ALUMINIUM ENCLOSED CONDUCTOR SYSTEMSINSTALLATION PROCEDURE LSV–LSVG FOR CATALOG 3a/E 19 12

Curves, switches and other specials should be installed first. Position Line Feed section as close aspossible to power supply outlet.The connecting cables must not restrict freemovement of the Powerail system.

Long lip side of the LSV and LSVG housingshould always be mounted towards the track.

Installation of support brackets:Generally, the type of support bracket de-pends on local requirements.The support brackets are either bolted orwelded; support centers are 2000 mm (6I-6II). Slotted holes in the brackets andhangerstuds allow for horizontal and verti-cal adjustment/alignment.We do recommend our standard brackets,which can be bolted directly to the I-beam.

Installation of the Powerail with plug-injoints:The plug-in type connectors serve tocompensate for the different expansionand contraction of the aluminium housingand the copper conductors. Use telescopesections for runs exceeding 200 m.

Where you start depends on the site con-ditions. Install one sliding hanger to oneof the support brackets. Then slide an-other hanger over the top profile of onePowerail standard section and push thePowerail into the first hanger. Install thesecond hanger to the next bracket. In

order to facilitate the further mountingprocedure put locating clamps close tothe first hanger, forming an anchor point.Make sure that all other hangers are in aperpenticular position and not twisted, sothat the Powerail can slide for expansionand contraction.

Now push this Powerail section towardsthe first section until the plug-in connec-tors and the grooved push pegs engage.Careful work in this stage is most impor-tant for proper function of the system.

Prepare the next Powerail section withplug-in connectors and push pegs (stag-ger the pins for easy insertion into the endof the section already mounted).Push sliding hangers on to this secondPowerail section and install on the nexttwo support brackets.

Ensure perfectly closed joint by usingwooden block and hammer from theblank end of the second Powerail section.Attach joint fish plates and tighten pro-perly.Fit premounted yellow-green groundingcable over the joint and bolt to the adja-cent Powerail section.

long lip

long lipSketch 1

Photo 2 Photo 3 Photo 4

Photo 1

PAUL VAHLE GMBH & CO. KG · D 59172 KAMEN/GERMANY · TEL. 02307/7040Internet: www.vahle.de · e-mail: postmaster@vahle.de · FAX 02307/74704

Reg. No. 3140-02

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Installation of the Powerail with boltedjoints:The bolted joint Powerail version requiresexpansion joints approx. every 50 metersin order to compensate for the differentexpansion and contraction of the alumini-um housing and the copper conductors.Install the first Powerail standard sectionas described.Push the preassembled connecting piecesover the copper conductors at one end ofthe Powerail section (photo 6).

Continue this installation procedure for allother Powerail sections.Remove the two locating clamps fromthe first installed section and fit them nextto one of the hangers in the approx. cen-ter of the runway.Make sure that hangers are not placeddirectly on joints. Minimum spacing be-tween hangers and joint plates should be100 mm (4 inches). If necessary rearrangesupport brackets.

Now install the second Powerail sectionand push tightly (as photo 4) towards thefirst section after inserting the groovedpegs for aligning the aluminium housing.Slide the connecting pieces exactly halfway over the adjoining copper conductorsand tighten hardware (photo 7).Place joint covers over joint and tightenproperly. Fit grounding cable as photo 8.

Insert the current collectors from eitherend of the Powerail system. Make surethat the safety key is facing the short lipof the aluminium housing. Trolleys willonly fit one way to avoid phase reversing.Allow for sufficient manual test runs. Thecollector trolley should run smoothly.

Install all other Powerail sections thesame way. Positioning of the locatingclamps, insertion of collectors and powerconnection as described.

Connect collector cables and tow arm tothe machinery.Connect current supply cables to powerfeeds. Cables, switches and fuses to besupplied by others.

