POWERAIL ENCLOSED CONDUCTOR SYSTEMS VKS VKL

Transcription

1 POWERAIL ENCLOSED CONDUCTOR SYSTEMS VKS VKL

2 19 12 POWERAILS VKS & VKL INDEX VKS VKL Basic description 3, 4 3, 4 Layout planning 5 5 Engineering data, Powerail standard sections 6, 7 23 Powerail curves 8 23 Jointing material 8 24 Hangers 9 24 End caps 9 24 Feeds 10, 11 24, 25 Transfer guides 12 Transfer funnels 13, 14 Expansion sections 14 Sectionalizing 24 Current collectors 16, Compact collectors 16 Accessories and spares for collectors KTW-Systems Standard brackets Snap-on brackets VKS-system, 7 pole for HRL 27 Examples for ordering 28, Questionnaire*, 31, 31 Production program Collector rings VKS (see leaflet No. 102 s) TECHNICAL DATA Electrical Properties: Ampacity: Voltage Dielectric strength Specific resistance Surface resistance Leakage resistance VKS VKL *** 140 A A 690 V 400 V DIN = -40 kv/mm DIN = 5 x 10 Ohm/cm DIN = Ohm IEC 112/VDE 03 = CTI Flame test proof per DIN 4102 part 1, class B1, no flaming particles, self extinguishing Conductor copper stainless units steel Cross sect mm 2 Impedance Ohm/ at 50 Hz 0 m Resistance Ohm/ 0 m Mechanical properties: Flexible strength = 7360 N/mm 2 ± 10 % Tensile strength = 4910 N/mm 2 ± 10 % Resistance to chemicals of PVC housing: at + 45 C (113 F) ambient temperature Resistant to gasoline, mineral oil, grease, sodalye up to 50 % hydro-chloric acid, concentrated sulphuric acid up to 50 % Water absorption: max. at C (212 F) = 1 % max. at 20 C ( 68 F) = 0,06 % Temperature resistance: ** from 20 C ( 4 F) up to + 55 C (131 F) up to 4 m section from 0 C (32 F) up to 40 C ( F) more than 4 m sections Please consult factory for galvanizing plants, pickling lines, other aggressive or deep freeze ambients, as well as low voltage and data transmission applications, indicating special environmental conditions. To speed up quotations and order processing, we would appreciate receiving your drawings or sketches for powerail systems with curves, dead sections, turntables, switches, etc. Please use our questionnaire, page and * ** *** Please enclose the Questionnaire to your inguiry. Consult factory for use below 0 C (32 F) [deep freeze housing]. 80% ED

3 POWERAILS VKS & VKL VAHLE Powerails VKS and VKL are space saving conductor systems, designed to prevent any accidental contact and hazard to personnel and are test finger proof to regulations VDE 0470, part 1 (EN 60529), protection code IP 21. Collectors are proof against accidental touch only when fully entered into powerail. Powerail installations within reach of hand require a special protection on the part of operator against accidental touch of current collectors which are leaving the powerail (e.g. locking or cut-off the power). This is applicable for voltages above 25 V AC respectively 60 V DC. The different plastic housings hold from 3 to 6 copper or stainless steel conductors. Multiple conductor systems can be easily designed by combining several plastic housings. The minimal space required allows the systems to be integrated in the crane or hoist track or in other special runway profiles. The VKS & VKL Powerail can be used for indoor and roof-over (rain protected) applications. They can be installed with lateral or suspended mounting and straight or curved tracks are available. VKS Powerail Systems are designed for safe mobile power feeding of: Hoists, Monorail Systems, Stacker Cranes, Machine Tools, Production and Testing Lines, also for Sliding Switches, Turntables, Hoisting Stations, Transfers, and many other Applications, incl. Data and Signal Transmission. Housing The well insulating plastic housing holds 3-6 conductors. 4 m standard lengths and shorter sections to coincide with your runway requirements are available. The asymmetrical housing avoids phase reversing. The ground conductor is identified by the international yellow colour coding. Joints The plastic sections are connected with plastic joint caps, the conductors with spring-loaded copper connectors. Feed Sets End feeds or line feeds with terminal boxes are available, also low mounting line feeds for cable connection. Line feeds come factory assembled on 1 m long Powerail sections. End feeds come unassembled without any Powerail section. Hangers All sections are to be suspended from at least 2 hangers and the maximum permissible support centres of 1 m (with double collectors 0.8 m) must be adhered to. The hangers are equipped with M 6 bolts & hardware and can be mounted directly to hanger brackets, monorail tracks or special runway profiles. The Powerail sections are snapped into the hangers. Sliding hangers allow free movement of the Powerail to compensate for temperature variations. Fixpoint hangers with tapping screw from anchor points (see installation procedure). Standard Support Brackets Support brackets for easy installation are available, (see page 21, 22). Collectors The collectors have a continuous rating of 6 A up to 120 A. One collector is required for each phase and earth conductor. The ground collectors have a yellow colour and different attachments to avoid interchangeability with phase collectors. The collectors have spring loaded carbon brushes for a constant positive contact with the conductors. Collectors are to be mounted onto towing plates or are to be attached to the moving equipment by means of towing brackets type UM. Systems with transfers, switches, turntables, etc. require 2 single collectors or one double collector per conductor. Conductor Dead Sections Conductor dead sections can be mounted at any position of the system. The plastic inserts are pushed into the copper profiles and ensure a smooth transfer of the collector brushes. The length of isolating section has to consider the total length of carbon brush and whether carbon brush must or must not bridge the isolating area. Special attention is required for double collectors or collectors switched in parallel. Use double isolating sections where necessary. Selection of conductors in accordance to ampere load and environmental conditions: VKS / 60 copper conductor for power and control system and data transmission / copper conductor for power and control system /120 copper conductor for power and control system /140 copper conductor for power and control system Several combinations of cross sections are possible for one conductor type. Consider the voltage drop calculation to maintain the limits established by the motor manufacturers: Formulas: AC: DC: u = 3 x I x l x Z u = 2 l x I x R u = Voltage drop [V] R = Resistance [Ohm/m] l = Ampere load [A] l = Power feed length [m] Z = Impedance [Ohm/m] L = System length [m] Effective length: l = L power feed located at the end of the system l = L/2 power feed located at the mid-point of the system l = L/4 power feed located at both ends of the system l = L/6 power feed located at L/6 from each end of the system The total ampere load is determined from the nominal rated current of all motors working simultaneously on the same feed section of your electrification system. 3

