Aero-Motive Products

POW-R-FEED

Pow-R-Feed

delivers a high-speed electrical power supply through continuous copper conductors that reach up to 1200 feet without joints. Pow-R-Feeds unique free-floating contacts reduce RFI and EMI problems, frequent brush replacement, arcing, and thermal expansion problems. Track components are available in straight or curved sections and handle from 50 to over 320 amps. Pow-R-Feed can be installed in half the time of conventional systems and is easy to modify. A pickup trolley rides inside a PVC housing containing up to seven independent, continuous copper conductors. The Pow-R-Feed system is designed to freely expand and contract with changing ambient conditions.

Features
Safety No exposed live electrical parts Continuous conductors Reduces brush wear, power loss, signal interference, arcing and corrosion Compact design Minimum space required: 7 conductors in a two-byfour-inch space Dust & humidity protection Housings are sealed and connected to each other, forming one continuous run Simple installation Lightweight housings, continuous copper and unique hanger design make for easy installation No expansion problems Free-floating housings and conductors (independent of each other) allow for thermal expansion Indoor & outdoor installation Epoxy-painted, galvanized steel hardware standardoptional stainless steel hardware available Multi-conductor combinations Up to seven conductors in four different sizes can be mixed in one standard housing Multiple trolleys Several machines can be powered simultaneously on one Pow-R-Feed system Unlimited travel distances Unique methods of dealing with thermal expansion and power connections eliminate length limitations High speeds Trolley travel speed can exceed 1000 ft/min. Temperature extremes Unique FreeFloating design allows for wide ranging ambient temperatures Special applications Standard components available to solve almost any electrification problem including horizontal and vertical curves, switches and transfers

The Pow-R-Feed system is supplied by Aero-Motive, a world leader in the design and manufacturing of Mobile Electrification Systems since 1939.

Applications 3 Pre-Engineered Systems 4 Collector Trolleys & Accessories 6 Conductor Housings 9 System Components 12 Installation 16

PAGE 2

Hobby-Eberly telescope features a motor-driven rotating dome powered by a Pow-R-Feed multiconductor bar. The system was configured into a circle 78 feet in diameter for inclusion inside the dome.

PAGE 3 The ability for Pow-RFeed to form curves makes it ideal for monorail applications.

Applications
The Pre-Engineered Systems (see pages 4 and 5) cover straight line applications within the length range of the continuous conductor strips. Due to the many variables involved in longer systems or those requiring curves and transfers it is impractical to offer all systems in a pre-engineered package. The examples on this page represent a few of the special types of applications which can easily be handled with Pow-R-Feed systems. This catalog contains sufficient information to select the necessary components for most applications, however, it is recommended that a detailed description of the system requirements be provided to the Aero-Motive sales office for component verification or selection assistance.
Mobile power suspended from ceiling of a fashion school keeps cords overhead.

Pow-R-Feed maneuvers hot air ballon around circular portion of department store showroom.

Where to use Pow-R-Feed

Outdoor and indoor applications such as those found in coal handling, pulp & paper mills and textile mills, where environmental conditions are a major concern. Overhead cranes where continuous duty is important and both maintenance and downtime must be minimized. Features high reliability and maintainability. High speed automated storage and retrieval system applications for both power and data signals. Plant automation and continuous testing applications where multiple signal and uninterrupted operation are important. Complex curved, transfer and switch applications for industries when both power and data are required.

Pre-Engineered Pow-R-Feed Systems

PRE-ENGINEERED SYSTEMS

Pre-Engineered Pow-R-Feed Systems are available for your convenience. They include all of the components required to install a multi-conductor current supply system, excluding the trolley tow arm and universal supports, which must be ordered separately. Pre-Engineered systems cover straight line applications. Type PFE (End Feed) systems have the power connection located at one end of the system and PFL

(Line Feed) systems have the power connection located at any point along the system. If longer travel, curves, switches, transfers, combinations of different amp ratings, etc., are required, Custom systems can be specified from individual components selected from the following pages. If assistance is required, consult the factory or your local representative.

End Feed (PFE)

Line Feed (PFL)

How to order
1 2 3
Determine if an end feed (PFE) or line feed (PFL) system will be required. Determine the type of housing and hardware required to meet your environmental conditions. For severe environments, consult factory. Systems are available with amp ratings of 50, 80, 125 or 160. Higher amperages can be attained by connecting the conductors in parallel. Determine maximum amp requirement and select a system rated the same or higher.* Note the length limitation from the chart on the right.
Amperage 50 amp 80 amp 125 amp 160 amp Max.Length m ft. 400 1312 300 984 250 820 200 656

*Amperage rating is for typical crane duty applications using 30 minute motors. If full-time motors see page 12 for derating.

