Safe-Lec 2 “V” Contact Bar

Installation, Operation & Maintenance

Manual

XA-964200.16 - 04.20.23 SAFE-LEC 2 CONDUCTOR BAR MANUAL

 CONDUCTIX INCORPORATED

The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE
DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS MANUAL. Conductix Inc. makes no warranty (and assumes
no liability) as to function of equipment or operation of systems built according to customer design or of the ability of any of its products to
interface, operate or function with any portions of customer systems not provided by Conductix Inc.
Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered
and reported to Seller within one year after shipment of such goods to Buyer.
Except where the nature of the defect is such that it is appropriate, in Seller’s judgment, to effect repairs on site, Seller’s obligation
hereunder to remedy defects shall be limited to repairing or replacing (at Seller’s option) FOB point of original shipment by Seller, any part
returned to Seller at the risk and cost of Buyer. Defective parts replaced by Seller shall become the property of Seller.
Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended
by Seller and altered only as authorized by Seller. Seller is not responsible for defects which arise from improper installation, neglect, or
improper use or from normal wear and tear.
Additionally, Seller’s obligation shall be limited by the manufacturer’s warranty (and is not further warranted by Seller) for all parts procured
from others according to published data, specifications or performance information not designed by or for Seller.
Seller further agrees to replace or at Seller’s option to provide a refund of the sales price of any goods that do not conform to applicable
specifications or which differ from that agreed to be supplied which non-conformity is discovered and forthwith reported to Seller within
thirty (30) days after shipment to the Buyer. Seller’s obligation to replace or refund the purchase price 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.
There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title and freedom
from encumbrances and, except as herein expressly stated and particularly, and without limiting the foregoing, there is no guarantee or
warranty, express or implied, of merchantability or of fitness for any particular purpose or against claim of infringement or the like.
Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyer’s design or of the
ability of any goods to interface, operate or function with any portions of Buyer’s system not provided by Seller.
Seller’s liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of,
connected with, or resulting from the manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in
no case exceed the price paid for the product or services or any part thereof which give rise to the claim. In no event shall Seller be liable
for consequential, special, incidental or other damages, nor shall Seller be liable in respect of personal injury or damage to property not
the subject matter hereof unless attributable to gross misconduct of Seller, which shall mean an act or omission by Seller demonstrating
reckless disregard of the foreseeable consequences thereof.
Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities
and design functions or under abnormal conditions. Seller assumes no liability for loss of time, damage or injuries to property or persons
resulting from the use of Seller’s products. Buyer shall hold Seller harmless from all liability, claims, suits and expenses in connection
with loss or damage resulting from operation of products or utilization of services, respectively, of Seller and shall defend any suit or action
which might arise there from in 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

 CONDUCTIX-WAMPFLER FIELD SERVICE

Need Field Service for our products? We Can Handle It!

Ask us for a quote on expert system installations,inspections, preventative maintenance, and repairs/retrofits.
As the world’s largest single source manufacturer of mobile electrification products, Conductix-Wampfler has the unique ability to offer a
degree of service not found anywhere else. Conductix-Wampfler’s team of highly qualified service technicians and engineers have years of
experience servicing our complete line of products.
We can provide:
• Annual Service contracts
• Installation
• Commissioning
• Installation supervision to ensure your installers avoid common mistakes.
• Troubleshooting to get you up and running.
• Pre-planned inspections to complement your preventive maintenance program.

Call 1-800-521-4888 for further details.

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 TABLE OF CONTENTS

SECTION 1 - SAFETY 5
1.0 Safety Information Responsibility 5
1.1 Safety Messages5
1.2 Limitation of Liability 5
1.3 Personnel Requirements-Qualifications 6
1.4 Personnel Requirements-Unauthorized Personnel 6
1.5 Personnel Requirements - Training 7
1.6 Personnel Protective Equipment 7
SECTION 2 - PRODUCT DISPOSAL 8
2.0 Product Disposal & Recycling 8
SECTION 3 - OVERVIEW 9
3.0 Conductor System Nomenclature 9
3.1 Typical 3-Phase system Overview 9
3.2 Environmental Considerations 9
3.3 Installation Tools 9
SECTION 4 - GENERAL ASSEMBLY INSTRUCTIONS 10
4.0 Installation Overview 10
4.1 Identifying and Organizing the Materials 10
4.2 Install Brackets 10
4.3 Final Installation Along the Runway 10
4.4 Collector Positioning 10
SECTION 5 - SUPPORT BRACKETS 13
5.0 Support Bracket Installation 13
SECTION 6 - CONDUCTOR HANGERS 14
6.0 Four Bar Conductor Hanger Mounting 14
6.1 Tools Needed 14
6.2 Mounting Instructions 14
6.3 Installing Conductors Into Hanger 14
SECTION 7 - ANCHOR HANGER SUPPORT ASSEMBLY 15
7.0 Tools Needed 15
7.1 Anchor Hanger Support Installation 15
SECTION 8 - BOLTED STEEL/COPPER JOINT ASSEMBLY 16
8.0 Tools Needed 16
8.1 Bolted Steel/Copper Joint Installation 16
SECTION 9 - BOLTED ALUMINUM JOINT ASSEMBLY 17
9.0 Tools Needed 17
9.1 Bolted Aluminum Joint Installation 17
SECTION 10 - JOINT COVER ASSEMBLY 18
10.0 Joint Cover Installation 18