4 19 12 POWERAILS VKS & VKL VKL Powerail Systems are designed for small current loads and serve for the power supply of light cranes and for control current systems. The VKL Powerail can also be used for Hoists, Jib Cranes, Power Tools, Machine Tools, electrically operated Gates, Testing Lines, and other Applications. Housing The plastic housing holds up to 5 conductors. The ground conductor is identified by international yellow colour code. 4 m standard lengths and shorter sections to coincide with your runway requirements are available. VKL Powerails can be used up to system lengths of m. Couplings The mechanical jointing of the Powerail housing is done by means of a two-piece plastic joint cap. The conductors get spring-loaded copper connectors. Feed Terminals End feeds and line feeds with terminal boxes are available. They are factory assembled on 1 m Powerail sections. Hangers All sections are to be suspended from at least 2 hangers and the maximum permissible support centres of 1 m must be adhered to. The hangers allow free movement of the powerail housing. The fix point in the centre of the run consists of a sliding hanger anchored by two locating clamps. Standard Support Brackets Support brackets for easy installation are available (see page 25). Collectors The glider type collectors are guided at the PVC housing. They are supplied with 1 m long connecting cable. Longer cables are available upon request. The carbon brushes have a continuous current capacity of 10 A ( A at 60 % intermittent duty). Use two collectors for higher ratings. The towing arm is the mechanical flexible connection between collector and moving equipment. Conductor Dead Sections Conductor dead sections are factory assembled at any required position of the run. 4

5 LAYOUT PLANNING FOR VKS & VKL Scheme /70 ca. 45/26 end cap line feed VLS/VLE joint material SVN/LV sliding or fixpoint hangers transfer guides line feed VNS/VNK end feed VEKS7VEK L = powerail section (1 m, 2 m, 3 m, 4 m or cut to suit the system) L 1 = support spacing for straight runs max. 1 m for curved runs max. 0,5 m L 2 = extending length (max. 200 mm) L 3 = air gap for transfers, e. g. switches and dropout sections (3-5 mm) L 4 = space to remove feed box cover, if applicable L 5 = clearance for expansion of powerail (min. 50 mm for VKS; 0 mm for VKL). 2. Symbols in layout plans Track Powerail Joint material Joint material Fixpoint hanger Sliding hanger VKS VKL VKS VKL SVN LV VEPS VEP VAS VA Line feed, power Line feed, control Line feed, power and control Transfer guide, straight Transfer guide, oblique VKS VKL VNS VNK VNS VNK VLS VLE VU VUS End cap VES VE Transfer funnel VEM End feed, power End feed, control VEKS VEKS VEK VEK Expansion section Isolating assembly DVKS VSTS VST 3. Max. Support spacing Type for straight runs for curred runs VKS 0 mm 500 mm with double collector KDST, KDSTL KDSTLU 800 mm 400 mm KST(L), KSTU, 55 picture 1 A VKL 0 mm 500 mm picture 1 A < 0 mm Support spacing 0,8 m A > 0 mm Support spacing 1,0 m 5

6 19 12 ENGINEERING DATA VKS Straight sections Standard length 4 and 6 m.***** HS = w/ PE SS = w/o PE *** 6 Attention: Joint material to be ordered separately (see page 8). LH RH Number Continuous Voltage Voltage drop Minimum Conductor Cross Section**** Type of Ampere Rating per m Clearence mm 2 con- Rating at full rating ductors A V V mm L1 - L3 PE 1, 2, N, L at 35 C VKS 3/ 60 HS x16 2x16 VKS 3/ 60 SS x16 2x16 VKS 3/ HS x25 2x25 VKS 3/ SS x25 2x25 VKS 3/120 HS x 2x VKS 3/120 SS x 2x VKS 3/140 HS 3 140** x35 2x35 VKS 3/140 SS 3 140** x35 2x35 Straight sections Standard length 4 und 6 m.***** *** 6 Attention: Joint material to be ordered separately (see page 8). LH RH Number Continuous Voltage Voltage drop Minimum Conductor Cross Section**** Type of Ampere Rating per m Clearence mm 2 con- Rating at full rating ductors A V V mm L1 - L3 PE 1, 2, N, L at 35 C VKS 4/ 60 HS x16 1x16 VKS 4/ 60 SS x16 1x16 VKS 4/ HS x25 1x16 VKS 4/ SS x25 1x16 VKS 4/120 HS x 1x16 VKS 4/120 SS x 1x16 VKS 4/140 HS 4 140** x35 1x16 VKS 4/140 SS 4 140** x35 1x16 Straight sections Standard length 4 und 6 m.***** *** 6 Attention: Joint material to be ordered separately (see page 8). LH RH Number Continuous Voltage Voltage drop Minimum Conductor Cross Section**** Type of Ampere Rating per m Clearence mm 2 con- Rating at full rating ductors A V V mm L1 - L3 PE 1, 2, N, L at 35 C VKS 5/ 60 HS* x16 1x16 1x16 VKS 5/ 60 SS* x16 1x16 1x16 VKS 5/ HS* x25 1x16 1x16 VKS 5/ SS* x25 1x16 1x16 VKS 5/120 HS* x 1x16 1x16 VKS 5/120 SS* x 1x16 1x16 VKS 5/140 HS* 5 140** x35 1x16 1x16 VKS 5/140 SS* 5 140** x35 1x16 1x16 VKS 6/ 60 HS x16 1x16 2x16 VKS 6/ 60 SS x16 1x16 2x16 VKS 6/ HS x25 1x16 2x16 VKS 6/ SS x25 1x16 2x16 VKS 6/120 HS x 1x16 2x16 VKS 6/120 SS x 1x16 2x16 VKS 6/140 HS 6 140** x35 1x16 2x16 VKS 6/140 SS 6 140** x35 1x16 2x16 6 * ** *** **** VKS 5 eliminates conductor number 6; plastic housing however identical to VKS % ED Section is superseded at 20 C UT. Same cross section at PE (ground) when used for control line. Other conductor combinations are possible.