4 5 6 7

Determine the number of conductors required (3 to 7). Calculate your systems length in meters (1 meter = 3.28 ft.). Note: the housing sections are 4 meters long, so the length must be divisible by 4. Create a Pre-Engineered system number from the above information you have specified above. See the graphic on the next page Select trolley or trolleys from pages 6 and 7.

PAGE 4

E N V I R O N M E N TA L O P T I O N S (N) Flexible neoprene sealing strips and sealing tape are standard on all systems. Standard systems have a PVC housing with a working temperature range of -30C to +60C (-22F to +140 F). Joint and hanger brackets are galvanized steel with an epoxy powdercoat finish. (S) Stainless Steel brackets and fasteners for highly corrosive areas. (T) High-temperature housings suitable for operating temperatures of -30 to +80C (-22 to +176F). (B) High-temperature housing with stainless steel brackets and fasteners. Note: On long systems, voltage drop or thermal expansion could require special consideration. Review the technical data on page 12 and/or contact the factory for assistance if required. For severe environments, consult factory.

PAGE 5

EXAMPLE PART NUMBER

Line feed (PFL) or End Feed (PFE) Environmental Option (N) Standard, (S) Stainless Steel, (T) High Temp,or (B) High Temp / Stainless Amp Rating (5) 50 amps, (8) 80 amps, (2) 125 amps or (6) 160 amps,

PFLN84 - 120
Length (m) No. of conductors (3) thru (7)

Example System includes these components: ALK1 1 Feed Box ALRNK7 1 Line Feed Housing - 1m VKK 4 Line Feed Clip AEN7 2 End Cap AT50 1 Insulating Tape AVMN7L 2 Fixed-Point Clamp ARN7 30 4 m PVC Housing ABN7L 60 Sliding Hangers AVN7L 32 Joint Clamp AK80M120 4 Conductor Strips AS7M120 2 Sealing Strips
These Transition Box components sold separately Tow Arms

Trolleys

PRE-ENGINEERED SYSTEMS

Standard Collector Trolleys

TROLLEYS & ACCESSORIES

Trolleys are available for 3, 4, 5, 6 and 7 conductors. Trolleys are connected in parallel to draw higher amperages. The CLP7X70 trolley is 2 trolleys connected in series and the CLP7X100 is 3 trolleys connected in series. The OG transition box option allows paralleling of the 2 and 3 trolley wires.

FEATURES
I Carbon/bronze alloy contact brush with rounded corners, stainless steel compression springs and double shunts. I 2 m pigtail prewired to each trolley I Glass filled nylon wheels suitable for speeds up to 100 mpm (328 fpm). I High wear resistant trolley body I Dovetail wheel set connection for quick mounting. I Double middle brush for optimum trolley stability. I Detachable trolley neck for quick cable and neck replacement.

Model CL7435

282mm 11.1"

176mm 6.93"

111mm 4.37" 3

50mm 1.97" 388mm 15.3" 2

262mm 10.31" -Z wheel option: Add 64 mm (2.52) to Width

Trolley Options Steel Ball Bearing WheelsAdd S suffix. Extra Middle Load WheelsAdd E suffix. Extra Top WheelsAdd T suffix. Extra Top and Side WheelsAdd Z suffix. Silver-Graphite BrushesAdd A suffix. Transfer Trolley for AITN7Change CL to CLTG. Transfer Trolley for AITKN7Change CL to CLTK Trolley with Extra PigtailAdd (length in m)& M suffix. Right Angle GlandAdd H. See page 8 for more details

PAGE 6

PAGE 7
Model CLP770

TROLLEY SELECTION
30 min. Motors 30 30 27 27 27 60 60 54 54 54 90 90 81 81 77 Full Time Motors 27 27 25 25 25 54 54 50 50 50 81 81 75 75 75 No. of Cond. 3 4 5 6 7 3 4 5 6 7 3 4 5 6 7 Model Numbers CL73352M CL74352M CL75352M CL76352M CL77352M CLP73702M CLP74702M CLP75702M CLP76702M CLP77702M CLP731002M CLP741002M CLP751002M CLP761002M CLP771002M ACCESSORIES Transition Box Tow Arm OG35-7 OG35-7 OG35-7 OG35-7 OG35-7 OG70-7 OG70-7 OG70-7 OG70-7 OG70-7 OG100-7 OG100-7 OG100-7 OG100-7 OG100-7 AMV35 AMV35 AMV35 AMV35 AMV35 AMV80 AMV80 AMV80 AMV80 AMV80 AMV80 AMV80 AMV80 AMV80 AMV80

Model CLP7100/S

ACCESSORIES Transition Boxes - OG35, OG70, OG100

All trolleys come in at least a 2M pigtail to terminate in either a transition box, or directly to the equipment. Every AMV35 and AMV80 tow arm includes a bracket for the transition box attachment.

