Magnetek ELECTROBAR FS Instruction Manual
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Magnetek ELECTROBAR FS Instruction Manual

Magnetek ELECTROBAR FS Instruction Manual

Electrification conductor bar system
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Electrification FS
Conductor Bar System
Electrification FS Instruction Manual
Part Number: 005-1066 R13
October 2019
© Copyright 2019 Magnetek Material Handling

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Summary of Contents for Magnetek ELECTROBAR FS

  • Page 1 Electrification FS Conductor Bar System Electrification FS Instruction Manual Part Number: 005-1066 R13 October 2019 © Copyright 2019 Magnetek Material Handling...
  • Page 2 Page Intentionally Left Blank...
  • Page 3 Sales: 262-783-3510 Service: 262-783-3508 Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetek.com. ©2019 MAGNETEK All rights reserved. This notice applies to all copyrighted materials included with this product, including, but not limited to, this manual and software embodied within the product. This manual is intended for the sole use of the person(s) to whom it was provided, and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden.

  • Page 4: Table Of Contents

    Table of Contents Chapter 1.0: Danger, Warnings and Cautions ..................5 Chapter 2.0: Disconnecting Means/Overcurrent Protection ..............8 Chapter 3.0: Assembly Guidelines ....................10 Chapter 4.0: Modular Hangers ......................14 Chapter 5.0: Joint Assembly ......................17 Chapter 6.0: Isolation Joint Assembly ....................20 Chapter 7.0: Electrification FS Expansion Elements.................

  • Page 5: Chapter 1.0: Danger, Warnings And Cautions

    It is the responsibility of the owners, users and operators of the Magnetek Products to know, understand and follow all of these requirements. It is the responsibility of the employer to make its employees aware of all of the above listed requirements and to make certain that all operators are properly trained.
  • Page 6 Registered Trademarks Trademarks are the property of their respective owners. Supplemental Safety Instructions Read and understand this manual before installing, operating, or servicing this product. Install the product according to this manual and local codes. The following conventions indicate safety messages in this manual. Failure to heed these messages could cause fatal injury or damage products and related equipment and systems.
  • Page 7 This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of Magnetek. Electrification FS Conductor Bar System Instruction Manual...

  • Page 8: Chapter 2.0: Disconnecting Means/Overcurrent Protection

    Chapter 2.0: Disconnecting Means/Overcurrent Protection NOTE: Magnetek recommends using the following Disconnecting Means and Overcurrent Protection Guidelines as published in the 2005 National Electrical Code, copyright 2004. 2.1: Disconnecting Means 2.1.(a): 610.31 Runway Conductor Disconnecting Means: A disconnecting means, having a continuous ampere rating not less than that computed in Sections 610.41(e) and (f), shall be provided between the runway contact conductors and the power supply.
  • Page 9 2.6.(a).(i): Fuse or Circuit Breaker Rating. Crane, hoist, and monorail hoist motor branch circuits shall be protected by fuses or inverse-time circuit breakers having a rating in accordance with Table 430.52. Where two or more motors operate a single motion, the sum of their nameplate current ratings shall be considered as that of a single motor.

  • Page 10: Chapter 3.0: Assembly Guidelines

    Chapter 3.0: Assembly Guidelines 3.1: System without Expansions The following are general system installation guidelines; see the following sections for specific component installation instructions. 3.1.(a): Check alignment of mounting brackets prior to assembling hangers and bar. Correct any brackets that are misaligned. Mounting brackets should not exceed ¼” in horizontal and vertical misalignment over 5’0”...
  • Page 11 3.1.(m): Collectors: Check that mounting post is an equal distance vertically from each conductor bar. This will provide equal tension per collector. Each collector is to be centered on the conductor on which it is to travel. 3.2: System with Expansions The following are general system installation guidelines;...
  • Page 12 3.2.(m): At the end of each conductor run, end caps are needed to properly insulate the system. 3.2.(n): With the system installed, except for the clamping of anchors to the bar, return to the first set of anchors located from the end of the conductor run and tighten the anchor hanger. 3.2.(o): Go to the first set of expansion assemblies located next to the previously tightened anchor hangers and confirm the expansion gap setting.
  • Page 13 Standard System Layout Without Expansion Standard System Layout With Multiple Expansions Standard System Layout with Isolation Joints – End Power Interrupting Sections Standard System Layout with Isolation Joints – Midpoint Power Interrupting Sections Electrification FS Conductor Bar System Instruction Manual October 2019 Page 13 of 34...

