Montageanw. U20, U30, U40 engl. - VAHLE, Inc

INSTALLATION PROCEDURE FOR U 20, 30, 40FOR CATALOG 2b/E19 12* Larger horizontal radius bends will require the same supportspacing as straight runs.Note:Always follow the layout plan which will be provided for systemswith curves, transfers, isolating sections etc.2. Symbols in layout plansCrane trackConductor railInstallation scheme1. Dimensions for installation scheme – table 1 Always stagger joints and power feeds for compact systems andmake sure that joints do not coincide with hangers.Type Standard Support spacing L 1 for ExtendindingAir gap Exten-length Straight tracks Horinzontal lengthlengthL mm and lateral curves curves* L 2 mm L 3 mm L 4 mmFirst hanger per table 1 (L 2 ).U 20 6000 1000 thru R H = 5 m: 500mm 200 max. 8 100U 30 6000 1500 thru R H = 10 m: 750mm 400 max. 10 140U 40 6000 2000 thru R H = 15 m: 1000mm 400 max. 12 1304. Insulated hangers and insulators with rail holders(photo 1)Secure hangers or insulators with rail holders to brackets. Slideconductor bars into hangers or rail holders.Important:Perpendicular position and alignment with conductors to allowfor expansion and contraction.Rigid jointExpansion jointLocating clampFeed terminal(power)Feed terminal(control)End capIsolating sectionHangerInsulatorTransfer funnelmulti-poleTransfer guideUV, UVBUDVUSKUE, UEV, UEVGUEN, UESUKIT/UUAM, UA, UAK,UIM, UAS, KA, KHGH, GHH, UIKEM, EMKUS, UTIPhoto 1: 4-pole conductor arrangement5. Compact hangers for U 20 and U 30Compact hanger KA (photo 2)– holes Ø 7 mm for U 20 and holes Ø 9 mm for U 30 must beprepared in the I-beam or other track– bolt compact hangers securely, whereby slotted holes requireflat washers on both sides of brackets3. Support bracketsSpacing between conductors see table 2 belowConductor arrangement U 20 U 30 U 40Rail joints side by side 50 80 130Rail joints and collectors staggered 40 50 100For transfer applications one-pole 65 200 270multipole 40 80 130With compact hangers KH 26 50 –With compact hangers KA 23 50 –Photo 2: Compact hanger KA 20/5Reg. No. 3140PAUL VAHLE GMBH & CO. KG · D 59172 KAMEN/GERMANY · TEL. 0 23 07/ 70 40Internet: www.vahle.de · e-mail: postmaster @ vahle.de · FAX 0 23 07/ 7 47 04