Tow Arms - AMV35, AMV 80

The tow arm is attached to the moving machinery and connected to the trolley by tow chains. The loose tow chains allow the trolley to readily adjust to small changes in housing alignment and lateral movements of equipment. NOTE: Tow eye of trolley should be 20 mm (0.8 inch prox.,) below tow hole of trolley.

Spring Loaded Tow Arm AMVSP35

Provides positive support for the CLTG transfer trolley passing through an AITN7 transfer guide. See page 8 for Multiple Fork Tow Arms

TROLLEY S & ACCESSORIES

Multiple Fork Tow Arms MFTA2 MFTA3 MFTA4

TROLLEY OPTION

MODEL
CL7-x-xxx/S CL7-x-xxx/S/Z
Call factory for special multi-fork tow arm. See Above

NOTES
May add as option to any trolley. Consider using multiple single CL7-x-35 trolleys for higher amperages on high-speed ASR-type systems instead of the -70 and -100 ganged trolleys. Requires a special multiple fork tow arm. Call factory for details.

TROLLEY OPTIONS

High speed 100-183 mpm (327-600 fpm) High Speed 183-500 mpm (600-1639 fpm)
Ball bearing wheels -S Top & Side rollers -Z

Systems with AKEV7 expansion joints

Middle wheel Model CL7535/E/Z

CL7-x-xxx/E

Systems with AITK7 transfer trumpet and AMVSP35 spring-loaded tow arm
Prepared neck for AMVSP35 Top rollers

CLTG7-x-35 AMVSP35 not included.

Can add other options like -S ball-bearing wheels, -Z side guide rollers or -XM longer cable. -Z option is only available with ball-bearing -S option.

Systems with AITN7 transfer trumpet and extended trolley tow bar
All ball bearing wheels -S Top & Side rollers -Z

CL7-x-35/S/Z +special tow bar (consult factory)

Tow bar to connect trolleys is unique for each application. Provide trumpet separation and total amps for quote. -Z option is only available with ballbearing -S option. If longer cable is needed add -?M option (see below). Gap at housings for transfer can only be max 8 mm (.315 ) for 4 and 5 conductor trolleys. For 3,6, and 7 conductor no more than 3mm (.118 ). Unless very large radius the -70 and 100 trolleys are not to be used in applications with curves.

Systems with AITKN7 small transfer

Middle wheel Top roller Use standard AMV tow arm

CLTK7-x-xxx

Systems with curves

Use standard trolley for curves 1000 mm (39 ) and above. Consult factory for tighter curves.

CL7-x-35 on curves 1000mm radius or more.

Systems with higher than CLP7-X-100 ratings

Use standard trolleys but parallel copper circuits to reach desired amperage. Example: 2 x AK125 (125 A) = 250 A

standard trolleys

Paralleling terminal strips to be supplied by customer.

Trolleys with Longer Pigtail

Order in whole-meter increments (2M is standard)
CTLG7-7-35 Transfer Trolley in AITN7 Transfer Trumpet supported by AMVSP35 Spring Loaded Tow Arm

CL7-x-xxx-?M (Ex. 3M = 3 meters)

Cable conductor size is 4 mm 2.

Trolley with silver-graphite brushes

Improves signal quality

CL7-x-xxx-A

In most cases standard double coppergraphite brushes will handle most applications down to 12V. Low clearance for pigtail

Right Angle Gland

CL7-7-35 H (side view)

Add H Consult Factory

Other trolley options

Silicone cable pigtail on trolleys for high & low temperature extremes. Ball-bearing wheels with low-temperature grease for freezer application. Hand safe trolleys

PAGE 8

Conductor Housings
ARN7
STANDARD HOUSING The ARN7 housing is available for operating temperatures ranging from -30C to 60C (-22F to 140F) and standard lengths of 4 meters (13.12 feet). An anti-reversing rib A is incorporated in the profile, which ensures that the collector trolley can only be installed in one direction, preventing accidental cross-phasing. The housing is bright orange in color for high visibility and has a yellow stripe B on one side to ensure proper alignment of the anti-reversing rib.

PAGE 9

ARNHS7

HAND SAFE

The ARNHS7 housing is designed for use in areas where it can be easily reached by personnel. The housing is the same as the ARN7 except extensions are added to both sides of the bottom slot so the conductors cannot be reached with a finger.