7 STRAIGHT SECTIONS VKS ➊ Conductor Weight Material kg/m Cu Cu Cu Cu Cu Cu Cu Cu Installation: lateral ➊ Installation: horizontal ➊ Conductor Weight Material kg/m Installation: lateral Cu Cu Cu Cu Cu Cu Cu Cu ➊ Installation: horizontal Conductor Weight Material kg/m Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu M max ,5 Installation: lateral 2 1 PE L3 L2 L1 7 M 6 max. 10 L1 L2 L3 PE Installation: horizontal ➊ Marking refers to control lines. ➊ 12, ➊ 21,5 ***** For supply lengths above 4 m refer to restricted ambient temperature (page 2). 7 For full type designation add length suffix of Powerail Section, e. g. VKS 4/120-2 HS for Other sections to coincide with your runway requirements are made up from the next larger straight length.

8 19 12 COMPONENTS VKS Curved sections* per your layout drawing max. L = 3.6 m, support spacing ~ 500 mm, max. angle 0 R Joint Material Horizontal curve, R. H. = web outside Horizontal curve, L. H. = web inside (not shown) Inside curve: R web Outside curve: R web Inside curve, lateral = conductor inside Outside curve, lateral = conductor outside (not shown) surcharge cat. nos. for R mm VKS 3 Horizontal curve, R. H Horizontal curve, L. H Horizontal curve, R. H. > Horizontal curve, L. H. > Inside curve, lateral Inside curve, lateral > Outside curve, lateral Outside curve, lateral > Type Poles Weight kg SVN 3/ SVN 3/ Curved sections* per your layout drawing max. L = 3.6 m, support spacing ~ 500 mm, max. angle 0 Configuration as shown above Joint Material surcharge cat. nos. for R mm VKS 4 Horizontal curve, R. H Horizontal curve, L. H Horizontal curve, R. H. > Horizontal curve, L. H. > Inside curve, lateral Inside curve, lateral > Outside curve, lateral Outside curve, lateral > Type Poles Weight kg SVN 4/ SVN 4/ Curved sections* per your layout drawing max. L = 3.6 m, support spacing ~ 500 mm, max. angle 0 Configuration as shown above Joint Material surcharge cat. nos. for R mm VKS 5 VKS 6 Horizontal curve, R. H Horizontal curve, L. H Horizontal curve, R. H. > Horizontal curve, L. H. > Inside curve, lateral Inside curve, lateral > Outside curve, lateral Outside curve, lateral > Horizontal curve radius < 00 mm up to 45 degrees Horizontal curve radius > 00 mm up to 90 degrees Type Poles Weight kg SVN 5/ SVN 5/ SVN 6/ SVN 6/ * Curved sections will be factory prepared with a mm straight section on both ends. Horizontal curves with more than 90 degrees should be divided in two or more sections.

9 COMPENENTS VKS Fixpoint hanger* with tapping screw & clamp Sliding hanger* End cap** suitable L. H. and R. H. M 6 M length of powerail tapping screw & clamp Type Weight kg VEPS Type Weight kg VAS Type Weight kg VES 3 - L VES 3 - M Fixpoint hanger* with tapping screw & clamp Sliding hanger* End cap** suitable L. H. and R. H. 20 M 6 20 M length of powerail tapping screw & clamp Type Weight kg VEPS Type. Weight kg Cat.-No VAS Type Weight kg VES 4 - L VES 4 - M Fixpoint hanger* with tapping screw & clamp Sliding hanger* End cap** suitable L. H. and R. H. 50 M 6 50 M length of powerail tapping screw & clamp Type Weight kg Type Weight kg VEPS VAS * Complete with hardware (bolts, nuts, spring washers). Support spacing see page 5. ** L = loose; c/w hardware M = Factory assembled Type. Weight kg Cat.-No VES 6 - L VES 6 - M

10 19 12 COMPONENTS VKS End feed* Terminal box with terminal clamps 0 13 Section 190 Type Cable Gland A Weight kg VEKS 3/ L ST-M 40 x Surcharge for assemblage End feed* Terminal box with terminal clamps 0 13 Section 190 Type Cable Gland A Weight kg VEKS 4/ L ST-M 40 x Surcharge for assemblage End feed* Terminal box with terminal clamps 0 13 Section 190 Type Cable Gland A Weight kg VEKS 5/ L ST-M 40 x 1.5 ST-M 20 x VEKS 6/ L ST-M 40 x 1.5 ST-M 20 x Surcharge for assemblage * End feeds loose as components. Sections are to be ordered separately (see page 7).

11 COMPONENTS VKS Line Feed* Terminal box with terminal clamps 190 (340) Dimensions in parenthesis for VNS 3/-140 Line Feed* without cable connection; cable by others terminal bolt M 6. through hole Ø 11 mm Type** Weight Cable A kg (w/ PE) (w/o PE) Glands HS SS **** VNS 3/ VNS 3/ ST-M 40 x 1, VNS 3/ VNS 3/140 ST-M 63 x 1, Weight Type** A kg (w/ PE) (w/o PE) HS SS VLS 3/ VLS 3/*** VLS 3/120*** VLS 3/140*** Line Feed* Terminal box with terminal clamps Line Feed* without cable connection; cable by others terminal bolt M (340) Dimensions in parenthesis for VNS 4/-140 through hole Ø 11 mm Weight Cable Type** A kg (w/ PE) (w/o PE) Glands HS SS **** VNS 4/ VNS 4/ ST-M 40 x 1, VNS 4/ VNS 4/140 ST-M 63 x 1, Weight Type** A kg (w/ PE) (w/o PE) HS SS VLS 4/ VLS 4/*** VLS 4/120*** VLS 4/140*** Line Feed* Terminal box with terminal clamps Line Feed* without cable connection; cable by others terminal bolt M (340) 0 through hole Ø 11 mm Dimensions in parenthesis for VNS 5/-140 and 6/ Type** Weight Cable A kg (w/ PE) (w/o PE) Glands HS SS **** VNS 5/ 60 1 x ST-M 40 x 1, VNS 5/ 1 x ST-M 20 x 1, VNS 5/ VNS 5/140 1x 1x ST-M ST-M x x 1,5 1, VNS 6/ x ST-M 40 x 1,5 VNS 6/ x ST-M 20 x 1,5 VNS 6/ VNS 6/140 1x 1x ST-M ST-M x x 1,5 1, Weight Type** A kg (w/ PE) (w/o PE) HS SS VLS 5/ VLS 5/*** VLS 5/120*** VLS 5/140*** VLS 6/ VLS 6/*** VLS 6/120*** VLS 6/140*** * ** Suffix types e. g. VNS 3/60 w/ PE VNS 3/60 HS *** Cable connection w/ special cable lug (enclosed) for 35 mm 2 single core cable (max. 8,5 mm Ø) for 140 A, 25 mm 2 (max. 8,2 mm Ø) for 120 A, 16 mm 2 (max. 6,5 mm Ø) for A. **** Cable gland ST-M 63 x 1,5 for D = 34 to 45, ST-M 40 x 1,5 for D = 19 to 28, ST-M 20 x 1,5 for D = 7 to 13 Feed sets come ready assembled on 1 m Powerail sections and are part of the system length. Cable by others. 11

