Safe-Lec 2 Conductor Bar Manual
XA-964200.13
www.conductix.us
Conductor Bar ManualSafe-Lec 2 “V” Contact Bar
Page 1: ...Safe Lec 2 Conductor Bar Manual XA 964200 13 Conductor Bar Manual Safe Lec 2 V Contact Bar...
Page 2: ...e for non conforming goods shall arise once Buyer returns such goods FOB point of original shipment by Seller at the risk and cost of Buyer Goods replaced by Seller shall become the property of Seller...
Page 3: ...4 CONDUCTOR HANGERS 14 Four Bar Conductor Hanger Mounting 14 Tools Needed 14 Mounting Instructions 14 Installing Conductors Into Hanger 15 SECTION 5 ANCHOR HANGER SUPPORT ASSEMBLY 16 Tools Needed 16 A...
Page 4: ...L CHART FOR GUIDELINES ONLY 27 SECTION 15 100 AMP COLLECTOR MOUNTING DETAILS 28 Installation 28 SECTION 16 200 AMP COLLECTOR 29 Installation 29 SECTION 17 CUSTOMER SUPPLIED CABLE INSTALLATION 30 SECTI...
Page 5: ...fe Lec 2 Conductor Bar Manual 5 TABLE OF CONTENTS Pickup Guide Assembly Instructions 36 SECTION 24 HANGER CENTERS DIAGRAMS 37 SECTION 25 CONDUCTOR BAR DE RATING CHART 38 NOTES 39 CONTACT INFORMATION 4...
Page 6: ...uct prior to familiarizing themselves with the information in this manual Safety Messages The following safety messages are used in this manual to alert you to specific and important safety related in...
Page 7: ...e Conductor Joint Position Expansion Section Transfer Cap End Cap Isolation Section Isolation Insulating Material Hanger Clamp Anchor Position Powerfeed Pickup Guide Isolation Section Isolation Air Ga...
Page 8: ...Section 120 36 5M Max Aluminum Bars 230 70M Max Steel Bars 160 49M Max Copper Bars 18 450mm Recommended 6 150mm Minimum 6 150mm Minimum Between components Powerfeed Joint powerfeed lands on splice Ma...
Page 9: ...over Polycarbonate is suitable up to 250 F The following acidic or corrosive environments require the use of stainless steel hangers Hydrochloric Acid Hydrofluoric Acid Sodium Hydrochloride Ammonium C...
Page 10: ...nches 4mm for securing feed cable to 100A collector and replacing shoe 5mm for securing feed cable to 200A collector and replacing shoe Deep sockets for cordless drill 8mm for anchor cross bolts 10mm...
Page 11: ...ee Table of Contents 3 Install transfer caps on the conductor ends if included Phase 4 Install hangers and conductors along the runway The installation will most likely be accomplished from a lift or...
Page 12: ...act surface of the bar Slide the collectors on the mounting staff Ensure the mounting base of each collector is centered below the corresponding conductor Ensure the collectors are evenly spaced Tight...
Page 13: ...support brackets 2 Observe all alignment tolerances See Figure 13 1 Datum height Maximum allowable deviation from datum height 5 0mm 3 16 Advantage of Factory Made Brackets Safe Lec 2 Hanger Support B...
Page 14: ...igure 14 1 3 Finger tighten M8 nut 4 Snap conductor bars into hangers 5 Tighten M8 nut to Conductix Wampfler recommended torque of 8 Nm 5 6 ft lbs NOTE This hanger may be used outside when the bar sys...
Page 15: ...arm More secure splice joint Bolted joints No special tools required No need for joint keepers or joint repair kits etc Fewer expansion sections required Safe Lec 2 can go 492 ft 150m before an expans...
Page 16: ...F open ended wrench Anchor Hanger Support Installation 1 Assemble anchor over cover so it is free to slide 2 Insert anchor hanger into support bracket 3 Tighten M5 Bolts until anchor stops meet check...
Page 17: ...bolt making sure alignment mark is in line with end faces of conductor bar 4 Fit washer and nut onto bolt in the order shown 5 Tighten nut to recommended torque of 8 Nm 5 6 ft lbs 6 Check that both f...
Page 18: ...bolts 4 Fit washer and nut as shown 5 Tighten nut to recommended torque of 8 Nm 5 6 ft lbs 6 Check that both faces of conductor bar are touching each other and that there is no gap exceeding 0 5mm 0 0...
Page 19: ...s to ease the fitting of the joint cover over the conductor bar 2 Fit the joint cover over the bolted joint Joint cover MUST NOT be opened up more than 45 on either side during the assembly over the j...