ARNHS7

ARNV7

FOR HIGH TEMPERATURES

T E C H N I C A L DATA - A R N 7 A N D A R N H S 7
Operating temperature range Flammability Flexural strength DIN 53452 Tensile strength DIN 53455 Impact strength (Charpy) DIN 53453 Softening point (Vicat) DIN 534608 Softening point BSI493/1958F Coefficient of linear thermal expansion VDE 0304 Volume resistivity DIN 53482 Dielectric strength DIN 53482 -30C to +60C (-22F to +140F) Self-extinguishing 025 kgf/cm2 (13,156 psi) 500 kgf/cm2 (7112 psi) No break 81C (178F) 80C (176F) 70 x 10-6 (.039 mm/mF) 4 x 10-15 /cm (10.16 x 10-15 /in.) 31.2 kV/mm (792 kV/in.)

ARNV7 housing is available for operating temperature ranges from -30C to 80C (-22 to 176F). It is dimensionally the same as ARN7 and is gray with a black stripe for easy identification. Use ARNV7 where temperature extremes exceed the temperature range of the ARN7 housings. Consult factory for temperature extremes greater or lower than above.

Chemical Resistance Resistant to grease, caustic soda solution up to 50%, gasoline, mineral oils, sulfuric acid up to 50% and concentrated hydrochloric acid (the Aero-Motive supplier should be consulted regarding the use of Pow-R-Feed under chemically aggressive conditions, since the above mentioned resistivities do not apply to the copper conductors). AS7 sealing strips provide a high degree of protection!

CONDUCTOR HOUSINGS

ARN7

Curved Housing Sections

CONDUCTOR HOUSINGS

CURVED PVC HOUSING SECTIONS ABRN7 Pow-R-Feed systems can be supplied with curved housings in horizontal and vertical planes. Supply a detailed sketch of proposed system before ordering. Horizontal Curves All curved housing sections are made to order with radius from 600 mm (23.6) (radius measured from housing center). For radius less than 1500 mm please consult factory for assistance. Maximum Section Length: 2800 mm (110.2) Maximum Section Angle: 180 degrees Curved housings have no internal anti-reversing rib and no yellow marking line on the outside, so there are no left or right turn curves. On curved systems usually the side conductors only are used (4c and 6c systems). In some instances the top (7th) conductor can be used but will require factory application assistance. Vertical Curves Radii above 1800 mm are available. Maximum length 2800 mm. Consult factory for further details.

H O R I Z O N TA L C U R V E PART NUMBER

Radius (m) Length (m)

M8631-X.XX-X.XX
Example: M8631-156-280; Radius 1.56 m, Length 2.80 m Example: Requirement 180 curve, 2000 mm radius Total length needed 2000 x 3.14 = 6280, Number of sections 6280/2800 = 2.3 or 3 Section Length 6280/3 = 2093 mm or 2.09 m Order (3) M8631-200-209 ABRN7 Curved Housings

Line Feed Housing

Allows power to be supplied anywhere along the system without a break in the conductors. LINE FEED HOUSING A line feed housing 1 meter (3.28 ft.) in length supplied with 7 holes in which feed clamp connectors fit. High-Temperature Applications Order ALRNKV7.

ALRNK7

Inline connector clamps for ALRNK7

VKG Double-point clamp connections for AK125 or AK160 conductors. Use with ALRNK7 and ALRNKV7 housings. VKK Single-point clamp connection. For AK50 and AK80 conductors. For use with the ALRNK7 and ALRNKV7 line feed housing only.

ALRN7

LINE FEED HOUSING Consists of 2 pieces of 500 mm (19.68 in.) each with 7 notches for connecting the supply line to the copper conductors. These sections are connected to the main housing with two standard joint clamps and fixed to the supporting structure with 2 fixed point clamps. High-Temperature Applications Order ALRNV7. Hand-Safe Safety Extensions Order ALRNHS7.
ALRN7

PAGE 10

Boxes
AK
END FEED BOXES
Use AK1 or AK5 for systems with AK50 or AK 80 copper. Use AK10 for systems with AK125 or AK 160 copper.

