Insulated Conductor System - VAHLE

FABA 100Insulated Conductor SystemMounting InstructionsPaul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 1FABA 100Mounting Instruction

IS 100 Z GBSystem FABA 100Installation InstructionsPage 3ContentsPageIntroduction4Hanger Clamp (Stud-mounting with spring clip)6Hanger Clamp (Clip-type)7Conductor Rails8Conductor Rails – Shortening8Conductor Rails Curves9Rail Connector (Screw-type)10Rail Connector (Plug-in type)11Fixing point12Power Feed Connector 100A14Power Feed Connector 50A16Separation Unit with one feed connection17Separation Unit without feed connection19Expansions20Transfer points for Sliding Switches and Lift Sections23Transfer Caps with feed cable26Transfer Caps without feed cable26Transfer Caps with adjustable 4 mm feed wedge terminal27Transfer Assembly Line up Procedure29Collector Shoe Wear Indicator31Current Collectors32Cable Connection for the Single arm collector34Cleaning Collector37Prefabricated Conductor Rail Systems38Removing Conductor Rail from Hanger Clamp41System checking42Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 2FABA 100Mounting Instruction

IS 100 Z GBPage 4System FABA 100Installation InstructionsIntroductionBASIC DIAGRAMMeasurement rementbcdefMeasurement gABCDEFGHThe hanger clamp distance: max. 800 mm in the straight sections; in bends max. 400 mm; to the endof the conductor rail min. 100mm; max. 300mm where no transfer sections are present.Separation of support clamps; required at least on one side as follows:For the rail connector of the conductor rail: min. 100 mm; max. 200 mm.For the feed: min. 100 mm; max. 200 mm.For the expansion: min. 100 mm; max. 200 mm.For electrical separations: min. 100 mm; max. 200 mm supported both sides.For transfer sections: min. 50 mm; max. 100 mm.Please refer to the special list IS 100 U for this.The height of the system upper edge of support clamp to lower edge of current collector fasteningNote: The assembly height is the height of the hanger clamp.Conductor railRail ConnectorHanger ClampPower Feed ConnectorExpansionElectrical SeparationTransfer section for switches and liftsCurrent Collectorwith standard collectorfor the assembly height 27 73 mmfor the assembly height 32 78 mmfor the assembly height 40 86 mmwith double arm collectorfor the assembly height 27 98 mmfor the assembly height 32 103 mmfor the assembly height 40 111 mmWith standard small collectorfor the assembly height 27 71 mmfor the assembly height 32 76 mmfor the assembly height 40 84 mmwith long double arm collectorfor the assembly height 27 108 mmfor the assembly height 32 113 mmfor the assembly height 40 121 mmPaul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deWith double shoe collectorfor the assembly height 27 98 mmfor the assembly height 32 103 mmfor the assembly height 40 111 mmFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 3FABA 100Mounting Instruction

IS 100 Z GBPage 5System FABA 100Installation InstructionsWe would like to draw your attention particularly to the regulations valid in the Federal Republic of Germany:German standardsVBG 4VBG 9ZH 1/72ZH 1/525VDE 0100 T.100VDE 0100 T.200VDE 0100 T.410VDE 0100 T.420VDE 0100 T.520VDE 0100 T.600DIN EN 60204-32VDE 0100 T.737VDE 0105 T.1VDE 0470 T.1DIN 40 050VDI 2345VDI 3643Act about technical equipment (Equipment Safety Act)International standardsAccident prevention regulation"Electrical systems and apparatus"Accident prevention regulation"Cranes"Safety instructions "Monorails"IEC 60634-1Ordinance on WorkplacesIEC 60050-826"General requirements"IEC 60364-4-41"General statements for the planning""Protection against dangerous bodycurrents"IEC 60364-4-42IEC 60364-5-52"Protection against thermal actions""Current rails" (Conductor rails)IEC/DIS 64(CO)9173"Initial tests"IEC 60204-32"Hoisting equipment""Damp and wet areas and rooms,outdoor installations"IEC 60529-1989; IEC 60529 "Operation of high-tension equipment"IEC 60529"IEC Test-finger""IP mponents of FABA conductor rails are largely stable against gasoline, usual oils,dilute bases and dilute acids.General remarksThis is the description of the installation for the Insulated Conductor Rail Systems FABA 100 for monorailtracks. For the basic description please refer to the latest edition of the Main Catalogue “FABA InsulatedConductor Rail Systems”.This installation instructions describe the standard type installation assuming an already prepared site.The complete Project description and technical information concerning the installation as well as theplanning instructions can also be found in the Catalogue.Preparation activitiesMark a line on the monorail track with a felt pen where separations for zone sections, expansions rails, andfixing points should be located. The monorail track surface must be free from dust, oil and grease.Before assembling the conductor rails, the tolerances of the monorail track at switches and lifts must bechecked. Maximum permissible vertical and lateral misalignment is /- 2 mm. Assemble the switches and thelift sections first, working away from these points.All the hanger clamps are designed to fit precisely into the AMS-profile; the backsides are provided with adurable adhesive strip at the factory to prevent lateral slip in the AMS-profile (AMS Automated MonorailSystem).Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 4FABA 100Mounting Instruction