  • Page 14: Chapter 4.0: Modular Hangers

    Chapter 4.0: Modular Hangers 4.1: FS-H2, FS-H3, FS-H3L, FS-H4 4.1.(a): Remove nut(s), lock washer(s) and flat washer(s) from hanger base mounting bolt(s). 4.1.(b): Assemble hanger base to mounting bracket by inserting hanger bolt(s) through mounting bracket hole(s). 4.1.(c): Assemble washer(s), lock washer(s) and bolt(s) to hanger bolt(s) and hand tighten. 4.1.(d): Assemble the snap-in hangers to the hanger base.
  • Page 15 4.2: Mounting Centers 4.2.(a): Standard centers for hanger installation are 5’0” on horizontal and vertical systems. 4.3: Single Mounting Hanger (FS-SH) 4.3.(a): Remove nut, lock washer and flat washer from hanger base mounting bolt. 4.3.(b): Assemble hanger base to mounting bracket by inserting hanger bolt through mounting bracket hole (NOTE: Minimum spacing of 1.75”).
  • Page 16 4.5: Anchor Hanger (FS-AH) 4.5.(a): Slide anchor hanger assembly over the end of the line element near the mounting bracket. NOTE: Slide the anchor hangers on the line element, with the clamping nut of the hanger facing the outside of the system, for ease of installation. 4.5.(b): Remove nut, lock washer and flat washer from anchor hanger mounting bolt.

  • Page 17: Chapter 5.0: Joint Assembly

    Chapter 5.0: Joint Assembly 5.1: FS-JNTG, FS-JNTC 5.1.(a): Verify that the clamping plate is 1/8” below the underside of the joint assembly bracket. If not, loosen or tighten the nuts to make the adjustment. 5.1.(b): Slide the joint assembly into upper slot of the end of the line element. Be sure the clamping plate is properly located in the end of the line element.
  • Page 18 5.2.(b): Remove packaging foam. 5.2.(c): Center joint cover over joint assembly. 5.2.(d): With light pressure, open the bottom of the joint cover sufficient to clear the sides of the line element. Damage may occur to joint cover if it is spread beyond 1¼” wide. 5.2.(e): Push joint cover down until lower lips of cover clear the bottom of the line element.
  • Page 19 5.3.(c): Push end cap hardware until it comes in contact with the conductor bar cover, and tighten the nut 55 in-lb. Trim the bolt to be flush with the nut. 5.3.(d): Push the end cover boot over the end of the bar and end cap hardware. Manipulate end cover boot until the nut relief in the boot is directly over the end cap hardware.

  • Page 20: Chapter 6.0: Isolation Joint Assembly

    Chapter 6.0: Isolation Joint Assembly 6.1: FS-JNIS 6.1.(a): Verify that the clamping plate is 1/8” below the underside of the isolation joint plastic. If not, loosen or tighten the nuts to make the adjustment. 6.1.(b): Slide the joint assembly into upper slot of the end of the line element. Be sure the clamping plate is properly located in the end of the line element.
  • Page 21 6.2.(e): Push joint cover down until lower lips of cover clear the bottom of the line element. If cover does not clear bottom of line element, verify the cover is centered between joint assembly bolts. 6.2.(f): Push on sides of joint cover so lips are positioned under the line elements. 6.2.(g): Pull up on the joint cover so the lips are in contact with bottom of the line element cover and insulate the vertical face of the exposed conductor bar.