PAGE 11

Connects the power supply to the copper conductor strips at the end of the Pow-RFeed system. If you are using the ARNHS7 conductor housing with safety extension, the Model Line Entrance AARNHS7 adapter AK1 Drill to size is required. AK10 Drill to size
AK5 1 diameter AK1
5.68 3.18 2.00

2.00

8.25
2.00

4.38

AK5

1 entrance

1.09

8.25

5.38 3.68

.99

AK10

ALK

LINE FEED BOXES

Connects the power supply to the copper conductor strips at any position along the conductor system. For Circular Systems Special line feed box ABLK28 is required consult factory.
Model ALK1 ALK10 Line Entrance Drill to size Drill to size

ALK10

Splice Box For use at conductor splices or when extending an existing system, order ALK1. Use ALK1 or ALK10 with handsafe housings.
Use ALK1 for systems with AK50 or AK 80 copper. Use ALK10 for systems with AK125 or AK 160 copper. ALK1350 is available for use in restrictive spaces (5.23H x 18.25 W)
8.25

8.25

.99 3.10

2.38 2

13.5 18.25

ALK1

CONDUCTOR HOUSINGS

3.10

6.75

Conductor Strips
SERIES AK
Model Number AK50MXXX AK80MXXX AK125MXXX AK160MXXX

COPPER CONDUCTOR STRIPS

For ARN7, ARNHS7 and ARNV7 conductor housing.

Amperage Rating 30 Min.. Motors Full Time 50 45 80 65 125 100 160 115

SYSTEM COMPONENTS

xxx = Length of individual strip in meters. Example: if system is 50a, 4c, and 50M long, order (4) AK50M050. By connecting 2 conductors in parallel a 7 conductor system can handle higher amperage 3-phase loads in one housing with the 7th conductor serving as ground at 50% rating. Consult factory. Low-voltage applications (under 12 volts) should consider silver-plated conductor strips and silver graphite brushes. Please consult factory. If you are ordering ALRN7 line-feed housing please specify number of conductor strips, conductor size and length. Each span between connections must be dealt with individually. Example: a 4-conductor AK80 system 500 meters long with a line feed connection located 200 meters from one end would require four pieces No. AK80, 300 meters long and four pieces No. AK80, 200 meters long.

TECHNICAL DATA
Maximum length of continuous conductor strip that can be pulled into the conductor housing
Model AK50 AK80 AK125 AK160 Line Entrance 400 m (1312 ft.) 300 m (984 ft.) 250 m (820 ft.) 200 m (656 ft.)

Voltage drop in volts per meter conductor/per amp of nominal current, cos = 1, +20C ambient
Conductor AK50 AK80 AK125 AK160 Single Phase 3-phase Power .00353 .00225 .00124 .00095 DC Power .00408 .00260 .00143 .00109

With the use of an ALRN7 line feed connection, located at the center of a system, lengths twice those shown above can be attained without the use of splices or expansion joints. Unlimited conductor lengths are possible by using expansion joints (see page 16.)

With a power factor of <1, the above figures must be changed accordingly, e.g. with cos j -.85 volt drop figures must be multiplied by .85. (Example: System of 300m with 3-phase, 40-amp load, end feed. AK50 copper 300 x 40 x .00353 = 423 V)

MAXIMUM TRACK LENGTHS WITH STANDARD JOINT CLAMPS Difference in min.. and max. ambient temperature Conductors AK50 and AK80 Max. length when end feed Max. length when center feed Conductors AK125 and AK160 Max. length when end feed 50F m ft. 68F m ft. 104F m ft. 140F m ft. >140F m ft.

190 623.2 380 1246.4 m ft.

180 590.4 360 1180.8 m ft.

160 524.8 320 1049.6 m ft.

140 459.2 280 918.4 m ft.

120 393.6 240 787.2 m ft.

150 492.0

140 459.2

130 426.4

120 393.6

100 328.0

PAGE 12

Max. length when center feed 300 984.0 280 918.4 260 852.8 240 787.2 200 656.0 Track lengths shown here indicate the maximum system length that can be installed without concern for the effects of thermal expansion. For greater lengths, expansion joints (page 16) may be required. Consult factory.

Clamps, Brackets & Tape

AT50
INSULATING TAPE Ensures a permanent shroud around the housing joints prior to installation of the joint clamps. This tape is required on all installations, both indoor and outdoor. Each No. AT50 roll of tape is 10 meters long and is enough to seal 40 joints.

PAGE 13

AVMN7L/R

FIXED POINT CLAMPS

Each system should be secured to the support structure adjacent to the electrical feed point via a fixed point clamp. The system is allowed to expand freely from this position. When a line feed is used, a fixed point clamp is positioned on each side of the feed box. AVMN7L Galvanized steel with epoxy coating for maximum corrosion protection. AVMN7R Stainless steel (AISI 304) for corrosive environments.

