POWERAIL CONDUCTOR SYSTEMS MKLD MKLF MKLS

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1 POWERAIL CONDUCTOR SYSTEMS

2 19 12 POWERAIL INDEX Page Powerail versions 3 Basic description 3 Technical data 3 Powerail types, cat. nos. and weights 4 Engineering data and configurations 5 Standard sections, curves and sealing strip 6 Jointing material, hangers 7 Brackets 8 End sections, end feeds 9 Line feeds 10, 11 Contact sections 12 Turntables, switches 12 Transfer funnels, transfer guides 13 Anti-condensation sections 14 Expansions joint sections 15 Collectors 16 Double collectors 16 Tow arms 17 Flexible tow arms 17 Flexible tow arm configurations 17 Flat copper 18 Cable glands 18 Assembling tools 19 Copper cassettes 19 Straightening tool 19 Conductor threading tools 19 Sectionalizing 20 Heating system 20 Example for ordering 21 Spare parts 21 Questionnaire 22, 23 Production programm 24 VAHLE-Powerail MKL Powerail MKL is a totally enclosed conductor system for indoor and outdoor use. The insulated housing can accommodate different copper sections Typ from 6 to 10 copper conductors continuous copper strips A copper strips come as separate items as coils. Typ from 6 to 10 copper conductors with factory-assembled plug-in joints A. Typ from 6 to 10 copper conductors with factory-assembled bolted joints A. MKL Powerails require the minimum of space, are easy to install and cannot corrode. They meet all national and international safety requirements. MKL can be equipped with neoprene sealing strips and with a heating system. Standard configurations are listed on page 5. Other configurations are possible. 2

3 BASIC DESCRIPTION OF POWERAILS AND COMPONENTS Applications Mobile power feeding of overhead cranes, monorail systems, electric hoists, electric power tools, machine tools, automated storage and retrieval systems, assembly and test lines, hangar doors, studio & station lighting systems and many others. Housing Gray colored, fully insulated, for 6 to 10 copper conductors. Standard sections are 1, 2, 3 or 4 m long. Specific lengths and curves are available. Ground conductor identified by international color code. Long and short lip housing profiles and collector safety keys avoid phase reversing. Any number of conductors can be accomplished by installing several Powerails side by side. Couplings of Housing By fully insulated joint caps. Feed sets End feeds or line feeds are available. End caps/sections uses end sections. & use end caps Fixpoint and sliding hangers for Powerail. Max. support spacing is 2000 mm. Expansion sections Expansion sections for length compensation are available and do not interrupt electric conductors. Anti-condensation sections For combined indoor/outdoor applications use anti-condensation sections. They do not interrupt electric conductors. Contact sections, turntables, switches Powerail for working areas and transfer applications see pages 12 & 13. Sectionalizing Factory-assembled conductor dead sections are available for & in the air gap and insulating piece version. Collectors The current collectors are made of impact-resistant polyamide. Spring loaded carbon brushes maintain uniform contact. Connecting cables, hinged or flexible towing arms are included. Double collectors to be used for transfer applications and higher amperage. Hangers Standard brackets for Powerail attachment to crane girder are available (see page 8). 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 22/23. Please consult the factory for low voltage applications and data transmission, indicating special environmental conditions. Stainless steel conductors are available (see page 18). Technical Data of Powerail MKL Electrical properties: Dielectric strength DIN KV/mm Specific resistance DIN x Ohm/cm Surface resistance DIN Ohm Leakage resistance IEC 112/VDE 0303 CTI Flame test proof: no flaming particles, DIN Class B 1 self extinguishing Part 1 Mechanical properties: Flexible strength 75N/mm 2 ± 10 % Tensile strength 40 N/mm 2 ± 10 % Temperature range (ambient): 30 C up to + 60 C Resistance to chemicals: at + 45 C Gasoline Mineral Oil Grease Sulphuric acid 50 % Caustic soda 25 % & 50 % Hydro-chloric acid, concentrated Consider the voltage drop calculation to maintain the limits established by the motor manufacturers: Formulas: AC: U = 3 x I x l x Z U 2 = U DC: U 1 = 2l x I x R V U 1 = Voltage drop [V] R = Resistence [Ohm/km] U 2 = Voltage drop [%] l = Power feed length [m] I = Ampere load [A] 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 Z = Impedance [Ohm/km] V = Voltage rating [V] 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. A diversity factor of can be considered. The conductor size and/or number of feed points should be increased or booster cables should be used in parallel in case the drop is exceeding the limitations. See page 5 for resistance and impedance values. 3

