL SUPPORT BRACKET Galvanized steel brackets are used to support the fixedpoint clamp and sliding clamps. They are provided with special sliding clamp assemblies which make it possible to mount to a wide range of I-beams without welding or drilling. The sliding clamp feature also provides simple horizontal alignment of the AeroBAR system. ABSS FLEXIBLE SEALING STRIPS ABSS (Neoprene Sealing Strip) The sealing strips are used to seal dirt, moisture and corrosive materials out of the ABH housing. They are recommended for outdoor installations. The collector trolley opens and closes the sealing strips while traversing. The sealing strips are sold in continuous lengths. Specify twice the length of the AeroBAR system when ordering. ABSSH (Hypalon) Same as ABSS but for applications requiring higher resistance to acids. ABSSH seals are used in environments such as galvanizing plants. Special Pressurized Systems For extremely dirty or corrosive atmospheres, clean and dry low pressure compressed air can be introduced into the housing at multiple points (about every 10 feet) to prevent the entrance of foreign material. ABIU INSPECTION UNIT The inspection unit may be used on installations where inspection of the collector trolley is not possible by removing an end cap or end feed cove. They are also used when several collector trolleys are operating in one system, or when a specific location for inspection is necessary. ABIU Housing halves and clamps ABSIU Housing halves and stainless steel clamps Page 4

5 1 ABEB END FEED BOX Connects the power supply to the copper conductor strips at the end of the system. ABEB End Feed Box with galvanized hardware ABSEB with optional stainless steel hardware ABLB LINE FEED KIT Connects the power supply to the copper conductor strips at any point along the system. 5 ft. housing section, box and connectors included. ABLB80 up to 80 amps (option: ABSLB80 Stainless Steel Hardware) ABLB160 up to 160 amps (option: ABSLB160 Stainless Steel Hardware) A = 11.5 (ABLB80)(ABSLB80) A = 17.5 (ABLB160)(ABSLB160) 8 AB1000 SPLICE LINE FEED KIT Same as line feed box except housing sections configured for splice line feed applications. Two 2.5 ft. housing sections, box, and hardware AB1000 with galvanized hardware ABS1000 with stainless steel hardware ABEJ EXPANSION JOINT Expansion joints are required on systems with locked-in housing sections where free expansion is restricted. They may also be needed on long systems exceeding maximum lengths with standard joint clamps as per chart on page 6. Expansion joints create small independently expanding sections, each with its own fixed point clamp, and installed so the expansion of that section is absorbed by gap set at this special joint. Contact Aero-Motive for proper specification. Must use double or triple gang trolley on systems with expansion joints. ABEJ with galvanized hardware ABSEJ with stainless steel hardware Kits include the expansion joint and a Fixed Point Clamp. Must use an ABTDX or ABTTX trolley; no single gang ABTSX allowed. Page 5

6 SERIES AB COPPER CONDUCTOR STRIPS Low-voltage applications (under 12 volts) should consider silver-plated conductor strips and silver graphite brushes. Please consult factory. If you are ordering AB1000 splice line feed box please specify number of conductor strips, conductor size and length. Each span between connections must be dealt with individually. Example: a 4-conductor AB80 system 500 feet long with a line feed connection located 200 feet from one end would require four pieces No. AB80, 300 feet long and four pieces No. AB80, 200 feet long. Voltage drop per foot conductor/ per amp of nominal current, cos ϕ =1, +20 C ambient Model Number Amperage Rating 30 Min. Motors Full Time Max. Continuous Copper Length 3-phase Power Single Phase DC Power AB ft AB ft AB ft With the use of a line feed connection, located at the center of a system, lengths twice those shown above can be attained. AITCS copper straightener is required for installation of AB125 or AB160 copper. See page 8 for system installation tools. With a power factor of <1, the above figures must be changed accordingly, e.g. with cos ϕ -.85 volt drop figures must be multiplied by.85. (Example: System of 300m with 3-phase, 40- amp load, end feed. AB50 copper 300 x 40 x = 423 V) M A X I M U M T R A C K L E N G T H S W I T H S TA N D A R D J O I N T C L A M P S Difference in min. and max. ambient temperature 50 F 68 F 104 F 140 F >140 F Conductors AB50 and AB80 ft. ft. ft. ft. ft. Max. length when end feed Max. length when center feed Conductors AB125 and AB160 ft. ft. ft. ft. ft. Max. length when end feed Max. length when center feed Track lengths shown here indicate the maximum system length that can be installed without concern for the effects of thermal expansion. For greater lengths, consult factory. ABHT TRANSFER GUIDES Transfer guides are required to guide collector trolleys properly from one conductor housing to another on rotating or sliding switches. Mechanical tolerances, horizontal and vertical, can be no greater than 10 mm (.394 ) ABHT Trumpet, splice box, two fixed-point clamps, and housing ABSHT Trumpet, splice box, two stainless fixed-point clamps, and housing NOTES: Consult Aero-Motive when selecting guides. Travel speed, expansion, amperage, and double trolleys, are only some of the many variables needing consideration. Transfer guide systems require special trolleys and tow arm. See trolley page (1657.2) R E F E R E N C E : AMPERAGE FOR AC MOTORS Induction type: Full load current in amps HP 230V 460V 575V These values of full-load current are for motors running at speeds usual for belted motors and motors with normal torque characteristics. Motors built for especially low speeds or high torques may require more running current, and multispeed motors will vary full-load current according to speed, in which case the nameplate current rating should be used (752.7) 6.6 ( (88.6) 11.5 (291.0) Page 6