AVN7L/R

JOINT CLAMPS

ABN7L/R

SLIDING HANGER BRACKETS

Sliding hangers are used to support the conductor housings. The hangers are designed with rounded edges and sufficient clearance to allow the free expansion of the system due to temperature changes. The hanger is suspended via a 10 mm bolt. The bolt is provided with additional locking nuts 78 for simple vertical alignment of (3.07) the system. Two hangers per 4 meter section required for 50 101 and 80 amp systems. Three (3.98) hangers per section for 125 and 160 amp systems. 32 60 ABN7L for standard or (1.26) (2.36) ABN7R for stainless steel (AISI 304) for corrosive environments. All brackets and clamps are suitable for high temperature systems.

SYSTEM COMPONENTS

The housing sections are connected by means of the AVN7L joint clamp. The joint clamps are provided with angle returns which grip the housing while aligning the clamp halves, this providing a quick means of ensuring a secure joint. AVN7L Galvanized steel with epoxy coating for maximum corro116 (4.56) sion protection. AVN7R Stainless steel (AISI 304) for corrosive environments. 60 100 (2.36) (3.94) All brackets and clamps are suitable for high temperature systems.

System Components
4400USB
UNIVERSAL SUPPORT BRACKET
2.95 Min. Min. 1.97

SYSTEM COMPONENTS

Length: 600 mm (23.6 in.) The 4400USB brackets are used to support the fixed-point clamp and sliding clamps. They are provided with special sliding clamp assemblies which make it possible to mount a wide range of I-beams without welding or drilling. The sliding clamp feature also provides simple horizontal alignment of the Pow-R-Feed system. Material: Galvanized steel.

.6

23.62 .6

Min. 1.97

Min. 3.54

AEN7

END CAP

Standard end cap used to seal off the open ends of a Pow-R-Feed system. NOTE: A joint clamp #AVN7-L is required to attach the end cap to the conductor housing.

Special End Caps:

AENV7 Same as AEN7 except for use in hightemperature applications (see ARNV7 housings) AENHS7 Used with type ARNHS7 conductor housing with safety extension.
305 mm 12

AUN7

INSPECTION UNIT

The inspection unit may be used on installations where inspection of the collector trolley is not possible by removing an end cap or end feed cover, such as endless curved tracks. They are also used when several collector trolleys are operating in one system, or when a specific location for inspection is necessary.

Special Inspection Units:

AUNHS7 for use with housing ARNHS7 with safety extension. AUNV7 for use with housing ARNV7 for high-temp applications. ABUN7-[radius] for circular systems.
OVERALL LENGTH: 200 mm (7.87 in) Note: Close joints with insulating tape after each inspection.

AKEV7

EXPANSION JOINT

Expansion joints are required when free expansion is restricted. This will occur depending on the length of the system and temperature variations (see chart on page 12). Use expansion joints where expansion is too great (refer to chart on page 12). For example, on very long systems in which there are several current supply connections or closed curved systems, etc. The conductor housing is then fixed to the support structure with a fixed-point clamp (AVMN7-L) adjacent to an expansion joint clamp at recommended positions. Consult factory. The expansion joint clamp has an internal rubber seal which makes it suitable for use outdoors and in dusty, humid or corrosive atmospheres, with the AS7 sealing strips. Use standard AKEV7 for high-temperature applications.
PAGE 14

NOTE: When expansion joints are used, the E option is required on the collector trolleys. See pages 8-9.

AS07

CONDUCTOR ISOLATION SECTION

PAGE 15

The conductor isolation section is used in installations in which it is necessary to isolate one or more conductors for control applications. The unit is fitted into a conductor system between the two line feed housings ALRN7 (page 10, order separately). This section is shrouded with an isolation section box ALK1 (order separately) with a fixed-point clamp located on both sides (order separately).
NOTES: I The conductor isolation section is suitable for use with single trolleys not greater than 35 amps. For different requirements consult factory. I When an isolation section is used it is necessary to consider and compensate for thermal expansion. Please provide drawings of your requirement to the Aero-Motive Company for assistance.

120 mm

AIT SERIES TRANSFER GUIDES

Transfer guides are required to guide collector trolleys properly from one conductor housing to another on rotating or sliding switches. There are two models available which must be selected based on the mechanical tolerance of the transfer system itself.
AITN7 Mechanical tolerances, horizontal and vertical, can be no greater than 10 mm (.394) AITKN7 Mechanical tolerances, horizontal and vertical, can be no greater than 2 mm (.080). Gap no greater than 8 mm (.315) for 4 & 5 conductor and no more than 3 mm (.118) for 3, 6 & 7 conductor.