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 TABLE OF CONTENTS

SECTION 11 - END CAP ONTO CONDUCTOR BAR ASSEMBLY 19

11.0 Galvanized Steel and Copper Conductor Bar Installation 19
11.0.1 Tools Needed 19
11.0.2 Installation 19
11.1 Aluminum/Stainless Steel Conductor Bar Installation 19
11.1.1 Tools Needed 19
11.1.2 Installation 19
SECTION 12 - EXPANSION SECTION ASSEMBLY 20
12.0 Allowable Length and Distance 20
12.1 Expansion Section Installation 20
SECTION 13 - END POWERFEED ASSEMBLY 21
13.0 Tools Needed 21
13.1 End Powerfeed Installation 21
SECTION 14 - LOW AMP JOINT POWERFEED ASSEMBLY 22
14.0 Tools Needed 22
14.1 Low Amp Joint Powerfeed Installation 22
14.3 Installation up to and Including 250 Amps 22
SECTION 15 - POWERFEED AND COVER ASSEMBLY 23
15.0 Installation Over 250 up to 400 Amps 23
SECTION 16 - TERMINAL CHART FOR GUIDELINES ONLY 24
SECTION 17 - 100 AMP COLLECTOR MOUNTING DETAILS 25
17.0 Installation 25
SECTION 18 - 200 AMP COLLECTOR MOUNTING DETAILS 26
18.0 Installation 26
SECTION 19 - CUSTOMER SUPPLIED CABLE INSTALLATION 27
SECTION 20 - TRANSFER CAP ASSEMBLY 28
20.0 Tools Needed 28
20.1 Transfer Cap Installation 28
SECTION 21 - TRANSFER CAP MOUNTING DETAILS 29
SECTION 22 - ASSEMBLY OF ISOLATION SPLICE ASSEMBLIES 30
22.0 Installation 30
SECTION 23 - SYSTEM MAINTENANCE AND INSTALLATION NOTES 31
23.0 Maintenance Notes 31
23.1 Installation Notes 31
SECTION 24 - COLLECTOR CONTACT SHOE AND SHOE HOLDER 32
24.0 Tools Needed 32
24.1 Replacement Instructions 32
24.2 Replacement of 200 Amp Collector Contact Shoe 32

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 TABLE OF CONTENTS

SECTION 25 - ASSEMBLY FOR PICKUP GUIDE 33

24.0 Pickup Guide Assembly Instructions 33
SECTION 26 - HANGER CENTER DIAGRAMS 34
SECTION 27 - CONDUCTOR BAR DE-RATING CHART 35
NOTES36
CONTACT INFORMATION 37

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 1 - SAFETY

1.0 Safety Information Responsibility

1.0.1 All owner, operator, and maintenance personnel must read and understand all manuals associated with this product before
installation, operation, or maintenance.
1.0.2 The manual provides information on the recommended installation, operation, and maintenance of this product. Failure to read and
follow the information provided could cause harm to yourself or others and/or cause product damage. No one should install, operate,
or attempt maintenance of this product prior to familiarizing themselves with the information in this manual.

1.1 Safety Messages

The following safety messages are used in this manual to alert you to specific and important safety related information.

CAUTION
CAUTION indicates unsafe actions or situations that have the potential to cause injury, and/or minor equipment or property damage.

DANGER
DANGER indicates hazards that have the potential to cause severe personal injury or death.

WARNING
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.

1.2 Limitation of Liability

1.2.1 All data and information in this mounting instructions have been compiled in compliance with the applicable standards and
regulations, best practice and our many years of experience and knowledge.
1.2.2 The manufacturer accepts no liability for damages resulting from:
• Failure to comply with this document
• Improper use
• Use by untrained personnel
• Unauthorized modifications
• Technical changes
• Use of unauthorized replacement parts and accessories
• T he actual scope of delivery may differ from the explanations and descriptions provided here if the model in question is a special
one, if additional equipped has been ordered or due to recent technical changes.
1.2.3 The obligations agreed upon in the delivery agreement and our General Terms and Conditions of business apply, as do the delivery
conditions of the manufacturer and the legal regulations applicable at the time the contract was concluded.
1.2.4 All products are subject to technical modifications in the context of improvement of function and further development.

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 1 - SAFETY

1.3. Personnel Requirements-Qualifications

WARNING
Inadequately trained persons are at risk of injury!
Improper use can result in serious personal injury or material damage. All activities must only be performed by qualified personnel.

1.3.1 Only persons who can be expected to perform their work reliably are acceptable personnel. People whose reactions are impaired by
drugs, alcohol or medications, for example, are not authorized.
1.3.2 When selecting personnel, follow all age- and occupation-specific guidelines applicable at the location of use.
1.3.3 The following qualifications are specified in the operating instructions for certain fields of activity.
1.3.4 Trained personnel and operators
•  ill have participated in a training session, given by the owner, on the tasks assigned to them and the potential hazards in case
W
of improper conduct.
• The owner of the machine or system must document that the appropriate training has taken place.
1.3.5 Specialist personnel
•  ill consist of persons capable of performing assigned tasks and independently identifying and avoiding potential hazards based
W
on their specialist training, knowledge and experience as well as their knowledge of the applicable regulations. Persons are
deemed to be technically qualified if they have successfully completed training as a master electrician, apprentice electrician,
electrical engineer or electrical technician. Persons are also considered technically qualified if they have been employed in an
appropriate capacity for several years, receiving theoretical and practical training in that line, and their knowledge and skills have
been tested by a specialist in the appropriate field of training.
• T he machine or system owner must document that the appropriate certificates or other proofs of qualification have been or are
being provided.

1.4 Personnel Requirements-Unauthorized Personnel

WARNING
Danger due to unauthorized personnel!
Unauthorized persons who do not meet the requirements described here are not acquainted with the dangers in the working area. Keep
unauthorized personnel away from the working area. In case of doubt, address the person and direct them away from the working area.
Stop working, as long as unauthorized persons are in the working area.

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 1 - SAFETY

1.5 Personnel Requirements-Training

1.5.1 Before commissioning the equipment, personnel must be trained by the owner. Log the implementation of training for better
traceability.
Example of a training log:

Date Name Training Type Training Instructor Signature

11/5/2019 John Doe First safety training for personnel Dave Miller

1.6 Personal Protective Equipment

1.6.1 For every task, always use:
Safety helmet: For protection against falling or flying parts and materials.
Protective gloves: F or the protection of hands against friction, scrapes, puncture or deeper wounds, as well as against contact with hot
surfaces.
Protective work clothing: P rimarily for protection against entrapment by moving machine parts. Work clothing must be close fitting with
a low resistance to tearing; it must have close-fitting sleeves and no protruding parts.
Protective footwear: F or protection against heavy falling parts and slipping on slippery floors. For special tasks, specific protective
equipment is required when executing particular tasks:
Safety eye wear: For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather effects.
Hearing protection: For protection against loud noises and to prevent acoustic trauma.
Breathing mask (FFP-3 - according to country-specific requirements): F or protection against materials, particles, and organisms.
In this case, for protection against the dust produced by the
abrasion of carbon brushes and the PVC insulation of the
conductor rail.