Page 20: ...the head on the set screw 2 Place bolt and joint plate assembly into conductor bar 3 Place end cover clamp washer and nut over bolt and joint plate assemblies ensure end cover clamp is flush with con...
Page 21: ...p surface 13mm 0 50 in from end face 2 Fit bolt into conductor bar 3 Ensure center line of setscrew bolt is on the center line marked on the conductor surface 4 Place nut lock washer and flat washer o...
Page 22: ...in or out of the expansion assembly BOTH HALVES MUST BE SET EQUAL Always allow sufficient time for the conductor bars to achieve ambient temperature before setting Expansion gap All Expansion assembl...
Page 23: ...t into joint plate wings on tab to face upward 5 Fit assembly into conductor bar 6 Fit clamp end over joint plate and bolt Secure with half nut Tighten half nut to recommended torque value of 10 Nm 7...
Page 24: ...emble joint to conductor bar as described previously 3 Pass supply cable through grommet 4 Crimp terminal to supply cable 5 Secure terminal to joint using washer and nut and tighten nut to a recommend...
Page 25: ...cable 6 Crimp terminal to supply cable see list of recommended terminals 7 Ensure the terminal is properly crimped as failure to do so will result in over heating on the powerfeed assembly 8 Fit termi...
Page 26: ...able 8 Crimp terminal to supply cable See list of recommended terminals 9 Ensure the terminal is properly crimped as failure to do so will result in over heating on the powerfeed assembly 10 Apply EJC...
Page 27: ...use of cables with solid non strained conductor is NOT RECOMMENDED Powerfeed p n Lug p n T B p n Dim A Dim B Dim C Cable Size AWG XA 310910B XA 310101 E72 1 32 60 5 16 6 XA 310201 F72 1 35 60 5 16 4...
Page 28: ...ting bracket 3 Ensure collectors are directly aligned with the center of the conductor bars Collector arms should be parallel with the running surface 4 Replace collector clamp and tighten Bolt 1 and...
Page 29: ...collector with the flag facing away from the other phase collectors as to prevent the ground conductor from being inserted into any of the phase rails 2 Align the two 3 2mm through holes located near...
Page 30: ...Screw Number 1 fully and ensure that the cable is clamped firmly into position 5 Ensure that the cables do not restrict the free movement of the collector arm or collector head The collector head mus...
Page 31: ...transfer cap onto bar and cover assembly using a soft mallet 3 Line up back edge of transfer cap with mark on the cover 4 Install transfer cap into support bracket not shown at 43mm 1 7 centers 5 Fit...
Page 32: ...w of transfer caps showing maximum alignment tolerance Plan view of transfer caps showing maximum alignment tolerance Please note Where transfer caps are used in a system tandem collectors must be use...
Page 33: ...late Ensure tab captivates the head on the setscrew 2 Slide bolt and joint plate into conductor bar ends respectively 3 Place cap over bolt 4 Fit washers and nuts in the order shown 5 Tighten nuts to...
Page 34: ...stallation Notes 1 Ensure all power is disconnected before attempting to install or maintain the system 2 Ensure all electrical joints are free from any contamination 3 Ensure correct alignment and lo...
Page 35: ...s and p n XA 577947 for 200A collectors Tools Needed 4mm hex wrench for 100A collector 5mm hex wrench for 200A collector Replacement Instructions 1 Loosen lower set screw with hex wrench 2 Remove shoe...
Page 36: ...d 6 Fit transfer cap support bracket over support stud 7 Fit nut lock washer and flat washer in order shown 8 Tighten nut to a recommended torque of 28 4 Nm 20 21 ft lbs 9 Remove nut lock washer and f...
Page 37: ...ER CENTERS DIAGRAMS XA 310821 XA 310857 XA 310835 XA 310859 43mm 1 69 310861 310871 43mm 1 69 XA 310861 XA 310871 43 mm 1 69 XA 310882 XA 310899 1 6900 42 93 XA 310969 43mm MIN 1 69 43mm MIN 1 69 XA 3...
Page 38: ...ctors are UL rated for continuous duty Us the appropriate curve on the graph to rate the conductors for your duty cycle Note Duty cycles are based on a 2 minute cycle time i e 50 1 minute on 1 minute...
Page 39: ...Safe Lec 2 Conductor Bar Manual 39 NOTES...
Page 40: ...5 Customer Support Phone 1 800 667 2487 Phone 1 450 565 9900 Fax 1 450 851 8591 info ca conductix com M XICO Calle Trevi o 983 C Zona Centro Apodaca NL M xico 66600 Customer Support Phone 52 81 1090 9...
