Insulated Conductor System - Vahle .br

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

IS 100 Z GBPage 12Fixing pointSystem FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 B GB Page 12Place the fixing clip into the hanger clamp andpush the rail into the hanger clamp. If possibledo not let it clip in.Mark the position of the fixing clip on the cover.Drill a 3 mm hole through the insulation, andthrough the back of the metal rail. Do not drillthrough the contact surface.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 11FABA 100Mounting Instruction

IS 100 Z GBPage 13System FABA 100Installation InstructionsBreak off the sharpened pin to prepare it for themounting. Place the pin in the existing hole.Mount the fixing clip according to the marking,using it as a template. If the rail is clipped in,remove it from the hanger with a dismantlingtool. Hammer fully the fixing clip into the drilledhole.Press firmly the conductor rail with the fixingclip into the hanger clamp 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 12FABA 100Mounting Instruction

IS 100 Z GBPage 14Power Feed Connector 100ASystem FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 B GB Pages 9,10Power feed connector till 100AUsable for assembly height 32mm or above(distance from monorail track to the bottom ofthe conductor rail sleeving see page 24)Assemble the cable on the connector, asshown, leaving the connector screw loose.Note that the threaded plate on the top shouldface the open end of the insulated cover. Thefeed cable is situated as shown.Care should be taken that the cable exit for theholes in the monorail web are protected by aninsulating grommet.Be sure to install the feed cable with a littleslack so that it can follow the linear expansionof the rail; for the installation through webs.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 13FABA 100Mounting Instruction

IS 100 Z GBPage 15System FABA 100Installation InstructionsSlide the power feed cover over the connectorpressing the cover together so that it aligns inthe retaining grooves of the rail cover. Pushuntil stop point is reached.Taking the adjacent rail, press the cover againto align with both rail sleeving grooves. Slideboth rails together.Push joint cover slightly until it looks into therecess. Then tighten with a 4mm Allen Key.Make sure the rails are aligned and the screwhead is recessed straight below the rail surface.Note:The power feed cover when assembled is offcenter.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 14FABA 100Mounting Instruction

IS 100 Z GBPage 16Power Feed Connector 50ASystem FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 B GB Pages 9,10This power feed connector for 50A is used onlyfor 27mm height. See page 24 referring toinstallation heights. Install feed clamp with thecable as shown leaving it loose.Push the cover by itself off center down overthe clamp and sleeving, as shown. Push both ofthe cover rims separately till they engage in thesleeving. Then push the adjacent rail togetherin the cover and tighten. Make sure the coveris tight in the sleeving rims.Note:The cover is off the center when completed.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 15FABA 100Mounting Instruction

IS 100 Z GBPage 17Separation Unit with one feed connectionSystem FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 B GB Pages 17, 18This picture is showing a layout of the partsrequired for the separation with one feedconnection.Press the terminal with the feed wire bending itdown only over the insulating sleeve. Thisprevents kinking the terminal.Push the rims of the cap together so that theyengage in the sleeving rims and tap in.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 16FABA 100Mounting Instruction

IS 100 Z GBPage 18System FABA 100Installation InstructionsDe-bur straight over the contact surface. Thisinsures that no plastic is higher than the contactsurface.Clip the completed feed connection into thesliding holes of the housing.Picture showing a completely assembledseparation with one feed wire. Expansionsetting is to be carried out by leaving openevery third separation and installing a fixing clip.This sequence should be carried out the wholelength of the conductor rail. Where separationexpansions have been set no additionalexpansion is required within 30 meters, exceptbuilding expansions. If the system is installedwith the contact surface facing downwards asshown, 2 hanger clamps must support eachsection of a rail to prevent a seesaw effect onthe unit.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 17FABA 100Mounting Instruction

IS 100 Z GBPage 19Separation Unit without feed connectionSystem FABA 100Installation InstructionsFor General Information refer to the CatalogueSection IS 100 B GB Pages 17,18Irrespective of whether a feed wire is required,the wire terminal must be installed as thiswedges the transfer cap tight.Insert the wire terminal and snip off the longerpart of the terminal end piece leaving the smallsection free or tap the terminal slightly downwith a hammer. The separation cap has nowroom to slide over the terminal.Press the rims of the cap together so that theyalign in the grooves of the sleeving, and de-burrstraight to the contact surface.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 18FABA 100Mounting Instruction