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 2 - PRODUCT DISPOSAL

2.0 Product Disposal and Recycling

2.0.1 Once the product has reached it’s end of life it must be disassembled and disposed of in accordance with local and regional
environmental requirements.
2.0.2 In the absence of a return and disposal agreement, disassembled components must be recycled as follows:
• All metallic parts must be sorted and recycled by material type
• All plastic components must be sorted and recycled by material type
• A ll other components are to be disposed of in accordance with their material composition. Take care with items identified as
Substances of Concern.
2.0.3 Local authorities or special disposal companies can provide information about environmentally appropriate disposal.

10

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 3 - OVERVIEW

3.0 Conductor System Nomenclature

Single Conductor Hanger Clamp

Joint Position Anchor Position

Expansion Section Powerfeed

Transfer Cap Pickup Guide

End Cap Isolation Section

Isolation = Air Gap

Isolation Section Collector

Isolation = Insulating Material

Power Interrupt
Figure: 3-1

3.1 Typical 3-Phase System Overview

Figure: 3-2

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 3 - OVERVIEW

3.2 Environmental Considerations

• Standard Cover (PVC) is suitable up to 160°F.
• Medium Heat Cover (Polycarbonate) is suitable up to 250°F.

NOTE: The following acidic or corrosive environments require the use of stainless steel hangers:
• 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 environment

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 3 - OVERVIEW

3.3 Installation Tools

3.3.1 Organize the following tools before doing installation
• Man lift or platform lift for access to the installation location (if needed)
• Sharp knife - to cut powerfeed grommets
• Steel rule or tape measure - to position collectors during installation
• Wire/cable stripper
• Cable lug crimping tool
• Cordless drill with socket adapter (1/4” or 3/8” drive)
• Hex Wrenches
> 4mm - for securing feed cable to 100 Amp collector and replacing shoe
> 5mm - for securing feed cable to 200 Amp collector and replacing shoe
• Deep sockets for Cordless Drill
> 8mm - for anchor cross bolts
> 10mm - for splices, isolation sections, and powerfeeds
> 13mm - for mounting hangers, anchors, and transfer caps
> 16mm - for mounting collector assemblies
• Torque wrench for sockets listed above
• 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

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 4 - GENERAL ASSEMBLY INSTRUCTIONS

WARNING
• Always lockout-tagout all electrical power before starting work

4.0 Installation Overview

4.0.1 This manual provides detailed instructions in the general order of system installation. System installation consists of five phases:
4.0.2 Phase 1 - Identify and Organize the Materials
4.0.2.1 C
 heck the pack list against the items received. Parts are labelled for your convenience. Review your specific installation layout
drawing (if provided) or the typical layout diagram seen previously in this manual to become familiar with component location
on the system. Note where the anchors, expansions, powerfeeds, and other assemblies will be located along the runway. Read
through these instructions before starting work.

NOTE:
• Make sure to check for smaller components that may be located inside the false bottom of the packaging.
4.0.3 Phase 2 - Install Brackets Along the Runway
4.0.3.1 Install brackets per diagram included at the start of this manual. Keep them as level and evenly spaced as possible. You may
install the hangers on the brackets before or after they are mounted along the runway.
4.0.4 Phase 3 - Assemble components as much as possible on the ground
4.0.4.1 It is faster, safer, and more convenient to assemble as much as possible on the ground should you drop something. Conductor
Bar and Expansion Sections will come from the factory with one splice pre-installed.
1. Install end caps on the end conductors, keeping these separated from the main runway conductors.
2. Install isolation splices (if included) on the ends of the conductors in accordance with the installation layout drawing and the
instructions (See Table of Contents).
3. Install transfer caps on the conductor ends (if included).
4.0.5 Phase 4 - Install Hangers and Conductors Along the Runway
4.0.5.1 The installation will most likely be accomplished from a lift or work platform.
1. Ensure the power is locked out-tagged out.
2. Install the hangers per instructions (See Table of Contents).
3. R oll adjacent conductors in the hangers as shown in Section 6.2. Conductix-Wampfler recommends the first accessible
conductor being the ground conductor.
4. M
 ove down the runway, install the next inboard conductor and join it to the corresponding conductor installed in Step 3.
Install the splice cover. Keep the splice assemblies 6-12 inches from the hanger brackets to allow for conductor movement
and expansion. Repeat for the remaining phases and ground conductors.
5. W
 hen you get to where the expansion assemblies are to be installed, refer to those instructions (See Table of Contents). Be
sure to divide the total expansion gap distance (from chart) between the two air gap locations in the expansion assembly.
6. Proceed with system installation, ensuring anchors are positioned the correct distance from the expansions and that they are
tightened to the correct torque.
7. If the conductor must be cut to a specific length, ensure that the cut end is properly de-burred. The conductor cover is always
shorter than the bar length, the proper cover length is 66 mm (2.60”) shorter than the bar length, (33 mm / 1.30” on each
end).
8. When you run the feed cable to the powerfeed assembly, ensure the cables have sufficient free length and are flexible
enough to enable movement of the conductor due to expansion. Locating the powerfeed as close as possible to the anchors
minimizes this concern. Do not support the weight of the feed cables with the conductors.
9. Install powerfeeds on conductor bars per layout and the instructions (See Table of Contents).
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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 4 - GENERAL ASSEMBLY INSTRUCTIONS

4.0.6 Phase 5 - Collector Positioning

4.0.6.1 Properly position and align Collector Assemblies to ensure safe, reliable operation.
• F or 100 Amp and 200 Amp collectors, the center line of the conductor mounting post must be 102 mm (4.0”) below the contact
surface of the conductor bars. When installed, the collector arms should be parallel with the contact surface of the bar.
• S lide 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. Tighten hardware to specifications and connect the power supply cable to
the collector per diagram (See Table of Contents).