IS 100 Z GBPage 6System FABA 100Installation InstructionsDepending on the type of the installation thehanger clamps are fastened directly or bymeans of the consoles to the track/conductorrail so that they align perfectly. The conductorrails are simply clipped into the hanger clampuntil they snap in with a click.The plastic plugs are passed through the predrilled holes in the monorail track web. Push theclips into the grooves on the plastic plugs.Hanger Clamp (Screw type)For General Information refer to the CatalogueSection IS 100 K GB Page 3Hanger clamp are fastened to the web of themonorail using a screw-on connection. Specialhanger clamps with 15mm hole spacing areprovided for this application.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 5FABA 100Mounting Instruction

IS 100 Z GBPage 7Hanger - Clamp (Clip-type)System FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 K GB Pages 4,5,6Remove the protective film before installing.Clip the hanger clamp in the rail and pressfirmly till it engages.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 6FABA 100Mounting Instruction

IS 100 Z GBPage 6Hanger – Clamp(Stud-mounting with spring clip)System FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 K GB Page 7 and IS 100 B GB Page 7Depending on the type of the installation thehanger clamps are fastened directly or bymeans of the consoles to the track/conductorrail so that they align perfectly. The conductorrails are simply clipped into the hanger clampuntil they snap in with a click.The plastic plugs are passed through the predrilled holes in the monorail track web. Push theclips into the grooves on the plastic plugs.Hanger Clamp (Screw type)For General Information refer to the CatalogueSection IS 100 K GB Page 3Hanger clamp are fastened to the web of themonorail using a screw-on connection. Specialhanger clamps with 15mm hole spacing areprovided for this application.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 7FABA 100Mounting Instruction

IS 100 Z GBSystem FABA 100Installation InstructionsPage 9Conductor Rails CurvesFor General Information refer to the CatalogueSection IS 100 B GB Pages 3,4Figure 1:For horizontal and vertical bending insert the 7x 3 mm black plastic strip in the space betweenthe back of the metal rail and the insulatingsleeve. When using the “screw-type” railconnectors or the separating or transfer caps,insert the strip 40 mm shorter. The strip mustnot be removed after bending. After bendingretract the strip by 20 mm.Figure 2:Figure 1When bending over the wide side of the rail, thered bending profile has to be inserted into theslit of the conductor surface and the blackbending strip has to be inserted into the back ofthe rail. Leave approx. 20 mm clear length onboth ends when using the screw-on railconnectors. The red strip can be reused. Theblack strip must remain in the rail.Figure 2For bending on a building site, determine thelength of the curve, e.g.: measure the length ofthe curve of the monorail track with a tape,transfer the length onto the conductor rail andmake an additional 150 mm mark on the railleaving a small amount to the end of a rail to becut. Insert the conductor rail into the bendingmachine to the point where the pen mark iseven with the outside of the bending machine.This corresponds to the original radius mark of150 mm in the middle of the roller. Lower thetop roller according to the required radius. Rollthe rail through the machine up to the 2ndmarking. It is possible to change the curveradius by reinserting the rail into the machine.If two rail curves are to be joined, the straightends must be cut off.Hanger ClampRail Connector(Screw-on type)Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 8FABA 100Mounting Instruction

IS 100 Z GBPage 10Rail Connector (Screw – type)System FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 B GB Page 6Loosen the socket head with the 4 mm AllenKey Screwdriver.Note:Use only the type of Allen Key shown as itallows sufficient torque. (Torque 6-7 Nm.)When a twisting motion is felt on the handle thetorque is then sufficient.Loosen the clamp and slide the clamp plates inbetween the upper part of the copper. Slide thecover over the clamp, so that it sits firmly in thesleeving rims. Carry out the same procedurewith the adjacent rail and press the connectioninto the hanger clamp.Finally then, push the two rails together andonly then tighten. If the rail has to be removed,again loose the connection before pulling out ofthe rail. This prevents buckling the steel plate ofthe connector. Make sure a hanger clamp issituated within 200 mm from the screw-in typeconnector so that the connection remains rigid.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 9FABA 100Mounting Instruction

IS 100 Z GBPage 11Rail Connector (Plug-in Type)System FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 B GB Page 5Figure 1:Push the plug-in rail connector into the holdingtool.Figure 2:Tap in the connector till the stop point is felt. (Itis situated in the middle.)Figure 1Figure 2Slide the insulating splice cover into thegrooves of the conductor sleeve until the stoppoint is reached. Press the end of the insulatedcover together and align the opposite rail intothe cover. Check that both insulating rims areembraced by the housing after clipping in thehanger clampsSnap the rail connecting tool fully expanded onthe conductor rails, and pull the right hand leverdownward until the rails are joined.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 10FABA 100Mounting Instruction