Gifas-electric MarkLED 4 User manual

MarkLED 4
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Created
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Modified
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Object-ID
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MarkLED 4
Installation instructions
VERSION
MODIFICATIONS
1.0
First edition

MarkLED 4
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Created
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Modified
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Object-ID
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Table of contents
1General information................................................................................................................5
1.1 Marking concept for hazards and hints............................................................................5
1.2 Responsibilities of the operator........................................................................................5
2Introduction ............................................................................................................................6
2.1 Installation conditions product MarkLED 4.......................................................................6
3Required tools ........................................................................................................................7
3.1 Standard tool...................................................................................................................7
3.2 Auxiliary tool....................................................................................................................8
3.3 Consumables ..................................................................................................................8
4Process ...................................................................................................................................9
5Installation ............................................................................................................................10
6Electric power supply of the unit.........................................................................................11
6.1 Two tubes without adaption zone in the opposite direction............................................11
6.2 Two tubes with adaption zone in the opposite direction.................................................11
6.3 A tube with contraflow ...................................................................................................11
7Measuring of MarkLED placement with current collector..................................................12
8System cable and current collector ....................................................................................13
8.1 Milling a groove in the shoulder.....................................................................................13
8.2 Remove bitumen from groove / remove old system.......................................................14
8.3 Create mounting and current collector bores.................................................................15
8.4 Inserting connecting cables...........................................................................................16
8.5 Mount current collector onto system cable.....................................................................17
8.6 Install current collector in groove...................................................................................18
8.7 Seal the groove (close)..................................................................................................19
8.8 Insert system profile ......................................................................................................20
8.8.1 Installation with roll-off and profile-laying car (hire material)...............................20
8.9 Assembly of the control unit and connection of the system cables.................................22
9Installation of MarkLED recess-mounted adapter in drilling core hole ............................23
9.1 Mark bores and groove..................................................................................................23
9.1.1 Mill groove..........................................................................................................23
9.1.2 Drill core holes...................................................................................................23
9.2 Clean groove and boreholes..........................................................................................24

MarkLED 4
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9.3 Mount installation conduit..............................................................................................24
9.4 Place levelling jig...........................................................................................................24
9.5 Set recess-mounted box................................................................................................24
9.5.1 Fill with mortar....................................................................................................25
9.5.2 Installing the recess-mounted adapter first step .................................................25
9.5.3 Remove levelling jig...........................................................................................25
9.5.4 Installing the recess-mounted adapter 2nd step.................................................25
9.6 Close groove.................................................................................................................26
9.6.1 Close groove with mortar ...................................................................................26
9.6.2 Close groove with hot bitumen...........................................................................26
9.7 Connection MarkLED ....................................................................................................27
9.7.1 Pull in the cable..................................................................................................27
9.7.2 Preparation of cables/conductors.......................................................................27
9.7.3 Connection MarkLED light module.....................................................................27
10 Installation MarkLED surface-mounted box .......................................................................29
10.1 Attachment....................................................................................................................29
10.2 Installation.....................................................................................................................29
10.3 Connection....................................................................................................................30
10.4 Sealing compound.........................................................................................................30
11 Installation of MarkLED recess-mounted adapter in formwork.........................................31
11.1 Mark, drill and fasten.....................................................................................................31
11.1.1 Alternative attachment with 4 screws ...............................................................31
11.2 Mount installation conduit..............................................................................................32
11.3 Remove formwork .........................................................................................................32
11.4 Connection and installation of MarkLED........................................................................32
12 Montage MarkLED wired......................................................................................................33
12.1 Mounting location..........................................................................................................33
12.2 Attachment....................................................................................................................33
12.3 Driling............................................................................................................................34
12.3.1 Dimensions for drilling holes.............................................................................34
12.4 Installation and connection of MarkLED.........................................................................34
12.5 Function check..............................................................................................................35
12.6 Drilling jig.......................................................................................................................36
13 Declaration of conformity ....................................................................................................37

MarkLED 4
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14 Service ..................................................................................................................................38
14.1 Service addresses.........................................................................................................38
14.2 Imprint...........................................................................................................................38

