Magnetek Electrobar 8-Bar, Instruction Manual

Page 1: ...Electrobar 8 Bar Conductor Bar System Electromotive Electrobar 8 Bar Instruction Manual Part Number 005 1044 R8 June 2010 Copyright 2010 Magnetek Material Handling ...

Page 2: ...lines 7 Chapter 4 0 Conductor Application and Support Spacing 10 Chapter 5 0 Mounting Brackets 11 Chapter 6 0 Hanger Assembly 13 Chapter 7 0 Joint Keeper Installation For Copper Conductors Only 14 Chapter 8 0 Joint Covers 15 Chapter 9 0 Expansion Sections 16 Chapter 10 0 Transfer Caps 18 Chapter 11 0 Collectors 19 Chapter 12 0 Final Inspection 24 Chapter 13 0 Special Applications and Field Instruc...

Page 3: ... personal injury Company shall not be liable for economic loss property damage or other consequential damages or physical injury sustained by the purchaser or by any third party as a result of such operation or service Company neither assumes nor authorizes any other person to assume for Company any other liability in connection with the sales or use of this product PRODUCT WARRANTY INFORMATION Fo...

Page 4: ...ng station to open the power circuit to all motors of the crane or monorail hoists 2 3 610 33 Rating of Disconnecting Means The continuous ampere rating of the switch or circuit breaker required by Section 610 32 shall not be less than 50 percent of the combined short time ampere rating of the motors or less than 75 percent of the sum of the short time ampere rating of the motors required for any ...

Page 5: ...ls 2 7 610 43 Motor and Branch Circuit Overload Protection Each motor motor controller and branch circuit conductor shall be protected from overload by one of the following means 2 7 a i A single motor shall be considered as protected where the branch circuit overcurrent device meets the rating requirement of Section 610 42 2 7 a ii Overload relay elements in each ungrounded circuit conductor with...

Page 6: ...010 Page 6 of 25 Electrobar 8 Bar Instruction Manual 005 1044 R8 Figure A Standard System Layout Without Expansion Standard System Layout With Single Expansion Standard System Layout With Multiple Expansion ...

Page 7: ...g brackets and tighten hangers to the mounting brackets 3 1 g Add the additional number of conductors to fill the snap in hangers Remember to space the hangers equally before tightening to mounting bracket bar 3 1 h Continue to mount bar in one direction from center applying conductors to the end of those previously assembled 3 1 i Between each individual bar and a joint keeper if applicable a joi...

Page 8: ...ditional conductors to the system in one direction from the expansion 3 2 f The expansion gap will need to be set as per the chart located on page 17 Note Set gap to the appropriate dimension This will need to be verified prior to clamping the anchor hangers 3 2 g Continue to assemble the system in one direction through the anchor hangers do not assemble at this time to the end or to the next expa...

Page 9: ...side of the expansion and assemble the anchor assembly to the bar if there is more than one expansion area on the system continue down the conductor run and repeat the above procedure 3 2 p Confirm gap settings at each expansion location 3 2 q Collectors Check that mounting post is an equal distance vertically from each conductor bar This will provide equal tension per collector Each collector is ...

Page 10: ...r Conductor Vertical Mount 4 Feet Horizontal Mount 5 Feet 350 Amp Copper Conductor Vertical Mount 4 Feet Joint keeper clips required on all 8 Bar copper conductor systems 4 2 Determine the maximum ambient temperature at the conductor system elevation 4 2 a Under 77 F use standard PVC insulating covered system 4 2 b 160 F 280 F use high heat insulating covered system 4 2 c Over 280 F consult the fa...

Page 11: ... tees etc at the required spacing see Conductor Application and Support on page 10 5 2 The brackets should be pre punched or drilled to accept 3 8 hanger mounting bolts The minimum distance from the web to the first hanger clamp is 3 Figure C Web Mounting Brackets Web Mount Bracket X Dimension Bracket X Dimension BKS W15 11 BKS W18 14 BKS W24 20 ...

Page 12: ...6 2 2010 Page 12 of 25 Electrobar 8 Bar Instruction Manual 005 1044 R8 Figure D Flange Mounting Brackets Flange Mount Bracket X Dimension Bracket X Dimension BKS F15 15 BKS F18 18 BKS F24 24 ...

Page 13: ...stems Anchor hangers should also be used where conductor movement must be restricted Install anchor hangers according to the following directions Figure E Anchor Hanger Universal 8 Bar 6 3 8 HA for Universal 8 Bar Systems see figure A page 6 6 3 a Insert conductor section into the clamp assembly Install an Anchor Hanger on both sides of a hanger clamp assembly 6 3 b Drill 3 16 hole through the han...