200 mm

455 mm

AITN7 The AITN7 transfer guide includes a 500 mm (19.68) section of conductor housing with AK125 conductors already installed and a 500 mm section without conductors (ALRN7) to attach the guide section to the conductor system.

Special Transfer Guides:

AITNV7 For high temperatures AITKNV7 For high temperatures AITNHS7 For safety extension AITKNHS7 For safety extension

AITKN7 The AITKN7 transfer guide includes a 500 mm (19.68) section of conductor housing with prepared internal guides and the conductor strips installed. Also a 500 mm section without conductors (ALRN7) to attach the guide section to the conductor system. A line feed box (page 11) must be ordered separately to shroud the connection between the guide section and the conductor system. The line feed can be used for connecting the power supply and should have a fixed point clamp (page 13) placed on each side.

AS7

FLEXIBLE SEALING STRIPS

The AS7 sealing strips are used to seal dirt, moisture and corrosive materials out of the ARN7 or ARVN7 housings. The sealing strips are fitted into an aperture provided on each side of the bottom slot. The collector trolley chassis is designed to open and close the sealing strips while traversing. The AS7 sealing strips are sold in continuous lengths. Specify twice the length of the Pow-RFeed system when ordering. Model numbers: AS7MXXX and AS7HMXXX. AS7H (Hypalon) Same as AS7 but for applications requiring higher resistance to acids. AS7H seals are used in environments such as galvanizing plants. XXX = Length of individual strips in meters. If system is 50 meters long, order (2) AS7M050.

Special Pressurized Systems

For extremely dirty or corrosive atmospheres, clean and dry low pressure compressed air can be introduced into the housing at multiple points (about every 4 meters) to prevent the entrance of foreign material. Sealing strips are recommended for outdoor installations and other such as concrete industries, brick works, coal handling installations, galvanizing plants, etc. Use of the AS7 sealing strips in applications such as these will greatly increase the life and reliability of the system.

SYSTEM COMPONENTS

NOTES: I It is important to consider travel speed when passing through transfer guides. In view of the many variables it is recommended that Aero-Motive Company be consulted when selecting guides. I Transfer guides are not suitable for switching systems of 160 amps or higher. I Transfer guide systems require special trolleys and tow arm. See trolley pages 8-10 to select.

POW-R-FEED INSTALLATION

Aero-Motive Pow-R-Feed Installation

Installation of Aero-Motive Pow-R-Feed is based on controlled expansion. This principle is the solution for common expansion problems, related to three different elements: synthetics-coppersupport conductor. The value of linear expansion and shrink for the conductor housing is 0.07 mm per C per m, which is approximately 5 times the value of support construction, usually steel. The Aero-Motive Pow-R-Feed design permits the free movement of the three elements thus resolving problems often experienced with other systems.

Most common installations with one feed point at the end or somewhere along the installation (see illustration, example A or B) are mounted on the basis of free expansion. The expansion movement takes place from the fixed point. Detailed instructions with drawings and/or photos are included with most parts supplied. In addition, a comprehensive installation manual is available by calling the factory.

Mounting dimensions
Use A dimensions if system uses AK50 or AK80 conductors. Note: Only 2 hangers are used per housing. Use B dimensions if system uses AK125 or AK160 conductors. Note: 3 hangers are used per housing. some higher temperature applications may require hangers with 1000mm separations.

PAGE 16

Installation Tools
AITCS
COPPER CONDUCTOR STRAIGHTENER The conductor straightener is available to straighten heavy amperage (125 amps or greater) copper conductors ensuring easy travel when pulling conductors through the housings.

PAGE 17

AITPB

PULLING BLOCK

Pulling blocks are available to assist in pulling the copper conductors through the conductor housings for long systems.

AITTT

TOM THUMB

The Tom Thumb is a device available to assist in pressing the sealing strips into the housing slots for long systems.

AB600K

COPPER BENT END PREPARER

This devise helps get the correct bend on copper conductors for end feed box connections and splices

AFC3

PORTABLE CONDUCTOR CASSETTE

A cassette is available to assist in feeding conductors into housings for long application systems. Contact the factory for details.
After the conductor housings are installed, the flat conductor strips may easily be pulled from rolls into the appropriate conductor slots. The copper conductor strips are supplied with a cassette which greatly simplifies installation.

AITRC

TURNTABLE CONDUCTOR INSTALLER

The turntable is a valuable tool for installing extra long systems. This tool may be returned for full credit after installation. Use for AK50 systems over 300M, AK80 systems over 230M, AK125 systems over 90M and AK160 systems over 80M.