MarkLED 4
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1 General information
1.1 Marking concept for hazards and hints
Hazard
Hazardous situation which will cause serious injury or even death if it is not prevented.
Caution
Hazardous situation which could cause slight to moderate injury if it is not prevented.
Hint
Indicates information which does not concern personal injury, e.g. hints in respect of material damage.
Protective measures
Increase safety by applying a protective measure.
1.2 Responsibilities of the operator
-Make sure that this document is always kept in a safe place in a legible form together with the product.
-Read these instructions carefully before first start-up of the product.
-This product has been developed and produced exclusively for the use indicated in these documents.
Every other use, which is not mentioned explicitly, could affect the intactness of the product and/or
could constitute a source of danger.
-The manufacturer rejects any liability for damage which has been caused by incorrect or non-intended
use of the product.
-In countries, which do not belong to the European Community, the national legal reference regulations
as well as the standards and regulations applicable in these countries have to be observed for warranty
of a corresponding safety level.
-The installation has to be carried out according to the applicable regulations.
-The manufacturer assumes no liability for inexpert execution of installation as well as deformations
which may occur during operation.
-The electric power supply has to be switched off before executing any action on the installation.
-Exclusively original parts of the manufacturer shall be used for maintenance. Maintenance work may
be carried out by qualified staff only.
-All procedures which are not explicitly mentioned by the manufacturer in the instructions are not per-
mitted.
-The packing material must not be stored within the reach of children as it could be a potential source
of danger.

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2 Introduction
To ensure proper installation, the following steps and notes must be complied with under all circum- stances.
Only this way can it be ensured that the product will work to complete satisfaction.
Hint
Read all instructions before starting installation. Our sales department will be happy to answer any questions
you may have.
2.1 Installation conditions product MarkLED 4
The system installation of MarkLED also depends on a professional installation!
Improper work:
-Extensive warranty work due to improper works
We instruct you on each project site for the correct assembly, so that a proper function of the system
MarkLED can be ensured!
The cable cross-section of the cable length must be adjusted to maintain the required operating voltage.
Installation work in which adhesives or hot bitumen are used must not be carried out at carriageway temper-
atures below 5°C or above 30°C. For details on specifications, use and safety instructions, see the manufac-
turer's specifications.

MarkLED 4
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3 Required tools
3.1 Standard tool
Drill hammer
Concrete drill ø10 mm and ø 40mm
Pliers to cut off cables
Light barping pliers for system cables 2x2,5mm²
Hot-air gun
Compressed air for cleaning the groove and the bores
Hand press for 310ml cartridges
In order to ensure the correct polarity and thereby the function as
early as the installation stage, we recommend using a supply volt-
age of 24VDC when connecting to the connection cables (if neces-
sary, a 24V battery can also be used).

MarkLED 4
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3.2 Auxiliary tool
Drilling jig item no. 860599 for mounting bore ø10 mm and in-
stallation bore current collector cone ø40 mm
Trolley for sealing profile item no. 172211 (loan material
GIFAS)
3.3 Consumables
Heat shrink tube with glue (6mm/2mm)
item no. 010300
insulation tape 2 M Scotch no. 23, black
item no. 152743
crimp connector 1.5-2.5 hot-shrinking Raychem, blue
item no. 019875
Solder connector 1.5-2.5 heat-shrinkable NSPA, transparent
item no. 172745
Device for unrolling cables
Cable lug crimping pliers for press connector
Head lamp, measuring tape, material/tool cart, etc.

MarkLED 4
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1.
Measure and mark
2a.
Milling a groove in the
shoulder
2b.
Remove bitumen from
groove / remove old system
3.
Rework of groove for cur-
rent collector
4.
Inserting the connecting
cables
5.
Mount current collector onto
system cable
6.
Install current collector in
groove
7.
Put on the MarkLED
8a.
Seal groove 8b. Insert system profile
10.
Installation of the control unit
including parameterisation
9.
Seal MarkLED
4 Process

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5 Installation
Example:
-Adaption area 12.5m
-Rest 25m

MarkLED 4
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6 Electric power supply of the unit
6.1 Two tubes without adaption zone in the opposite direction
6.2 Two tubes with adaption zone in the opposite direction
6.3 A tube with contraflow
Key:
Entry and crossover route
Entry and crossover route in the opposite direction
LED guidance system

MarkLED 4
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7 Measuring of MarkLED placement with current collector
-Marking of locations of MarkLED units in accordance with project default (by spray colour)
-Recommendation:
-Tunnel entrance (adaption): a MarkLED each 12.5 m (according to ASTRA/BAST regula-
tions)
-Middle of tunnel: a MarkLED each 25 m
-Tunnel exit (adaption): a MarkLED each 12.5 m (according to ASTRA/BAST regulations)
Colour markings
Hint
Due to obstacles (pit/joints etc.)
the location of MarkLED has to be
replaced as less as possible.