4 19 12 POWERAIL TYPES AND CAT.-NOS. HS c/w PE Weight Cat. SS w/o PE kg/m No. with continuous copper strips, to be drawn in during installation. Housing only (Copper strips to be drawn in during installation, see page 18. Configurations on page 5). - HS 1, SS 1, Housing with factory assembled copper strips ans plug-in joints 6/ 40- HS 2, / 40- SS 2, / 60- HS 2, /100- HS 2, with factory assembled copper strips and plug-in joints, ( A) 7/ 40- HS 2, / 40- SS 2, / 60- HS 2, /100- HS 2, with factory assembled copper strips and bolted joints, ( A) 8/ 40- HS 2, / 40- SS 2, / 60- HS 2, /100- HS 2, Housing with factory assembled copper strips and bolted joints 6/ 40- HS 2, / 40- SS 2, / 60- HS 2, /100- HS 2, /140- HS 2, /160- HS 3, /200- HS 3, / 40- HS 2, / 40- SS 2, / 60- HS 2, /100- HS 2, /140- HS 2, /160- HS 3, /200- HS 3, s, and with heating system 8/ 40- HS 2, / 40- SS 2, / 60- HS 2, /100- HS 2, /140- HS 3, /160- HS 3, /200- HS 3, Complete types e.g. -4 HS for 4 m with /40-4 HS for 4 m 8/40 with PE Add last number (1,2,3,4 length suffix) in accordance to bars required

5 ENGINEERING DATA Ampere- Impedance No. Copper cross section mm 2 rating max. at Resisof L1, L2, L3 Voltage 50 Hz tance Leakage configurations Con- Phases Rating 20 C at Distance HS c/w PE duc- Phase Control- 20 C SS w/o PE tors L1, L2, L3 line 100 % A V Ω/1000 m Ω/1000 m mm MKL 6/ 40 HS 6 3 x ,73 1,72 30 MKL 6/ 40 SS 6 6 x ,73 1,72 30 MKL 6/ 60 HS 6 3 x ,07 1,06 30 MKL 6/100 HS 6 3 x ,71 0,69 30 MKL 6/140 HS 6 3 x ,57 0,55 30 MKL 6/160 HS 6 3 x ,46 0,43 30 MKL 6/200 HS 6 3 x ,39 0,35 30 MKL 7/ 40 HS 7 3 x MKL 7/ 40 SS 7 MKL 7/ 60 HS 7 3 x MKL 7/100 HS 7 3 x MKL 7/140 HS 7 3 x MKL 7/160 HS 7 3 x MKL 7/200 HS 7 3 x x 11 6 x 10 1 x 11 1 x 11 1 x 11 1 x 11 1 x 11 1 x ,73 1, ,73 1, ,07 1, ,71 0, ,57 0, ,46 0, ,39 0,35 30 MKL 6pole MKL 7pole 6-8-poles MKL 8/ 40 HS 8 3 x MKL 8/ 40 SS 8 MKL 8/ 60 HS 8 3 x MKL 8/100 HS 8 3 x MKL 8/140 HS 8 3 x MKL 8/160 HS 8 3 x MKL 8/200 HS 8 3 x x 11 6 x 10 2 x 11 2 x 11 2 x 11 2 x 11 2 x 11 2 x ,73 1, ,73 1, ,07 1, ,71 0, ,57 0, ,46 0, ,39 0,35 30 MKL 8pole 9/ 40 HS 9 3 x / 40 SS 9 9/ 60 HS 9 3 x /100 HS 9 3 x /140 HS 9 3 x /160 HS 9 3 x /200 HS 9 3 x x 11 6 x 10 3 x 11 3 x 11 3 x 11 3 x 11 3 x 11 3 x ,73 1, ,73 1, ,07 1, ,71 0, ,57 0, ,46 0, ,39 0,35 30 MKL 9pole 9-10-poles 10/ 40 HS 10 3 x / 40 SS 10 10/ 60 HS 10 3 x /100 HS 10 3 x /140 HS 10 3 x /160 HS 10 3 x /200 HS 10 3 x x 11 6 x 11 4 x 11 4 x 11 4 x 11 4 x 11 4 x 11 4 x ,73 1, ,73 1, ,07 1, ,71 0, ,57 0, ,46 0, ,39 0,35 30 MKL 10pole Conductors 9 & 10 for max. 24 V AC or 60 V DC. 80% E.D.... Complete types e.g. 7/60 HS for 7 poles with bolted joints In case of using a neutral conductor copper pos.1 will be taken. layout of the sytem on request (please see page 3) Numbers in paranthesis apply to control line. 5