NOTE:
• Follow all lockout-tagout procedures.
• 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.

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 5 - SUPPORT BRACKETS

5.0 Support Bracket Installation

5.0.1 Locate and secure support brackets at the recommended spacing. (See Figure 5-1).

NOTE:
• L ocate support brackets at a spacing that is divisible into conductor bar lengths. This will ensure that the joint
positions do not interfere with the support brackets.
5.0.2 Observe all alignment tolerances. (See Figure 5-1).
> Datum height
> Maximum allowable deviation from datum height + 5.0 mm (+3/16”).

5.1 Advantage of Factory Made Brackets

5.1.1 Safe-Lec 2 Hanger 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
length: ± 5.0 mm (± 3/16”)

Bracket slots: 9mm wide. Will

accommodate 4 anchors on
43mm centers
Straight datum line running the
length of the runway system
ax
”M
59

x
” Ma
59

Figure: 5-1

16

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 6 - CONDUCTOR HANGERS

6.0 Four Bar Conductor Hanger Mounting

NOTE:
• For indoor and limited indoor use use part no. XA-310821
• For lateral mount - Consult Factory

6.1 Tools Needed

• A/F Wrench
> 13 mm

6.2 Mounting Instructions

1. Remove nut, lock washer, and washer from hanger assembly (the M8 bolt will stay in place inside the molding).
2. Assemble as shown in the diagram, ensuring the correct alignment is observed. (See Figure 6-1).
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:
• T his hanger may be used 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.

Nut 13mm A/F Zinc plated Grade 8.8

Support Bracket

M8 x 30 set screw
Zinc plated Graded 8.8 For Medium Heat Hangers
2 Flat Washers are Supplied.
Alignment tolerance over 4500 mm + 5mm (177” + 3/16”)

Straight Datum line running the length of the system.

Figure: 6-1

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 6 - CONDUCTOR HANGERS

6.3 Installing Conductors Into Hanger

“SNAP” INSTALLED
Recommended
Location for
Step 1 Step 2
Ground Rail

Figure: 6-2

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 7 - ANCHOR HANGER SUPPORT ASSEMBLY

NOTE:
• For ease of access to clamping screws, install anchor hanger assemblies as shown below.

7.0 Tools Needed

• A/F Open ended wrench
> 13 mm
> 8 mm

7.1 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 anchor is tight on cover).
4. Tighten M8 Bolt to a torque of 8 Nm (5-6 ft. lbs).

M8 Nut M8 Screw M8 Lock Washer

M8 Flat Washer

M5 Screw

M5 Flat Washer

M5 Nut
Clamp Anchor Half

Figure: 7-1

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 8 - BOLTED STEEL/COPPER JOINT ASSEMBLY

8.0 Tools Needed

• A/F open ended wrench
> 10 mm

8.1 Bolted Steel/Copper Joint Installation

1. Fit into joint plate (ensure tab captivates the head on the setscrew).
2. Slide bolt and joint plate into conductor bar ends.
3. Place joint over 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 faces of the conductor bar are touching each other and there is no gap exceeding 0.5mm (0.02”) at the faces.

NOTE:
• If the conductor was field cut, file off all burrs on conductor ends before assembling splices.

Nut

Washer

Joint

Bolt
Alignment Mark

Joint Plate

Conductor Bar

Figure: 8-1

20

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 9 - BOLTED ALUMINUM JOINT ASSEMBLY

9.0 Tools Needed

• A/F open ended wrench
> 10 mm
• Electrical Joint Compound (part no. XA-15629)

9.1 Bolted Aluminum Joint Installation

1. Apply electrical joint compound to all mating surfaces.
2. Slide bolt into conductor bar ends.
3. Place joint plate over 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 the conductor bar are touching each other and there is no gap exceeding 0.5mm (0.02”) at the faces.

NOTE:
• 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.

Nut

Washer

Joint Plate

Bolt

Conductor Bar Conductor Bar

Apply Electrical
Joint Compound
part no: XA-15629
to mating surfaces

33 mm
(1.3”)

Figure: 9-1

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 10 - JOINT COVER ASSEMBLY

10.0 Install Joint Cover onto Bolted Assemblies

1. Spring legs out in the directions “A-A” as shown (this is to ease the fitting of the joint cover over the conductor bar).
2. F it 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 “B”. Ensure the flaps “click” home on both sides.

Figure: 10-1

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 11 - END CAP ONTO CONDUCTOR BAR ASSEMBLY

11.0 Galvanized Steel and Copper Conductor Bar Installation

11.0.1 Install end caps onto galvanized steel and copper bars see Figure 11-1.

11.1 Tools Needed

• A/F open ended wrench
> 10 mm

11.2 Installation
1. Fit bolt into joint plate (ensure tab captivates the head on the set screw).
2. Place bolt and joint plate assembly into conductor bar.
3. P lace end cover clamp, washer, and nut over bolt and joint plate assemblies (ensure end cover clamp is flush with conductor bar
face).
4. Tighten nut to a recommended torque of (40-50 In-lbs) 5-6 Nm.
5. Slide End Cap End Plug into the grooves at the back of the Top Cover.
6. Place Top cover onto bar end making sure that the circular pocket aligns with the square bolt.
7. A lign Bottom Cover with Top Cover and End Plug. Apply slow but firm pressure to both Top and Bottom Covers, until all four tabs
have snapped securely into place.