MarkLED 4
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8 System cable and current collector
8.1 Milling a groove in the shoulder
-Milling of a continuous groove (width 6 mm/depth 30 mm)
-Distance between groove and roadway edge project-specifically
-Milling around obstacles (pits etc.) after project default
Breite 6mm
+1/-0
Hint
The system MarkLED makes a
very small distance to the roadway
edge possible.
depth 30mm
+5/0
distance to the
roadway edge
roadway edge
width 6mm
+1,5/0

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8.2 Remove bitumen from groove / remove old system
-Machine scratch-out of existing wiring (2 operations)
-Suction and blowing out of the groove
width 6mm
+1,5/0
depth 30mm
+5/0
distance to the
roadway edge
roadway edge
Hint
Waste has to be recycled in ac-
cordance with local/national regu-
lations.

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8.3 Create mounting and current collector bores
-Insert the drilling jig into the groove with the 2 lower guide pins.
-Move the drilling jig in the groove direction until it is centred on the previously marked light position
-Stand with both feet on the drilling jig and first, drill bore ø40 mm, depth 40+5/0 mm
-Make sure that the drilling jig stays in place and then drill a bore ø10 mm, depth 25+5/0 mm
-Tolerances are to be kept: in the depth +5/0 mm
-Then clean the entire groove and clean and dry all bores
Durchgehend
6mm breit
Länge 90mm
continuous
groove 6 mm
width

MarkLED 4
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8.4 Inserting connecting cables
-Unroll system cable and insert continuously into the groove (protect mechanically!)
-Cabling from control unit according to project specifications (observe channels / lines)
-Feed-in 24V voltage
Hint
System MarkLED only needs a
very small cross section due to the
small power input.
Even with consideration of the
voltage drop, the cross section of
2.5 mm2 is sufficient.
Hazard
Protect the cables against me-
chanical damage!
embedding in
the cleaned
groove
system cable 2.5 mm2
particularly heat proof
up to 250°

MarkLED 4
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8.5 Mount current collector onto system cable
-Insert system cable into current collector at the marking
-Screw current collector lid with 4 screws Item no. 165001 3x12 onto current collector with already
applied sticking compound. M = 1Nm
-Attention: Leave at least 15 - 20cm on the system cable end after the last current collector, separate
both strands approx. 10cm from the final part and finalise each strand separately with shrink tubing
with adhesive tightly over it.
-Finally, insert the sealed cable end into the groove and cast with liquid hot bitumen.
Hint
The function check can be carried out simultaneously when connecting the MarkLED by having a 24VDC
tension on the system cable.
It must be ensured that the screws are tightened with suitable tools. M = 1Nm.
Hazard
No other installation materials may be used!
Hint
By screwing the current collector lid and
the current collector with the 4 screws,
the two contact pins encased in butyl
sealant are inserted into the cable. This
sophisticated construction produces
tightness and permanent contact of the
current collector.
Hazard
Eine einmal «durchstochene» Isolation
nicht wieder öffnen!

MarkLED 4
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8.6 Install current collector in groove
Installation location must be dry and clean before installing MarkLED current collector.
Hint
Small unevenness (+/- approx. 1 mm) can be absorbed by using adhesives and sticking compound.
Apply Permafix to bottom of current collector.
Insert MarkLED into bores and press down, weigh
down if necessary.

MarkLED 4
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8.7 Seal the groove (close)
Seal the groove either with sealing compound or joint profile (according to the owner's stipulations)
-Pre-treat groove (if necessary) with primer
-Seal the groove with filler (hot bitumen or epoxy glue)
-do not use cold bitumen
-primer/sealing compound (according to stipulation)
Hazard
An electrical function check must
be performed before sealing!

MarkLED 4
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8.8 Insert system profile
-Instead of the hot sealing compound, a self-tapping joint profile can be inserted over the system ca-
ble.
-Leave 5 cm free both in front of and behind the MarkLED.
-Fix profile every 5m with Permafix in the groove and before/after every MarkLED.
Hazard
Always seal the groove in the passable area!
8.8.1 Installation with roll-off and profile-laying car (hire material)
self-tapping
joint profile