Conductix-Wampfler Safe-Lec 2 Manual
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Conductix-Wampfler Safe-Lec 2 Manual

Conductor v contact bar
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Conductor Bar Manual
Safe-Lec 2 "V" Contact Bar
XA-964200.13
Safe-Lec 2 Conductor Bar Manual

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Summary of Contents for Conductix-Wampfler Safe-Lec 2

  • Page 1 Conductor Bar Manual Safe-Lec 2 “V” Contact Bar XA-964200.13 Safe-Lec 2 Conductor Bar Manual...
  • Page 2 Buyer’s name - provided that Seller shall have the right to elect to defend any such suit or action for the account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer. Safe-Lec 2 Conductor Bar Manual...

  • Page 3: Table Of Contents

    SECTION 8 - JOINT COVER ASSEMBLY Joint Cover Installation SECTION 9 - END CAP ONTO CONDUCTOR BAR ASSEMBLY Galvanized Steel and Copper Conductor Bar Installation Tools Needed Installation Aluminium/Stainless Steel Conductor Bar Installation Tools Needed Installation Safe-Lec 2 Conductor Bar Manual...
  • Page 4 Maintenance Notes Installation Notes SECTION 22 - COLLECTOR CONTACT SHOE AND SHOE HOLDER Tools Needed Replacement Instructions Replacement of 200 Amp Collector Contact Shoe SECTION 23 - ASSEMBLY FOR 1, 2, 3, & 4-WAY PICKUP GUIDE Safe-Lec 2 Conductor Bar Manual...
  • Page 5 TABLE OF CONTENTS Pickup Guide Assembly Instructions SECTION 24 - HANGER CENTERS DIAGRAMS SECTION 25 - CONDUCTOR BAR DE-RATING CHART NOTES CONTACT INFORMATION Safe-Lec 2 Conductor Bar Manual...

  • Page 6: Section 1 - Safety

    • WARNING indicates unsafe actions or situations that have the potential to cause severe injury, death, and/or major equipment or property damage. NOTE • NOTE is used to alert you to installation, operation, programming, or maintenance information that is important, but not hazard related. Safe-Lec 2 Conductor Bar Manual...

  • Page 7: Section 2 - Overview

    Conductor System Nomenclature Hanger Clamp Single Conductor Anchor Position Joint Position Expansion Section Powerfeed Pickup Guide Transfer Cap End Cap Isolation Section Isolation = Air Gap Isolation Section Collector Isolation = Insulating Material Power Interrupt Safe-Lec 2 Conductor Bar Manual...

  • Page 8: Typical 3-Phase System Overview

    SECTION 2 - OVERVIEW Safe-Lec 2 Conductor Bar Manual...

  • Page 9: Environmental Considerations

    • Hydrochloric Acid • Hydrofluoric Acid • Sodium Hydrochloride • Ammonium Chloride • Chlorine Bleach • Chloride Ions • Fluoride Ions WARNING • Do not use standard (black) or medium heat (red) hangers in the above environments. Safe-Lec 2 Conductor Bar Manual...

  • Page 10: Installation Tools

    • Open/box end wrenches (use ratcheting box-end wrenches if you have them) » 8mm » 10mm » 13mm • Hacksaw • Flat file and/or rat tail file to remove burrs on field cut conductors • Pliers • # 1 Phillips Head Screwdriver Safe-Lec 2 Conductor Bar Manual...

  • Page 11: Section 2 - General Assembly Instructions

    1. Ensure the power is locked out-tagged out. 2. Install the hangers per instructions (see Table of Contents). 3. Roll adjacent conductors in the hangers as shown in Section 4. Conductix-Wampfler recommends the first accessible conductor being the ground conductor.

  • Page 12: Collector Positioning

    • Keep accessories at least 6” from hanger brackets. • Follow all torque specifications. • Allow for movement of accessories due to expansion. • Connect only flexible power cables to powerfeed assemblies. • Keep collectors straight, level and aligned with conductors. Safe-Lec 2 Conductor Bar Manual...

  • Page 13: Section 3 - Support Brackets

    » Maximum allowable deviation from datum height + 5.0mm (+3/16”). Advantage of Factory-Made Brackets Safe-Lec 2 Hanger Support Brackets come complete with all necessary mounting holes for easy installation of hangers via slide in slots or holes. Alignment tolerance over 4.5 meters (14.75 ft) in runway...

  • Page 14: Section 4 - Conductor Hangers

    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 system is covered and protected from the elements. If the bar system will be directly exposed to rain, snow, ice, or other precipitation, a single pole insulated hanger must be used.

  • Page 15: Installing Conductors Into Hanger

    • No need for “joint keepers” or “joint repair kits”, etc • Fewer expansion sections required • Safe-Lec 2 can go 492 ft (150m) before an expansion is • required Easier system alignment • Slotted brackets are available to reduce •...