12 19 12 TRANSFER GUIDES VKS Transfer guide* for transfers, switches, spur lines max. horizontal and vertical offset ± 2 mm Application: straight cuts oblique cuts, lateral Transfer guide oblique cut* for switches and turntables prepared per your layout drawings. Application: oblique cuts, horizontal 25 ** web ** web Powerail x IP 21 up to x = 45 Photo shows L. H. version Type L. H. version R. H. version VU 3 S-M VU 3 S-L 0 8 M = factory assembled L = loose; c/w hardware Transfer guide* for transfers, switches, spur lines max. horizontal and vertical offset ± 2 mm Application: straight cuts ** web Photo shows L. H. version Type L. H. version R. H. version VUS 3 H Transfer guide oblique cut* for switches and turntables prepared per your layout drawings. Application: oblique cuts, horizontal and lateral ** web x IP 21 up to x = 45 Photo shows L. H. version Type VUS 4 H Photo shows L. H. version Type VUS 4 S Type L. H. version R. H. version VU Type L. H. version R. H. version VUS 4 H VUS 4 S H = for horizontal mounting S = for lateral mounting Transfer guide* for transfers, switches, spur lines max. horizontal and vertical offset ± 2 mm Application: straight cuts oblique cuts, lateral 20** web 2 x M 6 inserts, 8 mm deep c/c 50 mm Transfer guide oblique cut* for switches and turntables prepared per your layout drawings. Application: oblique cuts, horizontal Type VUS 6 H ** web Photo shows L. H. version (also fits for VKS 5 & VKS 6 powerail) Type L. H. version R. H. version VU 6 S-M VU 6 S-L 0 2 Powerail Photo shows L. H. version x IP 21 up to x = 45 Type L. H. version R. H. version VUS 5 H VUS 6 H M = factory assembled L = loose; c/w hardware *** 12 *** *** *** Photos show transfer guides being integrated in or attached to a powerail section. These sections are to be ordered as a part of the system. Other entry/exit chutes are available. Consult factory. w/o conductors Preparation of Powerail ends by others, following attached instructions.

13 TRANSFER FUNNELS VKS Transfer funnels for KSTU /55 for max. Speed v = m/min.** 681 C A B D 82 82,5 20 9,4 24 Powerail with transfer guide VU is to be ordered seperately 35 max. 800 slotted Langloch hole 7x Type A mm B mm C mm D mm Weight kg VU L* VU R* EFT V3 - KSTU EFT V4 - KSTU EFT V6 - KSTU Transfer funnels for KSTLU / KDSTLU for max. Speed v = m/min.** ,5 B D C A 104,5 10, ,5 Powerail with transfer guide VU is to be ordered seperately 35 max. 800 slotted Langloch hole 7x Type A mm B mm C mm D mm Weight kg VU L* VU R* EFT V3 - KDSTLU EFT V4 - KDSTLU EFT V6 - KDSTLU ** Powerail section must be factory prepared. Order separately for left hand VU L, for right hand VU R. Higher speeds on request. ** 13

14 19 12 TRANSFER FUNNELS VKS EXPANSION SECTIONS VKS Transfer funnels for KSFU 25* for max. speed v = m/min.** ,5 24 Powerail with transfer guide VU is to be ordered seperately 35 max. 800 C A B D 4 slotted Langloch hole 7x 4,5 64 Type A mm B mm C mm D mm Weight kg VU L* VU R* EFT V3 - KSFU EFT V4 - KSFU EFT V6 - KSFU Expansion sections 0 (±25) A (0-50 mm) Type*** Weight Bestell-Nr. kg (w/ PE) (w/o PE) HS SS DVKS 3/ DVKS 3/ DVKS 3/ DVKS 3/ DVKS 4/ DVKS 4/ DVKS 4/ DVKS 4/ Weight Bestell-Nr. Type*** kg (w/ PE) (w/o PE) HS SS DVKS 5/ DVKS 5/ DVKS 5/ DVKS 5/ DVKS 6/ DVKS 6/ DVKS 6/ DVKS 6/ Application Expansion sections are required to compensate for expansion and contraction in system expansion gaps (building or track). The expansion capacity is 50 mm. More tolerance require more than one VKS expansion section. They do not interrupt electrical power, so there is no need for an extra feeding. Expansion joints do not influence the voltage drop of a system. Mounting The expansion section is installed in the center between two fix points in the building/track expansion gap area. The gap dimension A equals the gap of the building/track. See adjacent Fig. 1. Fig. 1 Expansion gap Fixpoint hanger Expansion section 14 * Powerail section must be factory prepared. Order separately for left hand VU L, or for right hand VU R. Higher speeds on request. Suffix types e. g. DVKS 3/10 with PE DVKS 3/60 HS 3 2. ** ***