Bend Sealing Strip towards the Powerailslot and pull trolley through, now pressingthe entire length of the sealing strip intoits proper position (photo 12).Systems exceeding 50 m length willrequire a coupling for the sealing strip(see sketch).The sealing strip will be interrupted inareas for transfer guides, telescope andexpansion joint sections. In this case cutthe ends of the sealing strip oblique andtighten with fastener (see adjacent sketch).For clearance of end caps cut back thesealing strip by approx. 60 mm.

After insertion of all required collectorssecure Powerail end caps. Follow exactly the factory prepared layoutplan when installing curves, switches,transfers etc.

Installation of Neoprene Sealing Strip“D”Each LSV-LSVG consignment with sealingstrip does include a mounting trolley.Start from one end of the Powerailsystem, pressing approx. 20 mm (~1II)sealing strip by hand into the profile.Insert the mounting trolley.

Inspect sealing strip for proper fit andadjust where necessary.

Sketch 2

Photo 5 Photo 6 Photo 7

Photo 8 Photo 9 Photo 10

Photo 11 Photo 12

Photo 13

INSTALLATION PROCEDURE LSV – LSVG & HEATING SYSTEM

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Installation of Shielding “FP”

The shielding comes in 4 m standard sec-tions.Start from one end of the systems (seephoto 14) and attach the shielding to thePowerail, extending approx. 60 mm (photo 15).Insert connecting peg approx. 10 mm.Attach next section of PVC shielding andpush towards first section, interlockingwith the connecting peg and form a com-pletely closed joint (photo 16).

Installation of heating cables

Each 4 m PVC shielding to be tightenedwith one tapping screw (see sketch 3).

As the PVC shielding will be interrupted inthe area of transfer guides, telescope andexpansion joint sections, cut ends of theshielding oblique as shown.For clearance of end caps cut back theshielding accordingly (approx. 60 mm).Inspect proper fit and joints of plastic shielding; adjust where necessary.

1. Pull the heating cable into the factoryassembled copper tube.Use a thin stiff wire and pull the heatingcable through the entire length of yourheating section (two men required forpulling from one end and pushing fromthe other end).Important: Smooth insertion of theheating cable and no kinking.

2. Connect the heating cable at the fac-tory assembled terminal box.The heating cable comes 1 m longerthan required for the heating section, sothat you can cut a suitable connectingend.Prepare the connecting end per adja-cent sketch as follows:a) Remove the sheathing for about 40

mm.b) Cut back the insulation for about 12

mm and bend the wire per sketch.

c) Prepare the 1.5 sqmm connectingcable, cut back the insulation forapprox. 6 mm.

d) Both, the heating cable and theconnecting cable, now to be jointed ina standard sleeve, using a crimpingtool.

e) Push shrink-tubing over the joint andbraise carefully with small lighter flame.

f) Cut the 1.5 sqmm connecting cable tosuit into the terminal box. Remove 6mm insulation and connect to the termi-nal clamp.

3. WiringConnect the supply cable (220, 380 V)to the terminal box.A considerable shortening of the hea-ting cable may cause overheating andburning – so never cut the heatingcable too much.The supply cable, switches, fuses andtemperature regulating devices to besupplied by the customer.When using thermostats for automaticregulation, these should be adjusted at+2° C/–3° C to put the heating systemin operation.

Sketch 3

Type LSV Type LSVGSketch 4

Sketch 5

Proper and careful installation is important for troublefree operation. Therefore, please follow the instructionsin all details. When in doubt, please ask. We shall be glad to give any information and put our experts at your disposal.Please call us or our area engineer.

Photo 14 Photo 15 Photo 16

Connecting peg

BASIC DIMENSIONS

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LSV

LSVG

Dimensions also refer to correspon-ding double collectors.

with collector SWK SWN SWNT

Dim. a 187 187 197+ 5–15

+ 5–15

+ 5–15

with collector

SWNG DSWNG SWNGT DSWNGT

Dim. a 225 255 243 268

Dim. b 455 495 460 500

+ 5–10

+ 5–10

+ 5–10

+ 5–10

+ 5–10

+ 5–10

+ 5–10

+ 5–10

Sketch shows LSV 5/300w/collector SWN

Sketch shows LSVG 6/300w/collector SWNG