  • Page 16: Section 5 - Anchor Hanger Support Assembly

    4. Tighten M8 Bolt to a torque of 8 Nm (5-6 ft. lbs.). Figure 16-1 1. Clamp Anchor Half 5. M5 Screw 2. M5 Nut 6. M5 Flat Washer 3. M8 Nut 7. M8 Flat Washer 4. M8 Screw 8. M8 Lock Washer Safe-Lec 2 Conductor Bar Manual...

  • Page 17: Section 6 - Bolted Steel/Copper Joint Assembly

    • If the conductor was field cut, file off all burrs on conductor ends before assembling splices. Figure 17-1 1. Nut 5. Joint Plate 2. Washer 6. Conductor Bar 3. Joint 7. Alignment Mark 4. Bolt Safe-Lec 2 Conductor Bar Manual...

  • Page 18: Section 7 - Bolted Aluminium Joint Assembly

    • If the conductor was field cut, file off all burrs on conductor ends before assembling splices. Exposed length of bar should be 33mm (1.3”) per end. Apply Electrical Joint Compound p/n XA-15629 to mating surfaces. 33mm (1.3”) Figure 18-1 1. Nut 2. Washer 3. Joint Plate 4. Bolt 5. Conductor Bar Safe-Lec 2 Conductor Bar Manual...

  • Page 19: Section 8 - Joint Cover Assembly

    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 joint. Ensure the “Location Section” sits between the two bolts. 3. Close the flaps in the direction “D”. Ensure the flaps “click” home on both sides. Location Section Figure 19-1 Safe-Lec 2 Conductor Bar Manual...

  • Page 20: Section 9 - End Cap Onto Conductor Bar Assembly

    5. Push end cover over assembly (ensure bolt is located in point “A” on end cover). This face to be flush with conductor face. NOTE: Wings on Tab to face upwards. Figure 20-1 1. Nut 4. Bolt 2. Washer 5. Joint Plate 3. End Cover Clamp 6. End Cover Safe-Lec 2 Conductor Bar Manual...

  • Page 21: Aluminium/Stainless Steel Conductor Bar Installation

    6. Push end cover over assembly (ensure bolt is located in point “A” on end cover). Figure 21-1 1. Bolt 2. End Cover 3. Nut 4. Flat Washer 5. Lock Washer UNIT MINIMUM MACHINED SURFACE Safe-Lec 2 Conductor Bar Manual...

  • Page 22: Section 10 - Expansion Section Assembly

    Once gap is set, go to second anchor clamp and tighten. Half Total Air Gap Half Total Air Gap ACTUAL SITE AMBIENT: Table 22-1 Expansion Air Gap Setting For Conductor Bars With PVC Cover Safe-Lec 2 Conductor Bar Manual...

  • Page 23: Section 11- End Powerfeed Assembly

    • Maximum cable size is 25 sq mm PVC 600/1000V stranded copper conductor (#4 AWG Extra Flexible). These faces to be flush Figure 23-1 1. Joint Plate 5. Washer 2. Bolt 6. Nut 3. Clamp End 7. Powerfeed End Cap 4. Half Nut Safe-Lec 2 Conductor Bar Manual...

  • Page 24: Section 12 - Low Amp Joint Powerfeed Assembly

    7. Once in position close flaps and ensure flaps click home. NOTE • Joint must not support the cable. • Max cable size 10sq. mm pvc 600/1000V stranded copper conductor (#8 AWG Extra Flexible). Figure 24-1 1. Washer 2. Nut 3. Powerfeed Cap Safe-Lec 2 Conductor Bar Manual...

  • Page 25: Installation Up To And Including 250 Amps (P/N Xa-310910B)

    Conductor cover support ears Figure 25-1 1. Splice Bolt 5. Powerfeed Cover 2. Bolt 6. Powerfeed Joint Cover 3. Grommet 7. Powerfeed Top Hat Assembly 4. Powerfeed Case 8. Washer Clip Assembly 9. Washer Safe-Lec 2 Conductor Bar Manual...

  • Page 26: Section 13 - Powerfeed And Cover Assembly

    1. Splice Bolt 5. Powerfeed Cover 9. Washer 2. Bolt 6. Powerfeed Joint Cover 10. Powerfeed Shunt Link 3. Grommet 7. Powerfeed Top Hat Assembly 11. Screw 4. Powerfeed Case Clip Assembly 8. Washer 12. Nut Safe-Lec 2 Conductor Bar Manual...

  • Page 27: Section 14 - Terminal Chart For Guidelines Only

    5/16 XA-310910B XA-310601 J972 1.94 5/16 1/0AN-2/0 XA-310401 L973 2.25 1.04 3/0AN-4/0 XA-310701 M972 2.28 1.12 5/16 4/0AN - 250 kcmil XA-310912B XA-310501 54178 2.33 1.25 5/16 300 kcmil XA-310911 XA-310101 1.13 XA-310034B XA-310101 1.13 Safe-Lec 2 Conductor Bar Manual...