19 12INSTALLATION PROCEDURE FOR U 20, 30, 40Compact hanger KH (photo 3)– bolt or weld bracket profiles 38/17 (photo 4) to the track– push compact hangers into brackets and set locating pins– make sure that position of brackets is in level and rectangularto the track.- push back conductor w/i shrouding cut shrouding by 2 L 3 and trimcut ends.- For U 20 and U 40 prepare additional recess in the shroudingwith length L 2 and trim cut ends.Sketch aPhoto 3: Compact hanger KH 20/5Sketch bPhoto 4: Bracket profile 38/176. Conductors and splice jointsConductor bars are rigidly connected by bolted joints.All conductor rail sections come ready prepared for joints.Rework the rail ends per 6.1. instructions whenever you have tocut/adjust in the field.Make sure that joints are clean of any residue; light greasing isrequired.Do not leave a gap between conductor ends. Tighten all bolts.U 20 and U 40:Assemble and bolt together insulated protection joint covers(photo 5). Make sure that covery fit accurately in the grooves ofthe conductor bar shrouding.U 30:Assemble joint cover halves from the sides to the conductor barjoint. Press the two halves together until they interlock. Tightencover bolts.U 20, U 30 and U 40:Slight height variations of the conductor profile are possible dueto production tolerances. Smooth-out joints where necessary.Table 3TypeDimensionL 1DimensionL 2DimensionL 3U 20 31 7 2U 30 – – 102U 40 20 13 78- reset copper conductor and place it equally within shrouding.7. Expansion sectionsExpansion joints come ready assembled on conductor railsections.Expansion joints will be required for:1. Lengths exceeding 100 meters, in approx. 42 m intervals.Make sure you have an anchor point in the center betweentwo expansion joints or between an expansion joint and theend of the system run (see sketch c).50 m 50 mSketch c2. Conductor lengths between two curves, switches or other fixpoints exceeding 20 meters (see sketch b).Sketch dFurthermore dimension L depends on the temperature difference( t):Photo 5: Bolted rigid joint6.1 Preparing of short lengthsIf short lengths have to be made at site prepare conductor endsas follows:- Mark conductor length, cut it and trim conductor ends.Table 4max. t max. L max. tU 20 U 30/U 40max. LU 20 U 30/U 4020 °C 88 m 100 m 40 °C 44 m 50 m30 °C 58 m 68 m 50 °C 35 m 40 m2Torque-moment for hardware : M 5 3,5 Nm; M 6 5 Nm; M 8 12 Nm; M 10 22 Nm; M 12 40 Nm; M 16 100 Nm

INSTALLATION PROCEDURE FOR U 20, 30, 4019 12Expansion joints compensate max.:U 20 = 30 mm U 30 = 35 mm U 40 = 35 mmTo determine the adjustable airgab of the expansion joint proceedas follows:a) Mark lowest and highest anticipated temperature in Sketch eand connect the two points.b) Indicate the ambient temperature during installation and computedimension »a« from the chart.Sketch eaU20 U30 U40Dim. a 6 mm 8 mm 10 mmTemperature during installation °CU 20aU 30/U 40aAir gap »a« in mmPhoto 6: Fixpoint (insulated rail holder with 2 locating clamps)9. Feeds (photo 7)The feeds are preferably set between two bars, taking theposition of the rigid joint near existing power supply (U 20 andU 30 type UE, U 40 type UEV, UEVG).Treatment of contact surfaces and further mounting as peritem 6.Feed cables must not restrict free movement of conductors andmust give clearance for the collectors passing through. Providetension relief for cable.Example: max. ambient = + 30° Cmin. ambient = – 10° C t = 40° Cduring installation = 20° Cdimension »a« = 7 mm for U 20= 8 mm for U 30/U 40– Set expansion joint with appropriate gap.8. Locating clamps (photo 6)Locating clamps are required to avoid unwanted sliding of conductors.Two locating clamps, left and right of a hanger make upan anchor point.Where to provide anchor points:In case of short straight runs – in the center (see sketch below)Sketch fIn bends, as well as in areas of switches, drop sections etc. –see sketch below.Photo 7: Feed terminal UEV 30 without capProcedure for assembling of feed terminals on conductorsections U 20 and U 40:– Slide shrouding over the conductor as per sketch a– Mark position of feeding on the conductor rail– Pull off shrouding from conductor and cut out at the markedposition (sketch h), trim cut areas of shrouding and push itback onto the conductor– Treatment of contact surfaces and further mounting as peritem 6➝L 1cut out➝➝➝➝L 2Shrouding➝Sketch hTable 5Dimension DimensionType L1 L2U 20 62 7U 30 (UEG) 196 11U 40 196 13Sketch gCheck shroud opening after tightening locating clamps(see photo 6, dim. a)U 30:– Slide shrouding over the conductor as per sketch b– Mark position of feeding on the conductor rail– Pull off shrouding from conductor and make a vertical cut atthe marked position– Shorten shrouding in this place by 102 mm each side, trimends and push shroudings back onto the conductor– Treatment of contact surfaces and further mounting as per item 63