15 SECTIONALIZING VKS CURRENT COLLECTOR VKS Conductor dead section for control signals please indicate where and which conductors are to be interrupted. Type Colour VSTS 1/10- M 0 0 black VSTS 1/10- L black VSTS 1/120 M white VSTS 1/120 L white VSTS 1/140 M white VSTS 1/140 L white M = factory assembled; L = loose dead section Current collectors Dimensions in parenthesis for KSTL with 2 m connecting cable; contact pressure: ~ 5 N Current collector Swivel & lift ± 10 mm Contact pressure: 3 N 13,5 (17,8 KSTU) , ,5 140 (190) 85 (95) plug terminal 6.3 x 0.8 for FLA 2.5 or WFLA 2.5 ca. 70 ZF 1 M 5, Phase M 6, Ground Typ e*** KST KST 55 KSTL KSTL 55 KSTU **** KSTU 55**** Ampacity A Connecting cable A/ d max/ mm 2 mm lift & swivel mm ±20 ±20 ± ± ±20 ±20 Weight kg phase - PH For double arrangement of current collectors and support spacing for Powerail see page 5. ground PE Type*** Ampacity Weight A kg Phase PH Ground PE KST Selection of connecting cable see page. Current collector ,2 Double current collector ca ,8 70 plug terminal 6.3 x 0.8 for FLA 2.5 or WFLA 2.5 ca. 70 ZF 1 M 5, Phase M 6, Ground 80 plug terminal 6.3 x 0.8 for FLA 2.5 or WFLA 2.5 ca. 70 plug terminal 6.3 x 0.8 for WFLA 2.5 ZF 2 M 5, Phase M 6, Ground Swivel & lift: ± 10 mm Contact pressure: 3.5 N Swivel & lift: ± 10 mm Contact pressure 3.5 N per brush Ampacity Weight Weight Type *** A kg Phase PH Ground PE Type *** kg Phase PH Ground PE KST KST 2/ Ampacity: 1 flat plug 25 A, 2 flat plugs 2 x 20 A Selection of connecting cable see page. Selection of connecting cable see page. * ** *** **** Marking of conductors see page 6. Length of conductor w/o power (other lengths on request). Suffix types e. g. KST 20 KST 20 PH 5 071, KST w/ PE KST HS Collector for transfer funnel EFT V KSTU. In the area of the funnel ± mm in every direction.

16 19 12 CURRENT COLLECTORS FOR VKS Compact current collector Ampacity: 1 plug terminal 32 A FLA 2,5 40 A FLA 4,0 max A FLA 6,0 For conductor spacing of mm Swivel & lift: ± mm Contact pressure: 3.5 N per brush Ground position per request (see page 5) for safety reasons during maintenance ground collector is always first and last contact 88 a b plug terminal 6.3 x 0.8 for FLA 53*** RF 3 max. DF 2 No. Type* of a ** b ** Weight for power incl. for control Poles mm mm kg 1 ground HS ST KESR , KESR , KESR , KESR , KESR , Separately available: PH PE KESR collector Selection of connecting cable see page Compact current collector Ampacity: 1 plug terminal 25 A max. 138 Compact current collector with 1 m connecting cable for transfer funnel EFT V KSFU 25 max a b plug terminal 6.3 x 0.8 for WFLA *** RF 3 max. DF 2 For conductor spacing of mm Swivel & lift: ± mm Contact pressure: 3.5 N per brush Ground position per request (see page 5) for safety reasons during maintenance ground collector is always first and last contact plug terminal 6.3 x 0.8 for FLA 2,5 Dimensions of base plate see KSF RF 3 max. DF 2 Type* No. of Poles a ** mm b ** mm Weight for power incl.for conrol kg 1 ground HS ST KSF KSF KSF KSF KSF Separately available: Phase PH Ground PE KSF 25 collector 0, Selection of connecting cable see page 17. Type* No. of Poles a ** mm b ** mm Weight for power incl.for control kg 1 ground HS ST KSFU KSFU KSFU KSFU KSFU Separately available: Phase PH Ground PE KSFU 25 collector Compact double current collector 1 Ampacity: 1 flat plug 25 A, 2 flat plugs 2 x 20 A max plug 3 2 terminal 6.3 x 0.8 for WFLA b DF 3 a 53** plug terminal 6.3 x 0.8 quick connect plug and flexible cable WFLA 2.5 sqmm, L = 0.5 m incl. max. 12 DF 1 For conductor spacing of mm Swivel & lift: ± mm Contact pressure: 3.5 N per brush Ground position per request (see page 5) for safety reasons during maintenance ground collector is always first and last contact Type* No. of a ** b ** Weight for power incl. for control Poles mm mm kg HS ST KDS 2/ KDS 2/ KDS 2/ KDS 2/ KDS 2/ Separately available: Phase PH Ground PE KDS 2/40 collector 0, * ** Suffix types e. g. KSF 25-3 w/ PE KSF 25-3 HS Base plate of KSF and KSFU 25 2-, 4- or 6-poles always. At KDS 2/40 and KESR or 6-poles always. Current collector 3 poles base plate 4 poles, 4 th pole is free. Current collector 5 poles base plate 6 poles, 6 th pole is free. *** for 5- and 6-poles execution only.

17 CURRENT COLLECTORS FOR VKS Current collector Double current collector c/w 2 m cable swivel & lift: ± 20 mm; contact pressure: 9 N Type** KST KST 40 KST 60 Ampacity Connecting cable A mm 2 ø max. mm Weight kg PE Phase PH ground PE c/w 2 x 2 m cable swivel & lift: ± 20 mm; contact pressure: 9 N per brush Type** KDST KDST 80 KDST 120 Ampacity Connecting cable A mm 2 ø max. mm Weight kg Phase PH ground PE Current collector Double current collector c/w 2 m cable swivel & lift: ± 40 mm; contact pressure: 9 N Type** KSTL KSTL 40 KSTL 60 Ampacity Connecting cable A mm 2 ø max. mm Weight kg PE Phase PH ground PE c/w 2 x 2 m cable swivel & lift: ± 40 mm; contact pressure: 9 N per brush Type** KDSTL KDSTL 80 KDSTL 120 Ampacity Connecting cable A mm 2 ø max. mm Weight kg Phase PH ground PE Current collector for transfer funnel* EFT V -KSTLU 17 4 Double current collector for transfer funnel* EFT V -KSTLU approx. 135 max. released hight ca. 135 max. released hight 12 approx approx. 50 c/w 2 m cable PE swivel: ± 40 mm; lift: ± 20 mm; (in funnel area ± mm) contact pressure: 9 N 12 c/w 2 x 2 m cable swivel: ± 40 mm; lift: ± 20 mm; (in funnel area ± mm) contact pressure: 9 N per brush Type** KSTLU KSTLU 40 KSTLU 60 Ampacity Connecting cable A mm 2 ø max. mm Weight kg Phase PH ground PE Type** KDSTLU KDSTLU 80 KDSTLU 120 Ampacity Connecting cable A mm 2 ø max. mm Weight kg Phase PH ground PE * ** Collector maintains center phase position for easy retracking. Suffix types e. g. KST KST PH