7 7 SERIES ABT COLLECTOR TROLLEYS Collector trolleys transfer current from the conductors in the AeroBAR housing to the mobile equipment. Spring-loaded copper graphite brushes or optional silver brushes on the trolley maintain positive contact. Trolleys are suitable for travel speeds up to 300 FPM. Trolleys can be ordered for 3, 4 or 5 conductors. Higher amperage is obtained by connecting multiple trolleys. Trolley No. of amps Accessories Model cond. full time transition box tow arm ABTS OG357 BMV35 ABTS OG357 BMV35 ABTS OG357 BMV35 ABTD OG705 BMV70 ABTD OG705 BMV70 ABTD OG705 BMV70 ABTT OG1005 BMV100 ABTT OG1005 BMV100 ABTT OG1005 BMV100 ABTS5 SPECIFYING TROLLEY OPTIONS ABT = AeroBAR Trolley S = single trolley, D = double, T = triple, P = single w/ spring loaded tow arm number of conductors (3, 4 or 5) none = copper-graphite brushes, AG = silver brushes, E = dedicated (CE) ground brushes T = top wheels included, Z = top and side wheels included none = standard wheels, S = wheels with ball bearings none = standard 5 ft. of cable lead, xf = x ft. of cable lead none = standard vertical cable lead, 90 = horizontal cable lead ABT D 4 AG T 10 EXAMPLE: 4 conductor double trolley with silver brushes, top wheels, 10 ft. lead ABTD5 ABTT5 OG TRANSITION BOXES Trolleys come with a 5ft. pig tail to terminate in a transition box or directly to the equipment. Use OG357 with ABTS trolleys, OG705 with ABTD trolleys and OG1005 with ABTT trolleys. BMV TOW ARMS The tow arm is attached to the moving equipment, which is attached to the trolley with tow chains. The chains allow the trolley to adjust to small variations in alignment between the fixed and moving equipment. Use BMV35 with ABTS trolleys, BMV70 with ABTD trolleys and BMV100 with ABTT trolleys. Transition box on tow arm ABTP SPRING LOADED TOW ARMS Provides positive support for single gang transfer trolley passing through an ABHT or ABSHT transfer guide. Trolley not included; specify above. Spring loaded tow arms cannot be used in conjunction with expansion joints. Please call factory for Tow Bar type trolley assembly for those applications. Page 7

8 AeroBAR Installation Tools After AeroBAR linear housing is installed, the flat conductor strips are easily pulled from rolls into the appropriate conductor slots. AITCS Conductor Straightener must be used to straighten high amperage (AB125 and AB160 amp) copper conductors, ensuring easy installation. AB2000 Pulling Block assists in the installation of conductors in longer systems. AB5000 Tom Thumb assists in pressing the sealing strips into the housing slots for long systems. AFC3 Portable Conductor Cassette is available to assist in feeding conductors into the housing. AITRC Portable Turntable Cassette is available for long applications. Consult factory for details. AB600K Copper Prep Angle is available to assist in forming an L bend in copper for splices and end feeds. ENCLOSED CONDUCTOR BAR SYSTEMS AeroBAR For simplified systems requiring no more than five conductors, the Aero-Motive AeroBAR system may be the most economical solution. It is the perfect alternative to single bar systems. POW-R-FEED The standard Pow-R-Feed system offers a full range of options including curved housings, transfer guides, isolation sections, up to 7 conductors and up to 160 amps. Most customers purchase the AFC3 and AB2000 as a basic kit and add the other tools if needed. Download the installation manual from our website. Component Checklist When requesting a quotation or component selection assistance from the Aero-Motive sales office please provide the following information. Type of equipment to be fed by AeroBAR. Total travel distance. Maximum travel speed. Duty cycle (traverse and electrical). Number of conductors required. Electrical data: volts, amps, AC/DC. Position of feed point: if line feed, give distance from end. Power supply: wire size or conduit size. Ambient conditions: temperature, dust, humidity, chemical, etc. Standard components Model number Quantity Conductor housing (10 ft. ea.) Conductor strips long Conductor strips long Joint clamp Insulating tape Fixed point clamp Sliding hanger End/Line feed End cap Collector trolley Optional components Trolley towing arm Transition box Flexible sealing strip Installation tools Expansion joint Transfer guide Inspection unit AEROBAR CLICKSPEC Specify a complete AeroBAR system right on your PC desktop. The program includes interactive system specifier, component parts order form, electrical and thermal expansion calculators, installation video and technical drawings. Order your free program today or download it from P.O. Box 2678 Kalamazoo, MI (269) FAX: Order No PE Reis 9/03