End Cap Top

Nut
Lock Washer
Square Bolt Flush with
Joint Plate Top bar end
Joint Plate Bottom

End Cap .47

End Plug (11.9) Conductor Bar & Cover
1.10-1.70 for Reference Only
(27.9-43.2)

End Cap Bottom

Figure: 11-1

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SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 11 - END CAP ONTO CONDUCTOR BAR ASSEMBLY

11.3 Aluminum/Stainless Steel Conductor Bar Installation

11.3.1 Install end caps onto aluminum/stainless steel conductor bars.

11.4 Tools Needed

• A/F open ended wrench
> 10 mm

11.5 Installation
1. Mark conductor bar top surface 11.9 mm (0.47”) 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 on bolt in the order shown in Figure 11-2.
5. Slide End Cap End Plug into the grooves at the back of the Top Cover.
6. Place Top cover onto bar end making sure that the circular pocket aligns with the square bolt.
7. A lign Bottom Cover with Top Cover and End Plug. Apply slow but firm pressure to both Top and Bottom Covers, until all four tabs
have snapped securely into place.

End Cap Top

Nut
Lock Washer
Flat Washer
Square Bolt

End Cap .47

End Plug (11.9) Condcutor Bar & Cover
1.10-1.70 for Reference Only
(27.9-43.2)

End Cap Bottom

Figure: 11-2

24

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 12 - EXPANSION SECTION ASSEMBLY

12.0 Allowable Length & Distance

• The maximum allowable conductor system length without an Expansion Section is 150 m (492’) - Assuming a Maximum
Temperature Range of 110° F.
• T he maximum distance between anchor points with an Expansion Section at mid-point is 70 m (230’) steel, 49 m (160’) copper,
36.5 m (120’) aluminum.

12.1 Expansion Section Installation

1. S et expansion air gaps when installing assembly to appropriate gap setting for ambient temperature (see Table 22-1). The gap is
adjusted by sliding the moving lengths of conductor in or out of the expansion assembly (BOTH HALVES MUST BE SET EQUAL).
Always allow sufficient time for conductor bars to achieve ambient temperature before setting expansion gap. All expansion
assemblies must be set at site, they are not pre-set before leaving the factory. Failure to set this part correctly could result in
buckling of conductors.
2. S et anchor clamp and torque on one side, install up to next anchor clamp but DO NOT TIGHTEN. Go back and set expansion to
correct gap setting per current ambient temperature. Once gap is set, go to second anchor clamp and tighten.

Half Total Air Gap Half Total Air Gap

Image: 12-1
Actual Site Ambient Temperature: °C (°F)
-25° -20° -15° -10° -5° 0° 5° 10° 15° 20° 25° 30° 35° 40° 45° 50° 55°
(-13) (-4) (5) (14) (23) (32) (41) (50) (59) (68) (77) (86) (95) (104) (113) (122) (131)

25° 50 45 41 36 32 27 23
(77) (1.97) (1.77) (1.61) (1.42) (1.26) (1.06) (0.91)
20° 50 46 42 38 33 29 25 21
Lowest Possible Site Ambient Temperature °C (°F) See Note

(68) (1.97) (1.81) (1.65) (1.50) (1.30) (1.14) (0.98) (0.83)

15° 50 46 42 38 35 31 27 23 19
(59) (1.97) (1.81) (1.65) (1.50) (1.38) (1.22) (1.06) (0.91) (0.75)
10° 50 46 43 39 36 32 29 25 21 18
(50) (1.97) (1.81) (1.69) (1.54) (1.42) (1.26) (1.14) (0.98) (0.83) (0.71)

Total Gap Setting: mm (in)

5° 50 47 43 40 37 33 30 27 23 20 17
(41) (1.97) (1.85) (1.69) (1.57) (1.46) (1.30) (1.18) (1.06) (0.91) (0.79) (0.67)
0° 50 47 44 41 38 34 31 28 25 22 19 16
(32) (1.97) (1.85) (1.73) (1.61) (1.50) (1.34) (1.22) (1.10) (0.98) (0.87) (0.75) (0.63)
-5° 50 47 44 41 38 35 32 29 26 24 21 18 15
(23) (1.97) (1.97) (1.73) (1.61) (1.50) (1.38) (1.26) (1.14) (1.02) (0.94) (0.83) (0.71) (0.59)
-10° 50 47 44 42 39 36 33 31 28 25 22 19 17 14
(14) (1.97) (1.85) (1.73) (1.65) (1.54) (1.42) (1.30) (1.22) (1.10) (0.98) (0.87) (0.75) (0.67) (0.55)
-15° 50 47 45 42 39 37 34 32 29 26 24 21 18 16 13
(5) (1.97) (1.85) (1.77) (1.65) (1.54) (1.46) (1.34) (1.26) (1.14) (1.02) (0.94) (0.83) (0.71) (0.63) (0.51)
-20° 50 48 45 43 40 38 35 33 30 28 25 23 20 18 15 13
(-4) (1.97) (1.89) (1.77) (1.69) (1.57) (1.50) (1.38) (1.30) (1.18) (1.10) (0.98) (0.91) (0.79) (0.71) (0.59) (0.51)
-25° 50 48 45 43 40 38 36 33 31 29 26 24 21 19 17 14 12
(-13) (1.97) (1.89) (1.77) (1.69) (1.57) (1.50) (1.30) (1.22) (1.14) (1.02) (0.94) (0.83) (0.75) (0.67) (0.55) (0.47)

Table: 12-1

25

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 13 - END POWERFEED ASSEMBLY

NOTE:
• Installation is for 100 Amp Conductor Bar Only.

13.0 Tools Needed

• A/F Wrench
> 10 mm
• Suitable Sharp Knife
• Cable Stripper
• Cable Crimping Tool
• Suitable Cable Terminal (see list of recommended suppliers and references).

13.1 End Powerfeed Installation

1. Cut powerfeed end cap to suit cable diameter.
2. Pass cable through powerfeed end cap.
3. Crimp terminal to cable.
4. Fit bolt into joint plate (wings on tab to face upward).
5. Fit assembly into conductor bar.
6. Fit clamp over joint plate and bolt. Secure with half nut. Tighten half nut to recommended torque value of 10 Nm (7-8 ft.-lbs.).
7. Fit terminal and secure washer and nut.
8. Tighten nut to recommended torque of 8 Nm (5-6 ft.-lbs.).
9. Push powerfeed end cap over assembly (ensure bolt is located in point "A" on powerfeed end cap).