18 19 12 COLLECTOR COMPONENTS FOR VKS Connecting cable high-flexible for current collector (Allocation to current collectors on pages and 16) FH WFH Cross section Ø Weight Type mm 2 mm kg phase ground black green/yellow FLA FLA FLA WFLA FLA 1 m long with flat plug 6.3 x 0.8 m; longer cable available WFLA Flat plug only Type for Cross section mm 2 FH FH WFH Collector brackets for current collector KST/KDST see page 17 for current collector KST -55 see page for control-collector KST/KDST page 17, KST -55 page w/ PE w/o PE 40 mm wide slotted hole x for ground collector mm wide slotted hole 11 x mm wide slotted hole 11 x Type Weight kg Type Weight kg Type Weight kg UMAS 12 HS -A UMAS 12 HS-B UMAS 12 ST Collector bracket for current collectors for KST to KDSTLU 120 Cable attachment clamp for current collectors for KST to KDSTLU prepared for ground collector Longer brackets furnished on special order. In this case you should provide an extra support to avoid bending or twisting of the collector bracket. Type Length mm Weight kg UMV Type Weight kg KBK

19 COLLECTOR COMPONENTS FOR VKS Copper-graphite brush assembly RH 19 RH 10 RH KMK RH GF 1 35 GF RH RH RH RH PE identification KMK -55 PH KMK -55 PE RH RH KMK 25 KMKU MK 40 25/* KMK 2/40 DSW 2/40 DS 2/40 KMK 60 KMK 60 U dim. RH = allowed rest of hight Type for collectors Thickness of brush RH mm Weight kg KMK -55 PH KST KSTL 55, KSTU mm KMK -55 PE KST KSTL 55, KSTU mm KMK 20 KST mm KMK 25 KST 25, KSF mm KMKU 25/ KSFU mm MK 55 KESR mm KMK 2/40 KST 2/ mm DSW 2/40 KDS 2/ mm DS 2/40 KDS 2/ mm KMK 60 KST KDSTL mm KMK 60 U KSTLU KDSTLU mm * mm wide. 19

20 19 12 COMPONENTS FOR VKS Springs S S D D L Pressure spring DF Guiding spring GF L Tension spring ZF/RF Type for collectors S D L mm mm mm ZF 1 KST 20, KST ZF 2 KST 2/ ZF 3 KST thru KDST ZF 4 KSTL thru KDSTL 120 and KSTLU thru KDSTLU DF 1 KDS 2/ DF 2 KSF 25, KESR DF 3 KDS 2/ RF 3 KSF 25, KESR GF 1 KDS 2/ Spare parts Type Joint cap for VKS Joint cap for VKS Joint cap for VKS 5 and Plug-in connector (1pole, copper) for VKS /10 - A Plug-in connector (1 pole, copper, tin plated) for VKS / A Insulating piece for sectionalizing (1 pole) for VSTS 1/10 - L Insulating piece for sectionalizing (1 pole) for VSTS 1/120 L Insulating piece for sectionalizing (1 pole) for VSTS 1/140 L Feed terminal, (1 pole) for line feed VNS Feed terminal, (1 pole) for line feed VLS

21 COLLECTOR COMPONENTS FOR VKS Current collector series KST thru KDSTLU 120 Part-No. Description Weight kg 1 Brush (see page 19) 2 Collector base for KST thru KST 60 Phase PH Ground PE Collector base for KDST thru KDST 120 Phase PH Ground PE Collector base for KSTL thru KSTL 60 Phase PH Ground PE Collector base for KSTLU thru KSTLU 60 Phase PH Ground PE Collector base for KDSTL thru KDSTL 120 Phase PH Ground PE Collector base for KDSTLU thru KDSTLU 120 Phase PH Ground PE Spring (see page 20) 5 Connecting cable AEA 2,5 PH, 2 m long Phase PH Connecting cable AEA 2,5 PE, 2 m long Ground PE Connecting cable AEA 6 PH, 2 m long Phase PH Connecting cable AEA 6 PE, 2 m long Ground PE Connecting cable AEA 10 PH, 2 m long Phase PH Connecting cable AEA 10 PE, 2 m long Ground PE Rubber spring* for KSTLU, KSTLU 40, KSTLU 60, KDSTLU, KDSTLU 80, KDSTLU 120 * When ordering brush the rubber spring as shown will be included. 21

22 19 12 COLLECTOR COMPONENTS FOR VKS Current collectors KST -55 thru KSTL -55, KSTU -55 Part-No. Description Weight kg 1 Brush Phase PH Brush Ground PE Collector base & arm KST, complete Phase PH Collector base & arm KSTL, complete Phase PH Collector base & arm KST, complete Ground PE Collector base & arm KSTL, complete Ground PE Terminal cap Phase PH (black) Terminal cap Ground PE (green) Spacer for KSTU -55 only Connecting cable RKA 2,5 PH, 2 m long Phase PH Connecting cable RKA 2,5 PE, 2 m long Ground PE Connecting cable RKA 6 PH, 2 m long Phase PH Connecting cable RKA 6 PE, 2 m long Ground PE Terminal bolt ➆

23 POWERAILS VKL Straight sections Standard section 4 m Support spacing 0 mm Max. system length m HS w/ PE SS w/o PE LH RH Type Poles Ampere rating continuous A Voltage rating max. V Voltage drop per m at full rating V Minimum clearance VKL 3/ HS ,3 9 1, VKL 3/ SS ,3 9 1, mm Copper cross section (per conductor) mm 2 Weight kg / m 5 pol. 4 pol. 3 pol. 5 pol. 4 pol. 3 pol. Power HS Control SS PE PE PE L3 L3 l 2 2 l L2 L2 L L1 L1 l 4 4 l N N VKL 4/ HS ,3 5,5 9 1, VKL 4/ SS ,3 5,5 9 1, VKL 5/ HS ,3 5,5 9 1, VKL 5/ SS ,3 5,5 9 1, M M8 max. 8 seitlich lateral mounting M8 max. 6,5 14, ,5 14, Suffix types e. g. 2 m VKL 4/ w/ PE VKL 4/ - 2 HS Shorter sections are made up from the next larger standard length PEL3L2L1N 74 suspended hängend mounting Curved sections* per your layout drawing max. L = 3.60 m, support spacing ~ 500 mm R min surcharge cat.-nos. for R min mm Cat- No. VKL Horizontal curve, R.H Horizontal curve, L.H Inside curve, lateral Outside curve, lateral horizontal curve, R.H. = web outside horizontal curve, L.H. = web inside (not shown) inside curve: R min inside curve, lateral = conductors inside outside curve, lateral = conductors outside (not shown) outside curve: R min * Curves with less than 2000 mm radius will be factory prepared with a mm straight section on both ends for easy connection. Horizontal curves with more than 90 degrees should be divided in two or more sections. 23