6 19 12 STANDARD SECTIONS SEALING STRIP Standard sections for continuous copper strips. A left A Standard section (view to short lip) right A-A 56 with plug-in joints, factory assembled. A MKL e.g. 6pole 93 left A Standard section (view to short lip) right with bolted joints, factory assembled. A short lip side 10,5 left A Standard section (view to short lip) right Straight standard sections have no stiffener clamps. Stiffener clamps can be supplied loose or assembled each meter. Stiffener clamps (paire) loose, galvanized steel loose, stainless steel Stiffener clamps (piece) factory assembled, galvanized steel factory assembled, stainless steel Curves Min. bending radius, horizontal = 1100 mm Max. length L = 3600 mm Max. 120 MKL e.g. 6pole Surcharge on request (piece) Horizontal curve LLI and LLA Vertical curve VO and VU LLI = long lip inside LLA = long lip outside VO = vertical curve upwards VU = vertical curve downwards Long lip side of Powerails should always be mounted facing the machinery track. long lip R for LLA R for LLI R for VU R for VO 56 Sealing strip with accessories Sealing strip, p. pair (max. length 50 m) Fastener (2 per end) Joint (2 per joint) MKL e.g. 8pole Not available for 9- and 10-pole systems. 6

7 158 JOINT MATERIAL HANGERS Joint cap, self-locking Ready installed 92 Weight kg MVMD 0, Joint cap, self-locking Ready installed Weight kg MVMS 0, Sliding hanger M 8 Fixpoint hanger max. 35 M max Fixpoint hanger mounted to Powerail section 71 Sliding hanger mounted to Powerail section 64 Weight kg MGA 0, Weight kg MFN 0,

8 19 12 BRACKETS EHK standard version View w/o I-beam 32 L 25 Attachment bracket max D Ø 13 M 8 Claw suitable for D = 6-15 mm 45 claw X B R D R = 10 x D X View w/o I-beam claw L 25 max. 48 D Ø 13 Attachment bracket 30 M 8 32 Claw suitable for D = mm 45 B EHK small claw version, D = max. 10 mm Attention: Make sure that hoist wheels have enough clearance. Use small claw if necessary. Check -beam dimension D. rail of EHK is identical to type S 1, Cat. 8a. X L B max Weight for standard with small mm mm mm kg version claw version EHK EHK EHK EHK EHK EHK EHK EHK Select next larger size bracket when your -beam dimension B is more than 170 mm. 8

9 END SECTIONS END FEEDS End sections 0,3 m long End feeds Housing empty 156 End feeds come loose w/o Powerail. They can be mounted at either end. Termination by others, using cable lugs and M 5 studs. Execution Weight kg MSED/L left 0, MSED/R right 0, Cable gland Weight kg dimensions see p. 18 MKED 6-8/ HS 0, M 25 & M 40 MKED 9-10/ HS 1, MKED 6-8/ 40 SS 0, M 25 MKED 9-10/ 40 SS 0, End cap End feeds pole 9-10 pole End feeds come loose w/o Powerail. They can be mounted at either end. Termination by others, using cable lugs and M 5 studs. Execution Weight kg MSES left & right 0, Cable gland Weight kg dimensions see p. 18 MKES 6-8/ HS M 25 and M 40 0, MKES 6-8/ 40 SS M 25 0,