NOTE:
• Maximum cable size is 25 sq mm PVC 600/1000V stranded copper conductor (#4 AWG Extra Flexible)

Nut

Lock Washer
Powerfeed End Cap
Half Nut
A
Clamp End

Bolt
These faces
to be flush Joint Plate
Figure: 13-1

26

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 14 - LOW AMP JOINT POWERFEED ASSEMBLY

NOTE:
• Installation up to 100 Amp.

14.0 Tools Needed

• A/F Wrench
> 10 mm
• Suitable Sharp Knife
• Cable Stripper
• Cable Crimping Tool
• Suitable Cable Terminal (see list of recommended suppliers and references).

14.1 Low Amp Joint Powerfeed Installation

1. Remove black plug on powerfeed cap.
2. Assemble 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 to tighten nut to a recommended torque of 8 Nm (5-6 ft.-lbs).
6. Fit powerfeed cap over assembly (ensure the cable is threaded carefully through grommet).
7. Once in position close flaps and ensure flaps click home.

NOTE:
• Joint must not support cable.
• Max. cable size 10sq. mm pvc 600/1000V stranded copper conductor (#8 AWG Extra Flexible).

Powerfeed Cap

Nut

Lock Washer

Figure: 14-1

27

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 14 - LOW AMP JOINT POWERFEED ASSEMBLY

NOTE:
•  lean all mating surfaces with 3M Scotch Brite pad, apply a small amount of Electrical Joint Compound (EJC) to all
C
mating parts.
• Apply anti-seize to bolt ends prior to assembly to any stainless steel nuts.

14.2 Installation up to and Including 250 Amps

1. Assemble joint to conductor bar as described previously (do not fit washers and nuts).
2. F it powerfeed top hat assembly to joint assembly. On copper and aluminum conductors apply Electrical Joint Compound (EJC)
between mating surfaces.
3. D
 iscard spring washers originally fitted to the joint assembly and fit external tooth lock washers (supplied in the kit) along with
nuts and bolts and tighten to a recommended torque of 8 Nm (5-6 ft.-lbs).
4. Fit joint powerfeed cover as shown previously.
5. Cut out grommet using suitable knife and fit over cover.
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 terminal to powerfeed top hat assembly and secure using washer and bolts. Torque bolt to 8 Nm (5-6 ft.-lbs).
9. T here is a second set of hardware (washers and bolt) for use with two cable feeds and should be left tight on powerfeed top hat
assembly if only one feed is used.
10. Fit powerfeed joint cover to assembly.
11. Ensure both grommets are fitted into powerfeed cover before closing halves together.
12. Make sure the legs of the cover fit under the conductor cover support ears (a little pressure at points "x-x" will ensure this).
13. Fit powerfeed case clip assembly to powerfeed cover and secure with screws.

“X”
Powerfeed Cover

“X”
Powerfeed Case Clip
Assembly
Bolt
Washer Grommet
Washer
Legs clip under
support ears on
Powerfeed Joint Cover conductor cover.

Conductor Cover
Powerfeed Top Hat Assembly Support Ears

Splice Bolt
Figure: 14-2

28

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 15 - POWERFEED AND COVER ASSEMBLY

15.0 Installation over 250 up to 400 Amps

1. Assemble joint to conductor bar as described previously (do not fit washers and nuts).
2. F it powerfeed top hat assembly to joint assembly. On copper and aluminum conductors apply Electrical Joint
Compound (EJC) between mating surfaces.
3. D
 iscard spring washers originally fitted to the joint assembly and fit external tooth lock washers (supplied in the
kit) along with nuts and tighten to a recommended torque of 8 Nm (5-6 ft.-lbs).
4. Fit powerfeed joint cover as shown previously.
5. Apply EJC between mating surfaces on powerfeed top hat assembly and powerfeed shunt link.
6. P lace powerfeed shunt link over powerfeed top hat assembly and secure with screws.
Torque to 8 Nm (5-6 ft.-lbs).
7. Cut out grommet using suitable knife and fit over cable.
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 to the center arc of powerfeed shunt link.
11. F it lug to the center powerfeed shunt link and secure using bolt, washer, and nut in the order shown. Torque to
8 Nm (5-6 ft.-lbs).
12. Fit powerfeed cover to assembly.
13. Ensure both grommets are fitted to powerfeed cover before closing halves together.
14. M
 ake sure the legs of the cover fit under the conductor cover support ears. A little pressure at points "x-x" will
ensure this.
15. Fit powerfeed case clip assembly to powerfeed cover and secure with screws.

“X”
Powerfeed Cover

“X”

Powerfeed Case Clip Assembly

Bolt Grommet

Lock Washer
Legs to clip under support ears
Washer
Powerfeed Shunt Link on conductor cover
Screw
Nut

Powerfeed Joint Cover

Conductor Cover Support Ears

Powerfeed Top Hat Assembly

Splice Bolt
Figure: 15-1

29

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 16 - TERMINAL GUIDELINES CHART

16.0 The Thomas and Betts (T&B) terminal part numbers are show below for reference only. Dimensions shown are the maximum
allowable sizes. All powerfeeds must have expansion loops incorporated in their installation. Flexible cables are recommended for all
powerfeed and collector assemblies. The use of cables with solid (non-strained) conductor is NOT RECOMMENDED.

Powerfeed Part No. Lug Part No. T&B Part No. Dim "A" Dim "B" Dim "C" Cable Size (AWG)
XA-310101 E72 1.32 .60 5/16 6
XA-310201 F72 1.35 .60 5/16 4
XA-310910B XA-310301 G972 1.59 .69 5/16 1-2
XA-310601 J972 1.94 .84 5/16 1/OAN-2/0
XA-310401 L973 2.25 1.04 3/8 3/OAN-4/0
XA-310701 M972 2.28 1.12 5/16 4/OAN - 250 kcmil
XA-310912B
XA-310501 54178 2.33 1.25 5/16 300 kcmil
XA-310911 XA-310101 E71 1.13 .48 1/4 6
XA-310034B XA-310101 D71 1.13 .48 1/4 8

30

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 17 - 100 AMP COLLECTOR MOUNTING DETAILS

17.0 XA-SL2-100S-1M Single Collector - Figure 17-1

17.0.1 When stationary, single collector is rated for 50 continuous amps on copper or galvanized steel bars, and 25 continuous amps on
aluminum-stainless steel bar.