Page 14: ...allation For Copper Conductors Only Note Joint Keepers must be used on all 8 Bar Copper Systems Figure F Joint Keeper Figure G Joint Keeper Begin installing on inner conductor and work to outside Install conductor bar with V facing away from I Beam Figure F1 Figure F3 Figure F2 Figure F4 Joint Keeper ...

Page 15: ... on power feed 8 3 Power Feed Wire Connection Power Feed cables must be sized to meet the ampere demands of the conductor bar and be connected to the power feed assembly using a properly sized connector See below for Minimum Feed Cable Size for each conductor amperage rating Reference NEC Table 610 14 for minimum cable sizing Conductor Bar Min Feed Cable Size 90 Amp 4 AWG 110 Amp 2 AWG 250 Amp 3 0...

Page 16: ...Up to 299 1 0 Up to 199 1 0 300 to 449 2 1 200 to 299 2 1 450 to 599 3 2 300 to 399 3 2 600 to 749 4 3 400 to 499 4 3 750 to 999 5 4 Note For outdoor applications additional expansions may be required Please consult the factory 9 1 d Snap or slide the conductors into the hangers When clamp type hangers are used tighten the clamping bolt only after the conductor sections are joined 9 1 e To join co...

Page 17: ...e Gap Width Setting 25 F 1 5 50 F 1 0 0 F 100 F 75 F 0 5 50 F 1 5 75 F 1 0 25 F 125 F 100 F 0 5 75 F 1 5 100 F 1 0 50 F 150 F 125 F 0 5 9 4 Anchoring Requirements All ELECTROBAR Conductor Bar Systems must be anchored to permit controlled expansion and contraction of the conductor bar Anchor all systems according to the following chart Two anchor hangers are provided with each ELECTROBAR 10ft expan...

Page 18: ...of conductor bars with 19 64 drill to accommodate transfer cap pins 10 1 b Tap in transfer cap with rubber mallet 10 1 c File or de burr any rough edges along collector tracking surfaces 10 1 d Align opposing conductor runs and anchor to prevent movement during vibration or collector transfer Figure H 8 Bar Transfer Cap Support Bracket Anchor Hanger 1 4 Max Cap Transfer End Cap Anchor Hanger Ancho...

Page 19: ... bar it is going to run in Note When mounting tandem collectors be sure each collector shoe is positioned in the appropriate conductor bar 11 1 b Tighten each bolt upper and lower until the collector is firmly in place 10 lb ft 11 1 c Termination of collector leads should be in accordance with NEC and local electrical standards Note Before performing any maintenance on the system be sure that the ...

Page 20: ...opriate conductor 11 2 b Tighten each bolt until the collector is firmly in place on the mounting post 10 lbs ft Note The size of the mounting posts may vary if the extension bracket does not tighten firmly against the mounting post after the bolts are tightened remove the bolt from above the post remove the spacer washer replace the bolt and re tighten 11 2 c Termination of the collector leads sh...

Page 21: ... 11 3 a Pivot the head assembly away from the bar Remove the cotter pin from the head pivot pin and then remove the pivot pin 11 3 b Remove collector head assembly from the collector To remove the shoe insert a small flat headed screwdriver into the slot on the end of the shoe holder and pivot downward ...

Page 22: ...2010 Page 22 of 25 Electrobar 8 Bar Instruction Manual 005 1044 R8 11 3 c Slide the shoe sleeve from the shoe holder 11 3 d Remove connector hardware from the collector shoe and discard worn collector shoe ...

Page 23: ...ear replace if necessary Assemble feed cable to the collector shoe as shown Push the collector shoe straight into the shoe holder until the shoe sleeve snaps into the shoe holder 11 3 f Re assemble the collector head assembly to the collector with pivot pin and cotter pin Re position the shoe into the appropriate conductor ...

Page 24: ...sulating covers joint covers power feed covers and end covers are securely in place to prevent any accidental contact by personnel 12 1 c Run the equipment back and forth several times along the entire system length to make sure the system functions properly 12 1 d File any conductor joints that are uneven or not smooth 12 1 e Make sure the conductors are able to float except at anchor points to a...

Page 25: ...w or hack saw 13 1 b If cut conductor section is to be joined with another conductor section cut insulating cover back 1 from end of conductor Leave insulating cover flush with end of conductor if transfer cap is to be installed 13 1 c Drill ends of cut conductors as follows For 90 Amp conductors use 19 64 drill For 110 250 and 350 Amp conductors use drill For transfer caps use 19 64 drill 13 1 d ...