24 19 12 COMPONENTS VKL Joint Material End cap suitable for left hand and right hand installation Type No. of conductors Weight kg LV LV LV Type Weight kg VE Fixpoint hanger Sliding hanger M 8 M Type Weight kg VEP Type Weight kg VA Conductor dead section for control signals **Please indicate where and which conductors are to be interrupted. Line feed* for direct cable connection max. cable outer Ø 16.5 mm, max. cable-cross-section 4 mm 2 terminal bolt M 4 torque moment = 3 Nm Type VST VST VST VST VST Type*** A Weight kg (w/ PE) HS (w/o PE) SS VLE 3/ VLE 4/ VLE 5/ *** ** The Line feeds come ready assembled on 1 m Powerail sections. Cable by others. Terminal markings see page 23. *** Suffix types e. g. VLE 3/ w/ PE VLE 3/ HS

25 COMPONENTS VKL KTW-SYSTEM FOR ELECTRIC TOOLS Line feed* with terminal box for connecting cable 4 mm 2 terminal bolt M 4 Torque moment = 3 Nm End feed, loose** cable gland to 4 mm Section St-M St-M 25 x 1,5 78 Web Type*** A Weight kg w/ PE HS w/o PE SS VNK 3/ VNK 4/ VNK 5/ Installation left or right possible for power and control Type*** A Weight kg VEK Current collector VSR for straight and curved runs travelling speed: 60 m/min. in curves 120 m/min. for straight runs carbon brushes not replacable. PE Two arm 45 12, ,5 31 Ø 8, Ø Ø 10 connecting cable: 1,5 mm 2 (1 m long) Type*** A 52 No. of poles Weight kg w/ PE w/o PE HS ST VSR 3/ VSR 4/ VSR 5/ VAHLE KTW-Systems These systems are unique to feed electric tools, such as drilling machines, grinders, screw drivers etc. along assembly lines or above work benches in any type of plant. No power cables on the floor to cause accidents and no obstruction to personnel by trailing cables. Containers or baskets carrying bolts and nuts or other hardware for the assembling work can also be supported from and pushed along the carrier rail. The KTW-Systems comprise a galvanized C-track taking the carrier trolleys or other hook-up elements, and the plastic- Enclosed Powerail with 3 to 6 conductors of to 200 Amp. capacity. Carrier rail and Powerail are attached to common brackets which serve as suspension structure. The Collector has a mechanical towing arm connection to the Carrier Trolley and the pick-up cable will feed into a plug and socket system or circuit breaker unit. These units as per customer s choice are mounted to the attachment plate of the carrier trolley. The elements can be factory assembled by us or field mounted. Ask for more details. Further literature on KTW-systems is available Type Weight kg VM for single collectors AM for double collectors (2 x VSR) KTW / V with powerail type VKL 52 *** *** Line feeds come ready assembled on 1 m powerail. Cable by others. End feed comes loose in components. Powerail section is to be ordered separately (see Page 23). *** Suffix types e. g. VNK 3/ w/ PE VNK 3/ HS

26 19 12 BRACKETS AND SNAP-ON BRACKETS VKS AND VKL Brackets L 50 Attachment bracket VKS 4-poles 21 6 VKL 10 28,5 42 Claw suitable for D = 6 to 16 mm Attachment bracket Attachment bracket VKS 6-poles VKS 3-poles Attachment bracket L 50 6 Claw suitable for D = to 25 mm VKS 4-poles Attachment bracket VKL ,5 Attachment bracket 42 VKS 6-poles VKS 3-poles Attention! Make sure that hoist wheels of monorail systems have enough clearance. C-rail of HKV is identical to type S 1, cat. 8 a Hangers to be ordered separately Type* X L B max Weight mm mm mm kg VKS VKL HK HK HK HK HK HK HK HK HK Snap-on brackets 68 tg 90 Snap-on brackets facilitate installation of Powerails on flat flange beams PE, PB, PPBI and PBv. They are adjustable to suit beam flange dimensions (tg) of up to 43 mm. AKL with VKS 3 AKL with VKL 80 tg 91 tg Type AKL Beam flange tg/mm Weight/kg AKL with VKS 4 AKL with VKS 6 Hangers for powerail to be ordered separately. 26 * Please complete Types p. e. for VKS HKVKS 200 for VKL HKVKL 200

27 POLE VKS-SYSTEM FOR AS/RS Fixpoint hanger VEPS and Sliding hanger VAS This system combines a VKS 4-pole and VKS 3-pole Powerail in a common hanger clamp. Possible fixing methods are shown below. All available VKS 4-pole and VKS 3-pole Powerails can be combined. All standard components of VKS Powerails cn be used. Restrictions apply to line feeds VNS, end feeds VEKS, transfers and towing arms (consult factory for these components). 22,5 9 22, ,5 53,5 31, S2 rail 45, , S2 rail M 6 45, , ,5 40, ,5 M 6 32, , , , , , , ,5 22,5 21, ,5 36,7 Type Wght. kg Type Wght. kg Type Wght. kg Type Wght. kg VEPS 4/3 SF M 6x VAS 4/3 SF M 6x VEPS 4/3 GP M VAS 4/3 GP M VEPS 4/3 M 6 x VAS 4/3 M 6 x VEPS 4/3 - GS VAS 4/3 - GS Fixpoint hanger Joint material Sliding hanger End caps Current collector Collector bracket 27