17.1 XA-SL2-100T-1M Tandem Collector - Figure 17-2

17.1.1 When stationary, tandem collector is rated for 100 continuous amps on copper or galvanized steel bars, and 50 continuous amps
on aluminum-stainless steel bar.

17.2 Tools Needed

• Socket Wrench
> 16 mm
• Steel rule or suitable tape measure
• Hex wrench
> 4mm
• Cable Stripper

17.3 Installation
1. Attach collector mounting bracket to a suitable support at the correct setting height (see Figs. 17-1 and 17-2).
2. Remove the collector clamp and place collector on the mounting bracket.
3. E nsure 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 Bolt 2 to a recommended torque of 24.4-27.1 Nm (18-20 ft.-lbs).
5. F or customer installed cable on the collectors, there must be 18" for 100 amp and 19.5" for 200 amp of cable length from the exit
of the cable clamp to the entrance of the collector head. Reference the striped cable sections of Figures 17-1, 17-2, 18-1, 18-2.

Working
Range
2.75 NOTE:
Contact Surface (69.9)
• Cable length between the exit of the cable clamp and the
4.0 1.25 cable entry hole on the collector head should be 18" for 100
(102)
1 (31.8) Amp Collectors and 19.5" 200 Amp Collectors to ensure proper
head movement on the collectors.
2

Figure: 17-1

Working Range 2.75 (69.9)

Contact Surface
4.0 (102.0) 1.25 (31.8)

1 2

Figure: 17-2

31

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 18 - 200 AMP COLLECTOR MOUNTING DETAILS

NOTE:
• Torque moutning hardware per the chart below.
• In the stationary position, these collectors are UL rated at 100 Amps continuous-duty on copper, and 50 Amps on
aluminum-stainless steel.
Collector Base Material Torque Spec
Aluminum 24.4 to 27.1 Nm (18-20 ft.-lb)

Working Range 2.75

Contact Surface (69.9) NOTE:
•  able length between the exit of the cable
C
4.0 1.25
(102) 1 clamp and the cable entry hole on the
(31.8)
collector head should be 18" for 100 Amp
Collectors and 19.5" 200 Amp Collectors
2 to ensure proper head movement on the
collectors.

Figure: 18-1

Working Range 2.75

Contact Surface (69.9)
4.0
(102.0) 1.25
(31.8)

Figure: 18-2

18.0 Ground Flag Installation

1. T he ground flag should be oriented on the ground collector with the flag
facing away from the other phase conductors as to prevent the ground
conductor from being inserted into any of the phase rails.
2. A lign the two 3.2 mm through holes located near the pivot post on the head
with the two holes on the ground flag.
3. T he supplied M3 locking nuts should be inserted into the flag where the
hexagonal nut bosses are molded into the flag. 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 on 0.9 Nm (8 in.-lb).

Figure: 18-3

32

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 19 - CUSTOMER SUPPLIED CABLE

19.0 Installation
1. Strip customer-supplied cable back 13-15 mm (0.5-0.6") using a suitable cable stripping tool.
2. Loosen Screw Number 1.
3. Push customer-supplied cable into entry hole.
4. Tighten Screw Number 1 fully and ensure that the cable is clamped firmly into position.
5. E nsure that the cables do not restrict the free movement of the collector arm or collector head. The collector head must be free to
track on the conductor bar within the movement tolerances noted on Page 31.
6. W
 e highly recommended the use of flexible, finely stranded cables to wire collectors. The use of cables with solid conductors is
not recommended.

Cable Entry
Hole

Figure: 19-1

33

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 20 - TRANSFER CAP ASSEMBLY

20.0 Tools Needed

• A/F Wrench
> 13mm
• Soft Mallet

20.1 Transfer Cap Installation

1. Mark Conductor cover 22mm (0.87" in from end of cover).
2. Gently tap transfer cap onto bar and cover assembly using a soft mallet.
3. Line up back edge of transfer cap with mark on cover.
4. Install transfer cap into support bracket (not shown) at 43mm (1.7") centers.
5. Fit nut and washers in order shown.
6. Tighten nut to a recommended torque of 28.4 Nm (20-21 ft.-lbs).

Nut

Lock Washer
Flat Washer
Support Stud
Transfer Cap

22mm
(0.87”)
33mm
(1.3”)

43mm
(1.69”)

Figure: 20-1

34

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 20 - TRANSFER CAP ASSEMBLY

20.2 Transfer Cap Mounting Details

20.2.1 Side Transfer Cap showing maximum alignment tolerance.

10 mm (0.4”)
MAX

5 mm (0.19”)
MAX
Figure: 20-2

20.2.2 Plan view of transfer caps showing maximum alignment tolerance.

2mm (.08”)
MAX

Figure: 20-3

NOTE:
• Where transfer caps are used in a system, tandem collectors must be used.

35

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 21 - ASSEMBLY OF ISOLATION SPLICE ASSEMBLIES

21.0 Tools Needed

• A/F open ended wrench
> 10 mm

20.1 Installation
1. Fit bolt into joint plate. 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 a recommended value of 8 Nm (5-6 ft-lbs).

Nut

Washer

Cap

Bolt

Conductor Bar

Joint Plate

Conductor Bar

Figure: 21-1

36

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 22 - SYSTEM MAINTENANCE AND INSTALLATION NOTES

22.0 Maintenance Notes

1. Contact shoes should be checked for wear on a monthly basis until a wear pattern can be established.
2. Check alignment of collector and conductor bars. Base of collector should be directly in-line with associated conductor.
3. Check conductor system to ensure no damage to insulation cover.
4. In environments that are subject to considerable build up of dust, especially conductive dust, remove this dust at regular intervals
by brushing.
5. Check collector pivot points are free from any contamination.
6. Uneven shoe wear indicates less than optimal collector alignment.