10 19 12 LINE FEEDS with terminal box; incl. 1 m Powerail Cable gland (dim. see p. 18) Weight kg Termination by others using cable lugs and M 8 studs. 83 MNGD 6/ HS 2, MNGD 7/ HS M 50 2, MNGD 8/ HS and 2, MNGD 9/ HS M25 2, MNGD 10/ HS 2, MNGD 6/ HS 2, MNGD 7/ HS M50 2, MNGD 8/ HS and 2, MNGD 9/ HS M25 2, MNGD 10/ HS 2, MNGD 6/ 40 SS 2, MNGD 7/ 40 SS 2, MNGD 8/ 40 SS M 25 2, MNGD 9/ 40 SS 2, MNGD 10/ 40 SS 2, Termination by others using cable lugs and M 8 studs. 83 Cable gland (dim. see p. 18) Weight kg MNGF 6/ 40 HS 3, MNGF 7/ 40 HS 3, MNGF 8/ 40 HS 3, MNGF 6/ 60 HS M50 3, MNGF 7/ 60 HS and 3, MNGF 8/ 60 HS M 25 3, MNGF 6/100 HS 3, MNGF 7/100 HS 4, MNGF 8/100 HS 4, MNGF 6/ 40 SS 3, MNGF 7/ 40 SS M 25 3, MNGF 8/ 40 SS 3, Cable gland (dim. see p. 18) Weight kg Termination by others using cable lugs and M 8 studs. 83 MNGS 6/ 40 HS 3, MNGS 7/ 40 HS 3, MNGS 8/ 40 HS 3, MNGS 6/ 60 HS M 50 3, MNGS 7/ 60 HS and 3, MNGS 8/ 60 HS M 25 4, MNGS 6/100 HS 3, MNGS 7/100 HS 4, MNGS 8/100 HS 4, MNGS 6/140 HS 4, MNGS 7/140 HS 4, MNGS 8/140 HS 4, MNGS 6/160 HS M50 3, MNGS 7/160 HS and 4, MNGS 8/160 HS M25 4, MNGS 6/200 HS 4, MNGS 7/200 HS 4, MNGS 8/200 HS 5, MNGS 6/ 40 SS 3, MNGS 7/ 40 SS M 25 3, MNGS 8/ 40 SS 3,

11 LINE FEEDS for single core cable connection, incl. 1 m Powerail section Cable gland (dim. see p. 18) Weight kg MNLD 6/ HS 2, MNLD 7/ HS M 25 for PE, 2, L1, L2, L3, MNLD 8/ HS M 25 for 1-4 2, MNLD 9/ HS M 25 for 9/10 2, MNLD 10/ HS 2, MNLD 6/ HS 2, MNLD 7/ HS M 25 for PE, 2, L1, L2, L3, MNLD 8/ HS M 25 for 1-4 2, MNLD 9/ HS M 25 for 9/10 2, MNLD 10/ HS 2, MNLD 6/ 40 SS 2, MNLD 7/ 40 SS 1 x M 25 2, MNLD 8/ 40 SS 2, MNLD 9/ 40 SS 2, x M 25 MNLD 10/ 40 SS 2, Termination by others using cable lugs and M 8 studs. 50 Cable gland (dim. see p. 18) Weight kg MNLF 6/ 40 HS 3, MNLF 7/ 40 HS 3, MNLF 8/ 40 HS 3, MNLF 6/ 60 HS M 25 for PE, 3, MNLF 7/ 60 HS L1, L2, L3, 3, MNLF 8/ 60 HS M 25 for 1-4 3, MNLF 6/100 HS 3, MNLF 7/100 HS 3, MNLF 8/100 HS 3, MNLF 6/ 40 SS 3, MNLF 7/ 40 SS M25 3, MNLF 8/ 40 SS 3, Termination by others using cable lugs and M 8 studs. 50 Cable gland (dim. see p. 18) Weight kg MNLS 6/ 40 HS 3, MNLS 7/ 40 HS 3, MNLS 8/ 40 HS 3, MNLS 6/ 60 HS M 25 for PE, 3, MNLS 7/ 60 HS L1, L2, L3, 3, MNLS 8/ 60 HS M 25 for 1-4 3, MNLS 6/100 HS 3, MNLS 7/100 HS 3, MNLS 8/100 HS 4, MNLS 6/140 HS 3, MNLS 7/140 HS 4, MNLS 8/140 HS 4, MNLS 6/160 HS M 25 for PE, 4, MNLS 7/160 HS L1, L2, L3, 4, MNLS 8/160 HS M 25 for 1-4 4, MNLS 6/200 HS 4, MNLS 7/200 HS 4, MNLS 8/200 HS 4, MNLS 6/ 40 SS 3, MNLS 7/ 40 SS M 25 3, MNLS 8/ 40 SS 3, Termination by others using cable lugs and M 8 studs