IS 100 Z GBSystem FABA 100Installation InstructionsPage 20ExpansionsExpansion splices are suitable for 50A and require no bridging cables. They must to be installed every 30m inthe middle of straight sections. Expansions must not be installed in curves. Distances above 20 metersbetween switches or lift sections must have an expansion in the middle. Lift or switch sections are to beconsidered as fixed points.Hanger clamps must support the expansion housing on both sides. Maximum distance is 200mm. Whereseparation caps are assembled on signal rails with the expansion gaps set (see page 18), expansion rails arenot necessary, except on building expansions.Figure 1: Standard Expansion splice max 50A with the built in spring contactsHanger ClampExpansion Housing15m Fixing PointFixing Point 15mFigure 2: Building Expansion layout using two expansions splicesBridging CablePower feed15m Fixing PointBuilding ExpansionsFixing Point 15mExpansion HousingNote:Bridging cables for building expansions are 1600mm long and are required for above 50A. They areconnected to feed connections spaced at 1500mm apart on the conductor rails. For the standard expansionapplications the bridging cable is one meter.Expansion setting clipExpansion Clip Setting Guide Room temperature under 150C - 2 clipsRoom temperature from 150C – 300C -1 clipRoom temperature above 300C - 1/2 clipPull the expansion apart and insert t the feed clamp leaving the connection loose.Slide the clamp into the transfer cap till it locksin the recess in front.3mmTransfer Caps without feed cableSlide the unit still loose into the conductor railso that it engages in the rims of the sleeving.Tighten with a Phillips screwdriver and smoothoff straight with a file. Caps can be adjusted3mm to align in the holding bracket.For General Information refer to the CatalogueSections IS 100 B GB Pages 19, 20 and IS 100 U GBTap in the transfer cap with a side of the fileand de-burr straight to the contact surface. Alltap-in caps can be removed by tapping withquick short blows on the side of the cap with afile.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 25FABA 100Mounting Instruction

IS 100 Z GBPage 27Transfer Caps with adjustable 4 mm feedwedge terminalSystem FABA 100Installation InstructionsFor General Information refer to the CatalogueSections IS 100 B GB Pages 19, 20 and IS 100 U GBParts shown required for a transfer cap withone feed connection. If a feed connection is notrequired the terminal must still be used for theinstallation. This would allow an additional4mm adjustment on the “unfed” side. Cutcrimping area off before installation.Push the contact terminal with cable over theplastic stud and push upward till it locks in therecess.Push the retaining wedge fully into the slit in thecap.Tap in the cap so that both sleeving rims areengaged. The cap can be adjusted by tappingon the side with a file.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 26FABA 100Mounting Instruction

IS 100 Z GBSystem FABA 100Installation InstructionsPage 28Used: For the phase and ground Rails FABA100RecessPlastic StudPlastic Retaining WedgePush the contact terminal with the cableover the plastic stud till it locks in recessPush the retaining bolt into the cut-out in the cap and tap in thecap. Shortened rail ends must be de-burred.Screw set shown without the plastic spacerCap HolderConductor railMax.4mm adjustable by tapping the side of the capAdjust the caps till they align with cut-out in holder. (Transfer caps are 4mm adjustable.) Lock into the cut-out inthe holder bracker. Line up assembly to cut on monorail track and tighten screw-set behind.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 27FABA 100Mounting Instruction

IS 100 Z GBPage 29System FABA 100Installation InstructionsTransfer Assembly Line up ProcedureUsing a flat object tap the unit flush with the cuton the monorail and tighten the retainingscrews behind.For the 450angled cuts place a flat object on thecut on the monorail. Adjust the unit till the 450angle on the caps correspond with the flatobject and tighten behind.Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 28FABA 100Mounting Instruction

IS 100 Z GBPage 30System FABA 100Installation InstructionsU Max. 5mmowith 90 cutU Max. 5mmowith 90 cutFor Lift Sections use:X 28mm or 55mmUse flat objectto alignMonorailConductor RailDepending on the hanger clampheight measurement y and zchange (see page 25)Height27mm32mm40mmy505563z383325Paul Vahle GmbH & Co. KGWesticker Str. 52 / D - 59174 Kamenwww.vahle.deFon: 49 (2307) 704 0Fax: 49 (2307) 704 444E-Mail: info@vahle.deSeite 29FABA 100Mounting Instruction

IS 100 Z GBSystem FABA 100Installation InstructionsPage 31Collector Shoe Wear IndicatorFor General Information refer to the CatalogueSection IS 100 M GBBefore assembling the unit a cut out must bemade in the monorail web. Three nuts are usedfor the micro switch timing. (Factory set) If achange i

IEC 60634-1 IEC 60050-826 IEC 60364-4-41 IEC 60364-4-42 IEC 60364-5-52 IEC/DIS 64(CO)9173 IEC 60204-32 IEC 60529-1989; IEC 60529 IEC 60529 Accident prevention regulation "Electrical systems and apparatus" Accident prevention regulation "Cranes" Safety instructions "Monorails"