  • Page 22: Chapter 7.0: Electrification Fs Expansion Elements

    Chapter 7.0: Electrification FS Expansion Elements 7.1: Galvanized Steel Elements (90A and 110A) 7.1.(a): Systems not exceeding 490’ do not require expansion elements when installed with an anchor hanger at the center of the line. In systems that are longer than 490’, expansions are needed every 240’, based on 100°F range in ambient temperature during the year.
  • Page 23 7.3.(d): Set and hold appropriate gap while installing the expansion. NOTE: Tools Required: 3/8” Wrench or Socket 7.4: Expansion Gap Settings NOTE: Failure to pre-set the air gap correctly could cause buckling of the conductors. Each expansion section must have a gap set at the time of installation. Refer to the following table for the appropriate settings.

  • Page 24: Chapter 8.0: Power Feed Wire/Connection

    Chapter 8.0: Power Feed Wire/Connection 8.1: Power feed cables must be sized to meet the ampere demands of the line element and be connected to the power feed assembly by using a properly sized and crimped ring terminal. See below for typical feed cables and ring terminals. Min.
  • Page 25 8.2.(f): Verify the end face of each line element is together. 8.2.(g): Tighten the other nut of the joint assembly 55 in-lb. 8.2.(h): Assemble power feed wire to one lug of the power feed assembly, using an appropriate terminal connector. Feed power feed wire through end of power feed cover before attaching the power feed cover to the joint.
  • Page 26 8.3: 250/400 Amp In-Line Power Feed Assembly (FS-PFC) 8.3.(a): Remove both nuts on the top side of the power feed base (joint connector). Verify that the clamping plate is 1/8” below the underside of the joint assembly bracket. 8.3.(b): Slide the joint assembly into the upper slot of the end of the line element. Be sure the clamping plate is properly located in the end of the line element.
  • Page 27 250/400 Amp In-Line Power Feed Assembly Electrification FS Conductor Bar System Instruction Manual October 2019 Page 27 of 34...
  • Page 28 8.4: In-Line Power Feed Assembly For Use As End-Line Power Feed Assembly 8.4.(a): Slide cover of the line element back approximately 12 inches. 8.4.(b): Cut and remove 10” of the cover protruding from the end of the line element. Slide the remaining cover back into place on the line element.

  • Page 29: Chapter 9.0: Transfer Cap

    Chapter 9.0: Transfer Cap 9.1: FS-TCAP 9.1.(a): Be sure set screws provided are backed out and will not interfere with installation. 9.1.(b): Slide transfer cap over end of conductor bar. The transfer cap should slide 1-7/16” over the end of the bar (3/4” over the bar cover) until the bar stops against the inside of the cap. 9.1.(c): Tighten each set screw equally against the conductor bar;...

  • Page 30: Chapter 10.0: Collectors

    Chapter 10.0: Collectors 10.1: Mount the collector mounting post so the horizontal centerline of the post is 4”± 0.5” from the running surface of the conductor bar. 10.1.(a): Slide each of the collectors onto the mounting post until they are directly under the conductor bar it is going to run in.
  • Page 31 10.2: Collector Shoe Replacement 10.2.(a): Remove the cotter pin (1) from the head pivot tube. Discard the old cotter pin and replace it with a new one. 10.2.(b): Remove the collector head assembly (2) from the pivot tube. If replacing the entire collector, move on to 10.2.(c) and stop after step 10.2.(d);...
  • Page 32 10.2.(h): Reassemble the new collector head assembly into the collector pivot tube and insert the new cotter pin. Electrification FS Conductor Bar System Instruction Manual October 2019 Page 32 of 34...

  • Page 33: Chapter 11.0: Final Inspection

    Chapter 11.0: Final Inspection 11.1: Final inspection of all components should be made, including the following important items: 11.1.(a): Make sure the conductor bar runs are straight. Adjust any hanger clamps, which are not straight, and replace any conductor bar which may have been bent or damaged. 11.1.(b): No HOT (electrically energized) bare metal parts should be exposed.
  • Page 34 Electrification FS Conductor Bar System Instruction Manual October 2019...

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