12 19 12 CONTACT SECTIONS, TURNTABLES AND SWITCHES Contact section Turntable Sliding switch KSG Please submit drawings of transfer applications. Specify dimensions a, b, c, R and angle. ( max. 50 ). 12 Contact sections must not be activated before collectors are fully engaged. Flexible support type tow arms MFM (see page 17) for collectors are essential with contact sections.

13 TRANSFER FUNNELS TRANSFER GUIDES incl. sections Transfer funnels Energize Powerail only after current collector brushes have full contact with copper conductors. Do not use transfer funnel like a switch. B 140 ± 10 Weight kg L.H. version R.H. version MTN 6/ HS 2, MTN 7/ HS 2, MTN 8/ HS 2, MTN 9/ HS 2, MTN 10/ HS 2, MTN 6/ 40 SS 2, MTN 7/ 40 SS 2, MTN 8/ 40 SS 2, MTN 9/ 40 SS 2, MTN 10/ 40 SS 2, horizontal offset ± 15 mm vertical offset + 10 mm short lip for & 525 for B L.H. version w/o cond. B short lip R.H. version 110 Transfer guides, straight 165 B Weight kg L.H. version R.H. version MUN 6/ HS 2, MUN 7/ HS 2, MUN 8/ HS 2, MUN 9/ HS 2, MUN 10/ HS 2, MUN 6/ 40 SS 2, MUN 7/ 40 SS 2, MUN 8/ 40 SS 2, MUN 9/ 40 SS 2, MUN 10/ 40 SS 2, horizontal offset ± 8 mm vertical offset ± 3 mm short lip B L.H. version 70 w/o cond. 350 for & 375 for B short lip R.H. version 75 Transfer guides, oblique 205 B Weight kg L.H. version R.H. version MUNS 6/ HS 2, MUNS 7/ HS 2, MUNS 8/ HS 2, MUNS 9/ HS 2, MUNS 10/ HS 2, MUNS 6/ 40 SS 2, MUNS 7/ 40 SS 2, MUNS 8/ 40 SS 2, MUNS 9/ 40 SS 2, MUNS 10/ 40 SS 2, horizontal offset ± 8 mm vertical offset ± 3 mm short lip Details of oblique cut per system layout. B L.H. version 350 for & 375 for B R.H. version 110 w/o cond. short lip 75 Complete types e.g. MUN 6/ HS L.H.-version: MUN 6/ L HS