19 12INSTALLATION PROCEDURE FOR U 20, 30, 4010. Isolating sectionsThese sections provide electrical interruption (discontinuous circuits)in the conductor line.They normally come factory assembled per layout plan; for fieldassembling consider the following:Mark the desired position on a conductor rail section.Pull out conductor and cut at the marking point, the length youcut away depends on the type of rail-dead-section you areusing.Insert the isolating piece and the two conductor lengths into theshrouding.Prepare Ø 3 DIN 1481 fix points at the bar-ends as shownbelow (locking pins).Multi-pole systems require an accurate side by side position ofthe isolating sections.An additional hanger on each side of the isolating section mustbe provided for stability.(One hanger each side at max. 200 mm for U 20, 300 mm forU 30, 400 mm for U 40).rail11. Transfer guides (photo 8)These units are mainly required for switch and drop sectionapplications.Installation:Conductor U 20 and U 30 will be cut straight; sand paperwhere necessary. Push type US transfer guide over the end andsecure tightly.Type UTI transfer guides always come factory assembled.Max. vertical and horizontal offset: U 20 ± 2 mmU 30 ± 4 mmU 40 ± 6 mm13. End caps (photo 10)The end caps are closing the conductor rail ends and are securedby means of nylon screws.In case you have to field cut the end conductor bar make surethat you are securing the shrouding with a locking pin Ø 3DIN 1481 before assembling the end cap.Type US 20Photo 10: End capType UTIPhoto 8: Transfer guide12. Transfer funnel (photo 9)These transfer funnels come factory assembled with conductorsections to meet your system layout.Make sure the transfer funnel is fastened to a non-vibrating supportstructure.Consider proper alignment for re-tracking your collectors. Thesetransfer funnels serve for any length of conductor railinterruption.14. Bending of conductor railsAll insulated conductor rails can be bent. Field bending of U 20with radius > 2500 mm smaller radii and U 30 and U 40 curvesare available on request from the factory.Bending procedure:– Install hangers.Push or press conductor rails into the hangers and the flexibilityof the conductors allows to follow the required curve.Small support intervals for curves guarantee a proper layoutwithout kinking.– Check the entry slot of the shrouding. It should beU 20 = 6 mm ± 1U 30 = 8 mm ± 1U 40 = 10 mm ± 1Photo 9: Transfer funnel15. Collectors:Collectors for U 20 and U 30 conductors are square bar mounted.The triangular attachement is prepared for the groundcollector.Weld the square bar bracket to the moving equipment, rectangularand in level with conductors. Consider the normal workingheights of the collectors.4

INSTALLATION PROCEDURE FOR U 20, 30, 4019 12All collectors for U 40 conductors are for bolt mounting (M 16).Stud spacing for phase collectors is 70 mm, for ground collectors120 mm.Specially balanced and re-tracking collectors are available fortransfer applications. Always make sure that the collector shoe isin parallel with the conductor rails and entering transfer funnelsslightly (min. 20 mm) beneath the top part of these guides.16. Commissioning and final check-up:Make test runs; start with low speed and inspect all componentsfor proper function. Check positive contact between pick upshoes and conductors – no vibration of collectors and no sparking.In case of sparking clean conductor contact suface.All transfer applications require special attention for proper passingover and re-tracking of collectors.17. Maintenance instructions:VAHLE unipole insulated conductor rail systems require a minimumof maintenance.1) Visual inspection of conductors and collectors in regularintervals, depending on the duty cycle. Consult factory incase of irregularities.2) Collector shoes must be replaced prior to the brush holdertouches the conductor shrouding.3) Transfer funnels require replacement of the isolating cover, ifcollector trackings are 2–2.5 mm deep.4) If cleaning of the conductor surface becomes necessary werecommend:a) Cleaning with high pressure water streamb) Cleaning with liquid Rivolta SRK.Use a flat brush or impregnated felt, dry the cleanedsurfaces afterwards.Hints for the Installation Procedure:Proper and careful treatment of all materials, especially the non-metallic parts, keeping everything clean etc. isimportant. Make sure, that joints and all other connecting points are clean of any residue. Tighten all hardware,using lockwashers etc. carefully. Take care of proper alignment between conductor rails and crane runway.Install conductor rails in accordance to appertaining layout plans. Make sure that position of expansion jointsand locating clamps is exactly per drawing and/or catalog instructions.Safety Regulations for work with electrical equipment:1. Disconnect mains2. Prevent reconnection3. Test for absence of harmful voltages4. Ground and short circuit5. Cover or close off nearby live partsTo energize, apply in reverse order.5