22.1 Installation 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 location of support brackets.
4. Ensure conductor joints are not against hanger clamps. Adequate clearance must be allowed for expansion and contraction.
5. Ensure correct alignment of collector with conductor bar. Collector arms should be parallel with contact surface.
6. Ensure all power cables are flexible to allow expansion and contraction of the conductor bar system.
7. E nsure 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.

37

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 23 - COLLECTOR CONTACT SHOE AND SHOE HOLDER

NOTE:
•  ollector contact shoe is supplied as replacement part no. XA-577940 for 100A collectors and
C
part no. XA-577947 for 200A collectors.

23.0 Tools Needed

• Hex Wrench
> 4mm for 100A collector
> 5mm for 200A collector
23.1 Replacement Instructions
1. Loosen upper set screw with hex wrench.
2. Remove shoe by pulling upward, take care not to lose the shim located between the shoe and the setscrew. See Figure: 23-1.
3. R eplace shoe with new shoe. Place shim in pocket between setscrew and shoe, and install new shoe into collector head.
See Figure: 23-2.
4. Tighten set screw to 1.69 Nm (15 in.-lb).

Shoe
Shim
Shim Pocket

Figure: 23-1

Shoe
Shim

Shim
Pocket

Figure: 23-2

38

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 24 - PICKUP GUIDES

24.0 Overview
24.0.1 For areas in which the collector must be driven in or out of the conductor rail system, pickup guides are used in combination with
current collectors provided for this purpose. The speed for pickup guide entry must not exceed 60 m/min (196 ft/min) and pickup
guides must be considered as wearing parts.
24.0.2 Installation tolerances must be taken into consideration. Simultaneous alignment gaps with maximum tolerances in the X and Y
directions are not permitted.

10.28
(261)
5/16-18

4.23
(107)
6.62
(168)

M8

1.30 1.30 1.30

(33) (33) (33)
Figure: 24-1

6.62
(168)

14.17
(360)
17.05
(433)
Figure: 24-2

39

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 24 - PICKUP GUIDES

24.1 Dimensions
7.75 6.44
(197) (164)

B c

Figure: 24-3

Dimensions Number of Poles

1 2 3 4
B 2.96" (75) 7.67" (195) 8.97" (228) 10.26" (261)
C 1.51" (38) 2.74" (70) 4.04" (103) 5.32" (135)

24.1.1 The pickup guide centers the current collector with a maximum lateral and vertical alignment tolerance of ± 0.50" (12.7).
24.1.2 In installations with pickup guides, a corresponding number of current collectors must be available, and mounted in intervals that
ensure that just the necessary number of current collectors needed for momentary power requirements are in use.

DANGER
The user must ensure that the current collector between the pickup guides are disconnected from power or are protected
against accidental contact!

40

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 24 - PICKUP GUIDES

24.2 Hanger clamp spacing for installations with pickup guides

39.37 42.00 + X 39.37
(1000) (1067) (1000)
29.00 + X
(737)
3.07 X
(78)

24.00 + X
(610)
Figure: 24-4

CAUTION
The middle distance (phase distance) between two conductors is 43 mm. This is reduced to 33 mm at the pickup guide in order
to ensure that the collectors enter the pickup guide precisely.

24.3 Hanger Clamp Spacing For Installations With Pickup Guide

39.37 59.06 MAX TYP
(1000) (1500 MAX)

Figure: 24-5

1.30 1.69
(33) (43)
Figure: 24-6

41

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 24 - ASSEMBLY FOR 1, 2, 3 & 4-WAY PICKUP GUIDE

Assembly Instructions
1. Remove nut, lock washer, and flat washer from transfer caps. Remove transfer caps from pickup guide.
2. Insert the ends of the conductor rails into the end of the transfer caps. Ensure the rails are fully seated. A soft mallet may be used
to gently tap the transfer cap onto the bar and cover assembly.
3. Ensure any hanger clamps are at least one meter back from the transfer cap.
4. Squeeze transfer caps together and fit pickup guide over support stud.
5. Fit transfer cap support bracket over support stud and torque to 28.4 Nm (20-21 ft.-lbs).
NOTE: Bracket width must not exceed 40mm (1.55").
6. Attach ramp end of the pickup guide to a bracket and torque to 28.4 Nm (20-21 ft.-lbs).

Customer Nut Lock Washer

Supplied Flat Washer
Brackets *

Bolt
Supoort Stud 78.0 mm
Nut (3.07”)
Lock Washer
Flat Washer

Figure: 24-7

NOTE: W hen using pickup guides, collector part XA-SL2C-100SX-1M-PG must be used. Please contact the factory when
ordering.

42

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 SECTION 25 - HANGER CENTERS DIAGRAM

XA-310969 XA-310918
XA-310824
XA-310834
XA-310829

43mm MIN
(1.69”)

43mm MIN 43mm MIN

(1.69”) (1.69”)

XA-310882
XA-310861
XA-310899
XA-310871

43 mm
43mm (1.69”)
(1.69”)

XA-310821 43 mm
XA-310857 (1.69”)
XA-310835
XA-310859

43 mm
(1.69”)
43 mm
(1.69”)

43

SAFE-LEC 2 CONDUCTOR BAR MANUAL

 44
310501

Conductors are UL rated for continuous duty. Us the appropriate

310410 curve on the graph to rate the conductors for your duty cycle.
Note: Duty cycles are based on a 2 minute cycle time.
310701 (i.e. 50% = 1 minute on 1 minute off.)

310601

310301

SAFE-LEC 2 CONDUCTOR BAR MANUAL

310201
310101

300A
250A
200A
SECTION 26 - CONDUCTOR BAR DE-RATING CHART

160A
100A
85A
 45

SAFE-LEC 2 CONDUCTOR BAR MANUAL

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SAFE-LEC 2 CONDUCTOR BAR MANUAL XA-964200.16 - 04.20.23