14 19 12 ANTI-CONDENSATION SECTIONS incl. 1 m section Weight kg MBD- HS 2, MBD- SS 2, »XX«X: See page 2 for different versions of Powerail ends The anti-condensation section consists of 1 m Powerail with air circulation holes, covered by a protection hood. The anti-condensation section is to be used where Powerails are passing from indoor to outdoor, preventing condensation of hot air, escaping from the indoor section, in the cooler outdoor section. Weight kg MBF- 6/ 40 HS 3, MBF- 7/ 40 HS 3, MBF- 8/ 40 HS 3, MBF- 6/ 60 HS 3, MBF- 7/ 60 HS 3, MBF- 8/ 60 HS 3, MBF- 6/100 HS 3, MBF- 7/100 HS 3, MBF- 8/100 HS 3, MBF- 6/ 40 SS 3, MBF- 7/ 40 SS 3, MBF- 8/ 40 SS 3, Feeding No extra feeds required as the Powerail is not interrupted. Collectors No extra collectors required. Installation The anti-condensation section is to be placed outdoors, close to the transfer point. Weight kg MBS- 6/ 40 HS 3, MBS- 7/ 40 HS 3, MBS- 8/ 40 HS 3, MBS- 6/ 60 HS 3, MBS- 7/ 60 HS 3, MBS- 8/ 60 HS 3, MBS- 6/100 HS 3, MBS- 7/100 HS 3, MBS- 8/100 HS 3, MBS- 6/140 HS 3, MBS- 7/140 HS 3, MBS- 8/140 HS 4, MBS- 6/160 HS 4, MBS- 7/160 HS 4, MBS- 8/160 HS 4, MBS- 6/200 HS 4, MBS- 7/200 HS 4, MBS- 8/200 HS 4, MBS- 6/ 40 SS 3, MBS- 7/ 40 SS 3, MBS- 8/ 40 SS 3, For longer runs use expansion joint section (see page 15)

15 EXPANSION JOINT SECTIONS incl. 1 m section Weight kg MDD- 6-8 HS 1, MDD- 9 HS 1, MDD- 10 HS 1, MDD- 6-8 SS 1, MDD- 9 SS 1, MDD- 10 SS 1, Dim.»a«max. 70 mm a a 500 Expansion section Typ MDD is required to compensate difference in expansion between insulated housing and copper conductors. The expansion joints are used if the Powerail length between feeds, curves, transfer guides and other fix points is exceeding 10 m. Max. length to temperature differences t 20 C = 70 m t 40 C = 35 m t 80 C = 17 m t 30 C = 45 m t 60 C = 23 m Longer runs or higher differences in temperature require several expansion joints. Additional feed points and collectors are not necessary as the conductor rail is not electrically separated. Weight kg MDS- 6/ HS 5, MDS- 7/ HS 5, MDS- 8/ HS 5, MDS- 6/ HS 5, MDS- 7/ HS 6, MDS- 8/ HS 6, MDS- 6/ 40 SS 5, MDS- 7/ 40 SS 5, MDS- 8/ 40 SS 5, »X«500 Dim.»a«max. 100 mm»x«see page 2 for finish of ends a a Expansion joint section MDS is required to compensate difference in expansion between insulated housing and supporting structure: The expansion joints are used if the powerail length between feeds, curves, transfer guides and other fix points is exceeding 20 m. Max. length to temperature differences: t 90 C ( 30 C to + 60 C) one expansion joint section per 100 m, and so on each 100 m. 500»X«Additional feed points and collectors are not necessary as the conductor rail is not electrically separated. 15

16 COLLECTORS DOUBLE COLLECTORS Collectors 223 Connecting cables: for power line: cable 1 4 x 6 mm 2 cable 2 x 1,5 mm 2 for control line: cable 1 x 2,5 mm 2 (two cables for 8-pole and more) cable 2 cable 1 Ampacity at 60% ED A No. of poles ø of connecting cables mm cable 1 cable 2 Travelling speed normal Transfer m/min. m/min. Weight kg MSW 6/50-1 HS ,0 7, , MSW 7/50-1 HS ,0 7, , MSW 8/50-1 HS ,0 8, , MSW 9/50-1 HS ,0 9, , MSW 10/50-1 HS ,0 10, , MSW 6/25-1 ST , , MSW 7/25-1 ST , , MSW 8/25-1 ST ,0 11, , MSW 9/25-1 ST ,0 11, , MSW 10/25-1 ST ,0 11, , Collectors for higher speeds on request. For curves use single collectors only. Connecting cable 1 m, longer cable available. Example of ordering collector with 2 m cable for collector MSW 6/50-2 HS Double collectors 533 Connecting cables: for power line: cable 1 4 x 6 mm 2 cable 2 x 1,5 mm 2 for control line: cable 1 x 2,5 mm 2 (two cables for 8-pole and more) 310 cable 2 cable 1 Ampacity at 60% ED A No. of poles ø of connecting cables mm cable 1 cable 2 Travelling speed normal Transfer m/min. m/min. DMSW 6/100 S-1 HS ,0 7, , DMSW 7/100 S-1 HS ,0 7, , DMSW 8/100 S-1 HS ,0 8, , DMSW 9/100 S-1 HS ,0 9, , DMSW 10/100 S-1 HS ,0 10, , DMSW 6/50 S-1 ST , , DMSW 7/50 S-1 ST , , DMSW 8/50 S-1 ST ,0 11, , DMSW 9/50 S-1 ST ,0 11, , DMSW 10/50 S-1 ST ,0 11, , Connecting cable 1 m, longer cables available. Example of ordering double collectors with 2 m cable for collector DMSW 6/100-2 HS Weight kg 16