28 19 12 EXAMPLES FOR ORDERING VKS AND VKL Straight track with end feed* 12 m VKS 3/ HS; 12 m VKL 3/ HS Layout VKS: L R L = left side R = right side Layout VKL: L R Copper Conductors this side Copper Conductors this side Qty Description Type Qty Type 2 Powerails, 4 m long VKS 3/-4 HS VKL 3/-4 HS Powerail, 3 m long VKS 3/-3 HS VKL 3/-3 HS Powerail, 1 m long VKS 3/-1 HS VKL 3/-1 HS Joint material SVN 3/ LV Fixpoint hangers VEPS VEP Sliding hangers VAS VA End cap VES VE End feed, 1 m long VEKS 3/ L VEK Collectors, phase KST 25 PH Collector, ground KST 25 PE Collector 1 VSR 3/10 HS Tow arm 1 VM Brackets HKVKS HKVKL Curved track with end feed* m VKL 5/ HS Qty Description Type 2 Powerails, 4 m long VKL 5/-4 HS Powerail, 2 m long VKL 5/-2 HS Powerail, 4 m long VKL 5/-4 HS for inside curve lateral 90 ; R = 2000 mm; L = 3142 mm 1 Bending surcharge for inside curve lateral 4 Joint material LV Fixpoint hanger VEP Sliding hangers VA End cap VE End feed, 1 m long VEK 5/ L HS Collector VSR 5/10 HS Tow arm VM L = left side R = right side Copper Conductors this side 28 * Layout symbols see page 5.

29 EXAMPLE FOR ORDERING VKS Curved track with switch (lateral mounting)* 27,857 m VKS 6/60 HS Qty Description Type Position 1 Powerail, 4 m long VKS 6/60-4 HS Powerails, 3 m long VKS 6/60-3 HS cut to: 1 x 2,985 m 1 x 2,0 m 3 Powerails, 2 m long VKS 6/60-2 HS cut to: 1 x 1,985 m 1 x 1,200 m 1 x 1,170 m 2 Powerails, 1 m long VKS 6/60-1 HS cut to: 1 x 0,985 m 1 x 0,585 m 2 Powerails, 4 m long VKS 6/60-4 HS x for outside curve 90 ; R = 2020 mm; L = 3,373 m 1 x for inside curve 90 ; R = 2000 mm; L = 3,342 m 2 Powerails, 2 m long VKS 6/60-2 HS x for outside curve ~ 45 ; R = 2000 mm; L = 1,656 m 1 x for inside curve 45 ; R = 2000 mm; L = 1,771 m 1 Bending surcharge (outside curve) 2 3 Bending surcharge (inside curve) Joint material SVN 6/ Fixpoint hangers VEPS Sliding hangers VAS End caps on above position 1, 9, 14 VES 6-M Line feeds, 1 m long VLS 6/60 HS Line feeds on above position 7, 11 VLS 6/60 HS Transfer guides, left, on above position 6, 7, 11 VU 6 S-M Transfer guides, right, on above position 7, 8, 10, 12 VU 6 S-M Compact collector ground on No. 3 KDS 2/40-6- HS * Layout symbols see page 5 29

30 19 12 QUESTIONNAIRE FOR VKS AND VKL Customer Adress Tel.: Fax: Internet: (URL) Attention of 1. Type of machinery to be electrified 2. Type of powerail prefered 3. Voltage Volts ~/=: Phases: c/s: 4. Number of conductors power lines, control lines, (ground) 5. Length of conductor systems 6. Indoor Outdoor: 7. Special site conditions (humidity, dust, chemical effects, etc.) 8. Temperature conditions C min. C max. 9. Horizontal mounting Lateral mounting 10. Installation height m 11. Hanger spacing m 12. Straight track Curved track (pls. submit prints or sketches; see page 23, 24) 13. Position of feed points 14. Number of feed points. Number of cranes / machines supplied by the one system 16. Ampere load of each crane/machine: (use table on page ) 17. Travelling speed of machinery:. Other important data: Please submit prints or sketches for curved tracks, discontinuous circuits etc.

31 QUESTIONNAIRE FOR VKS AND VKL To the nearest local VAHLE agency: Date: Motordata Power kw Crane 1 Nominal current Starting current A cos N % ED A cos A Type of motor** Power kw Crane 2 Nominal current Starting current A cos N % ED A cos A Type of motor** Hoist motor Auxiliary hoist Long travel Cross travel Motordata Power kw Crane 3 Nominal current Starting current A cos N % ED A cos A Type of motor** Power kw Crane 4 Nominal current Starting current A cos N % ED A cos A Type of motor** Hoist motor Auxiliary hoist Long travel Cross travel Mark motors* which can operate simultaneously. Mark motors which can start simultaneously. **Use K for squirrel cage motor S for slipring motor F for frequency controlled motor Further remarks: Signature: 31

32 Catalog No. 4 b/e 2004 MANAGEMENTSYSTEM DQS - zertifiziert nach DIN EN ISO 9001:2000 OHSAS 001 (Reg.-Nr QM OH) Catalog No. Copperhead Conductor Systems 1 a Battery Charging Systems 1 b Insulated Conductor Systems U 10 2 a Insulated Conductor Systems U 20 U U 40 2 b Insulated Conductor Systems U U 25 U 35 2 c Aluminium Enclosed Conductor Systems LSV LSVG 3 a Powerail Enclosed Conductor Systems KBSL KSL KSLT KSG 4 a Powerail Enclosed Conductor Systems VKS VKL 4 b Powerail Enclosed Conductor System MKLD MKLF MKLS 4 c Heavy Enclosed Conductor Systems 5 Trolley Wire and Accessories 6 Cable Tenders 7 Cable Carriers for -tracks 8 a Cable Carriers for Flatform Cable on -beams 8 bf Cable Carriers for Round Cable on -beams 8 br Cable Carriers for -tracks 8 c Conductor Cables and Fittings 8 L Spring Operated Cable Reels 9 a VAHLE POWERCOM Data Transmission Systems 9 c CPS Contactless Power Supply 9 d SMG Slotted Microwave Guide 9 e WCS Position Encoding System 9 f Motor Powered Cable Reels on request 0404 Printed in Germany /04 PAUL VAHLE GMBH & CO. KG WESTICKER STRASSE 52 D KAMEN/GERMANY TEL. (+49) 23 07/70 40 Internet: postmaster@vahle.de FAX (+49) 23 07/