  • Page 28: Section 15 - 100 Amp Collector Mounting Details

    100 Amp Collectors and 19.5” for 200 Amp Collectors to ensure proper head movement on the collectors. Figure 28-1 XA-SLC2-100S-1M Single Collector Working Range 2.75 (69.9) Contact Surface 1.25 (31.8) (102.0) Figure 28-2 XA-SLC2-100T-1M Tandem Collector Safe-Lec 2 Conductor Bar Manual...

  • Page 29: Section 16 - 200 Amp Collector

    Orient the nylon section of the nuts facing away from the collector. 4. Insert the two M3 x 30 screws through the collector head and into the flag and flag nuts. 5. Tighten the M3 screws to 0.9N-m (8in-lb) Safe-Lec 2 Conductor Bar Manual...

  • Page 30: Section 17 - Customer Supplied Cable Installation

    28. 6. We recommend the use of flexible, finely stranded cables to wire collectors. The use of cables with solid conductors is not recommended. Cable Entry Hole Figure 30-1 Safe-Lec 2 Conductor Bar Manual...

  • Page 31: Section 18 - Transfer Cap Assembly

    5. Fit nut and washers in the order shown. 6. Tighten nut to a recommended torque of 28.4 Nm (20 - 21 ft-lbs). 22mm (0.87”) 33mm (1.3”) Figure 31-1 1. Nut 2. Washer 3. Washer 4. Support Stud 5. Transfer Cap Safe-Lec 2 Conductor Bar Manual...

  • Page 32: Section 19 - Transfer Cap Mounting Details

    SECTION 19 - TRANSFER CAP MOUNTING DETAILS Side view 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 used. Safe-Lec 2 Conductor Bar Manual...

  • Page 33: Section 20 - Assembly Of Isolation Splice Assemblies

    5. Tighten nuts to a recommended value of 8 Nm (5-6 ft-lbs). Note: Tab wings must be faced upwards. Figure 33-1 1. Nut 2. Washer 3. Cap 4. Bolt 5. Joint Plate 6. Conductor Bar 7. Conductor Bar Safe-Lec 2 Conductor Bar Manual...

  • Page 34: Section 21 - System Maintenance And Installation Notes

    7. Ensure all armored cables are terminated into a suitable junction box and only flexible cables are installed into the powerfeed assemblies. 8. Ensure conductor bars DO NOT support the weight of the feed cables. 9. Conductix-Wampfler recommends that the first accessible conductor bar should be the ground bar. Safe-Lec 2 Conductor Bar Manual...

  • Page 35: Section 22 - Collector Contact Shoe And Shoe Holder

    2. Remove shoe by pulling downward. 3. Replace shoe with new shoe. 4. Tighten 100A shoe set screw to 13-16 Nm (10-12 in-lb). Tighten 200A shoe set screw to 24-27 Nm (18-20 in-lb). Figure 35-1 Safe-Lec 2 Conductor Bar Manual...

  • Page 36: Section 23 - Assembly For 1, 2, 3, & 4-Way Pickup Guide

    • When using pick-up guides, you must use collector part number XA-577973. Please contact factory when ordering. Figure 36-1 1. Support Stud 5. Bolt 2. Nut 6. Nut 3. Lock Washer 7. Lock Washer 4. Flat Washer 8. Flat Washer Safe-Lec 2 Conductor Bar Manual...

  • Page 37: Section 24 - Hanger Centers Diagrams

    SECTION 24 - HANGER CENTERS DIAGRAMS XA-310918 XA-310969 XA-310824 XA-310834 XA-310829 43mm MIN (1.69”) 43mm MIN 43mm MIN 1.6900 [42.93] (1.69”) (1.69”) XA-310882 XA-310821 XA-310899 XA-310857 43 mm (1.69”) 43mm (1.69”) XA-310861 310861 XA-310871 XA-310835 310871 XA-310859 43mm (1.69") Safe-Lec 2 Conductor Bar Manual...

  • Page 38: Section 25 - Conductor Bar De-Rating Chart

    SECTION 25 - CONDUCTOR BAR DE-RATING CHART Safe-Lec 2 Conductor Bar Manual...

  • Page 39: Notes

    NOTES Safe-Lec 2 Conductor Bar Manual...

  • Page 40: Contact Information

    (+52 81) 1090 9025 (+52 81) 1090 9013 Phone +1-402-339-9300 Phone +1-450-565-9900 +1-402-339-9627 +1-450-851-8591 (+52 81) 1090 9014 (+55 11) 4813 7330 info.us@conductix.com info.ca@conductix.com info.mx@conductix.com info.br@conductix.com latinamerica@conductix.com Contact USA for our Global Sales Offices Safe-Lec 2 Conductor Bar Manual XA-964200.13...

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