19 12INSTALLATION PROCEDURE FOR U 20, 30, 40Copper-graphite brushes for U 2010010RhRemaining height = RhConductor Reference dim. brush typeType X KMK 60 / KMK 60 UKMK 60 / KMK 60 UU 20/50 AFU 20/50 CE 2U 20/50 AC 3,5U 20/50 C 3U 20/50 CH 4Rh30KMU 40 / KMU 60Remaining height = RhConductor Reference dim. brush typeType X KMU 40 / KMU 40 UKMU 60 / KMU 60 UU 20/50 AFU 20/50 CE 20U 20/50 AC 8U 20/50 C 21U 20/50 CH 22KMU 40 / KMU 60 U9RhRh25min. Xmin. XRemaining height = RhConductor Reference dim. brush typeType X KM 55KM 55 phase / groundU 20/50 AFU 20/50 CEU 20/50 AC 3 0U 20/50 CU 20/50 CH 16

INSTALLATION PROCEDURE FOR U 20, 30, 4019 12Copper-graphite brushes for U 30min. Xmin. X120Rh58KMK 100/30Remaining height = RhConductor Reference dim. brush typeTypeXKMK 100/30 KMK 140/30U 30/125 AC 47 9U 30/225 AC 43 6U 30/120 CE 53 16U 30/ 75 C 47 10U 30/100 C 9 54 17U 30/130 CH 54 17U 30/150 C 50 13U 30/200 C 46 9U 30/200 CH 48 11140KMK 140/30Rh22,5Copper-graphite brushes for U 40ConductorReference dim.Remaining height = RhTypeXbrush typeKMU 200U 40/300 AC19U 40/200 C20U 40/400 CU 40/300 CU 40/400 CH 825U 40/300 CH 19U 40/500 CH 18U 40/500 C 15U 40/500 CHH 12KMU 200Rh377

Reg. No. 3140Catalog No.Copperhead Conductor Systems1 aBattery Charging Systems1 bInsulated Conductor Systems U 102 aInsulated Conductor Systems U 20 - U 30 - U 402 bInsulated Conductor Systems U 15 - U 25 - U 352 cAluminium Enclosed Conductor Systems3 aSteel Enclosed Conductor Systems3 bPowerail Enclosed Conductor Systems KBSL - KSL - KSLT - KSG 4 aPowerail Enclosed Conductor Systems VKS - VKL4 bPowerail Enclosed Conductor System MKL4 cHeavy Enclosed Conductor Systems 5Trolley Wire and Accessories 6Cable Tenders 7Cable Carriers for -tracks 8 aCable Carriers for Flatform Cable on -beams8 bFCable Carriers for Round Cable on -beams8 bRCable Carriers for -tracks 8 cConductor Cables and Fittings8 LSpring Operated Cable Reels9 aOverload Protection Systems9 bPowercom ® Data Transmission Systems9 cCPS - Contactless Power Supply9 dSMG - Slotted Microwave Guide9 eMotor Powered Cable Reels 100004 · Printed in Germany · CD-Rom · 4/00PAUL VAHLE GMBH & CO. KG · D 59172 KAMEN/GERMANY · TEL. 0 23 07/ 70 40Internet: www.vahle.de · e-mail: postmaster @ vahle.de · FAX 0 23 07/ 7 47 04