AITK

INSTALLATION TOOL KITS

The following kits are pre-configured. An installation video is also available. Service Pulling Portable Kit System Manual Block Cassette Number Type SM601003 AITPB AFC3 AITK AK50 or AK80, < 100M or no AS7 X X X AITKS AK50 or AK80, >100M X X X AITK100 AK125 or AK160, < 100M or no AS7 X X X AITK100S AK125 or AK160, >100M X X X Download installation and service manuals from our web site www.aeromotive.com Tom Conductor Thumb Straightener AITTT AITCS X X X X

POW-R-FEED INSTALLATION

Pow-R-Feed Application Types

Pre-Engineered Systems (see page 4 & 5) cover straight line applications within the length range of the continuous conductor strips. Due to the many variables involved in longer systems or those requiring curves and transfers, it is impractical to offer all systems in pre-engineered packages. The following examples represent a few of the special types of applications which can be configured with the custom components in this catalog. Contact your Aero-Motive sales rep for assistance in specifying your system. You can use the chart on the next page as an ordering guide

Long Systems When a system exceeds the maximum length of the conductor strips, or when voltage drop becomes a problem, additional line feed or connection boxes must be used. These boxes must be anchored with fixed-point clamps, which will restrict the free expansion of the conductor housing between them. This makes it necessary to use expansion joints (AKEV7 page 14) in the areas between boxes. The end sections, which are free to expand in one direction, do not normally require expansion joints.
11 22 33 44 55 66 33

APPLICATIONS

Horizontal Curves Curved housing sections (page 10) are available in any radius 2 2 from a minimum of 600 mm (23.6).
33 22 66

Curved systems should be limited to 6 conductors, excluding the top conductor channel. If the seventh conductor is necessary, please consult factory.

1 End Cap 2 Joint Clamp 3 Line Feed Box/

End Feed Box

4 Fixed-Point Clamp 5 Expansion Joint

Clamp

Closed Loops and Circles Closed

loops do not allow free expansion of the conductor housing. Therefore, expansion joints (AKEV7 page 14) may be required. An inspection unit (AUN7 page 14) may also be desired in a closed system.
66 66 55 44 44 33 77 22 22 55

6 Sliding Hanger 7 Inspection Unit

Vertical Curves Vertically curved

housing sections (page 10) are available in any radius from a minimum of 1800 mm (70.8 in.).
44 33 55 66 66 44

55 33

For ease of installation the curved section can be pre-assembled with line feed or connection boxes on each end.

Multiconductor Combinations
With the standard housings and the four different copper conductors a large number of combinations of current conductors is possible; always in the same compact housing. A few examples are shown below.

PAGE 18

standard 4-conductor

standard 5-conductor

5-conductor for systems with curves

6-conductor

7-conductor, 3 phase + ground and 3 conductors D for control or data

7-conductor, per phase 2 conductors in parallel + ground

Transfer and Switch Arrangements

Transfer guides (page 15) may be used for many types of switching and transfer applications.
PAGE 19

Sliding Switch

Turntable

Transfer Contact Section

(limited distance)

Notes: The spring-loaded trolley towing arm (AMVSP35 page 7) are sometimes used when transfer guides (AITN7) are employed. See trolleys on pages 6-8 Transfer guides must be held rigidly in place. Therefore, expansion joints are required in place of joint clamps between transfer guides.

Component Checklist
When requesting a quotation or component selection assistance from the Woodhead sales office please provide the following information: I I I I I I I Type of equipment to be fed by Pow-R-Feed. Total travel distance. Maximum travel speed. Duty cycle (traverse and electrical). Number of conductors required. Electrical data: volts, amps, AC/DC. Track configuration: straight, curved (give details).
Model number _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ Quantity ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________

I Position of feed point: if line feed, give distance from end. I Power supply: wire size or conduit size. I Ambient conditions: temperature, dust, humidity, chemical, etc. I Transfers required? Give details.

Standard components Conductor housing (4 m ea.) Conductor strips ______ long Conductor strips ______ long Joint clamp Insulating tape Fixed point clamp End/Line feed End cap Collector trolley

Standard components Trolley towing arm Flexible sealing strip Connecting section Inspection unit Curved section Transfer guide Expansion joint Conductor isolation section Conductor isolation box

Model number _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________

Quantity ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________

INSTALLATION INSTRUCTIONS

AERO-MOTIVE

CABLE REELS

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AERO-MOTIVE PRODUCTS

www.woodhead.com

CABLE REELS

Aero-Motive is a trademark of Woodhead Industries Inc. All trademarks herein are the property of their respective owners.

2004 Woodhead L.P.

DWPF LCP 1104 5M

FESTOON SYSTEMS