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Series C Installation Guide

Collectors are mounted on a 1" square bar at a 45° angle. The spacings and clearances match those of the conductors and are shown in the dimensional drawings. Good alignment is essential to the function of the system. Pigtails to the collectors should be flexible cable to allow free movement of the collector head. Dual collectors are tightened onto the 1" square bar by lifting one post and using a socket wrench.

Conductors are supported on brackets on 5' centers for C Series. The brackets are available as a catalog item or can be made up of light 1-1/2" angle to be welded or bolted to runway or bridge. 3/8" holes are drilled for the hanger clamps normally on 2" centers. 1-1/2" minimum centers may be used where space is a factor. 3" centers must be used for pick-up or transfer guides and for outdoor use with spool clamps. Length of bracket is determined by clearances involved, taking into account splice plates, end play of bridge or trolley, etc.

Vertical Mount-- Conductors are mounted as described above. Allow 1-1/2" clearance between innermost conductor and nearest obstruction such as splice plates, web ribs, etc. plus allowance for end play of bridge or hoist trolley on its rails. Where conductors are mounted in tiers, allow 3" clearance below conductor bar mount to top of bracket supporting lower tier of conductors. Spacing from conductor bracket to collector bar mount is 5-1/2" for standard collectors, 7-1/2" for long arm collectors and 5" for the light, 35 amp collector. For spool hanger clamps, add 1".

Lateral Mount-- To conserve space, conductors may be mounted on their sides (for clean, dry indoor installations only). The same spacing requirements apply as with vertical mounts but, for greater accessibility in servicing, alternate collectors should be faced in opposite directions when mounting on the collector bar mount. Special, counter-balanced collectors are not required with laterally mounted Saf-T-Bar Series C conductors. No metal clips are needed to secure insulating cover.

Outdoor Installation-- Where conductors are in service outdoors or in dusty or dirty areas, conductors are mounted vertically and insulating spools are used on the hanger clamps. Mounting on 2" centers is recommended. Spacing from conductor bracket to collector bar mount is increased 1" with the spool clamp. Where conductors are subjected to ice, sleet, falling objects or immediate personnel contact, a sheet metal hood can be mounted over the bracket clamp assembly.

Monorail Installation-- On narrow monorails and for use with light hoists, conductors should be mounted on opposite sides of the rail to balance upward pressure of the collectors against the conductors. Tilting trolley wheels should be allowed for. Long arm collectors are used where there is excessive trolley sway or vertical motion, instead of standard series.

Attach hanger clamps to brackets. Snap three 10' conductors into place in clamps. Take up on hanger cross bolts, except on plastic snap hangers that do not have cross bolts, to allow conductor to slide in expansion except the clamp at the anchor point which is taken up tight. On cross bolt anchor hangers, torque cross bolt to 6 ft. lbs. On plastic snap hangers install anchor pin. The standard adjustment for sliding cross bolt hangers is to tighten cross bolts, then back off ¼ turn. Snap next three conductors in place, and make up joints working from inside conductor outward. "C" series has friction joint using long-handled pliers or special lever tool to pull conductor together. Then tighten cross bolts on hangers and repeat above.

Powerfeeds can be mounted at any point along the conductor by cutting out 1-1/4" of the insulating cover. The preferred location is at a point where the cover is easily cut back. In mounting the powerfeed on a female end of conductor, drive a joint pin into the conductor for electrical conductivity and to reinforce distorting bar ends to retain end caps.

Expansion Conductors should be hung to expand from center anchor outwardly through sliding tight clamps. Expansion gap kits 1" motion, or gap assemblies (10') with 2" motion are available. Expansion gap kits are required every 150 feet for steel conductors and every 100 feet for copper conductors. Expansion gap assemblies are required every 300' for steel conductors and every 200' for copper conductors, and replace a 10' section of conductor.

Transfers-- At fixed gaps in the conductors such as at INTERLOCKS and SWITCHES, end caps driven onto the ends of the conductors provide a transfer passage for the collector shoe and insulate the conductors against grounding or cross phasing. The end caps will tolerate 1/8" misalignment. Conductor ends must be rigidly supported at interlocks.

Transfer Guides are used only where there is poor alignment at the interlocks, angular displacement for the conductor due to racking or at TONGUE SWITCHES, to track the collector through misalignments of ½". Use dual collectors to prevent contact loss through the interlock. Transfer guides are installed like pick-up guides and require 3" conductor spacing. Mounting dimensions on request.

Pick-Up Guides are used to retrace CENTERING collectors on discontinuous circuits such as bridge control circuits, runway circuits at fire doors, etc. The guide itself is secured to the bracket with a 3/8" bolt and the conductor is secured to the guide with a hanger clamp. The 3" width of the guide requires 3" minimum center conductor spacing.

End Caps are driven on the exposed ends of the conductors to complete the insulation of the bar. Excessive looseness of end caps may require distorting conductor ends to retain end caps.

Isolation Sleeve is used to electrically isolate adjacent conductor sections wit a ½" over-surface gap. The sleeve will support adjacent conductor sections but should have hangers within 6" of each side of the isolation sleeve. Collectors will bridge the gap electrically. Two sleeves separated by 6" of conductor would be required to prevent collectors bridging the gap as in signal or control functions.

Cutting-- The Series C conductors can best be cut with a tine-tooth hacksaw. They may be cut at any point and any rough edges should be filed smooth after cutting. Short lengths may be driven together over the joint pins where the using of a joint tool would require additional notching.

Bending Curves down to 18" radius is done with a special bending hickey for C Series. The end of the conductor is hooked into the left end of the hickey while the length of the conductor is drawn around its curved portion. The part thus curved is advanced through the hickey and the action repeated to form curves of any length and radius. On tight curves, it may be necessary to cut the lower half of the cover on the inside of the curve every 4 inches or so to prevent buckling. Instructions are included with each hickey. Use hickey Cat. # 100U with Series C.


(WARNING: Power Service Disconnect must be locked
in the OFF position before attempting any conductor service.)