17 50 ±10 TOW ARMS Installation to tube for single and double collectors tube Ø 34 by others up to middle of tube Weight kg MGR 0, MGR/K 0, Installation to plain surface for single and double collectors 257 Ø Weight kg MGF 0, MGF/K 0, For single collectors flexible support type for systems with transfer funnels MTN slotted hole 9 x Weight kg MFM 1, max. horizontal offset ± 15 mm, max. vertical offset ± 10 mm. Flexible tow arm configuration max. horizontal offset ±15 mm max. vertical offset ±10 mm ca. 82 tread slotted hole 9 x 18 ca

18 19 12 FLAT COPPER AND STAINLESS STEEL STRIPS Max. length of 11 mm wide strips for shaft I Weight Cu Weightt Inox kg/m kg/m. 11 mm 2 max. length (m) x 1 mm (40 A) of cassette A B C 0, , Max. length of 13 mm wide strips for shaft II Weight Cu Weight Inox kg kg. 10 mm 2 max. length (m) x 0,8 mm (40 A) of cassette A B C 17 mm 2 max. length (m) x 1,3 mm (60 A) of cassette A B C 26 mm 2 max. length (m) x 2 mm (100 A) of cassette A B C 33 mm 2 max. length (m) x 2,5 mm (140 A) of cassette A B C 42 mm 2 max. length (m) 25 60(80) (120) 13 x 3,2 mm (160 A) of cassette A B C 0, , , , , , Shaft I Shaft II Shaft I 51 mm 2 max. length (m) 22 50(65) (100) 0, x 3,9 mm (200 A) of cassette A B C Longer lengths to be connected with bolted joints. Use bolted joints and possibly expansion sections for bigger lengths than shown in the table. In this case installation by Vahle experts is recommended, especially for copper cross section of 42 mm 2 and 51 mm 2. Consult factory for proper layout. With straightening tool (see page 19). Cable glands for feeds Cable glands for cable-ø capacity A page in mm execution: D/F/S M 25 and M and HS 9 M SS 9 M 25 and M and HS 10 M 25 and M and HS 10 M SS 10 M 25 for PE and L1/L2/L HS 11 M 25 for 1 4 and 9/ HS 11 M pole SS 11 18

19 ASSEMBLING TOOLS Copper cassettes Arrangement of laying mechanism Execution Dim.» X«Dim.» Y«Weight kg of cassette A EZK 1 single , B EZK 2 single , C EZK 3 single , A DEZK 1 double , B DEZK 2 double , C DEZK 3 double , of copper cassette depends on copper cross section and system length (see page 18). X Y Single copper casstte type EZK Straightening tool (required from strip sections 26 mm 2 upwards) Weight kg RV 1, Double copper cassette type DEZK Conductor threading tools and installation carrier appr. 5 m long Typ EZR 6-8 Weight kg EZR 6-8 for conductors inside housing, shafts I & II EZR 9/10 for conductors outside housing, shafts I (not shown) Installation carrier (for sealing strip; not shown)

20 19 12 SECTIONALIZING HEATING SYSTEM Sectionalizing Illustration shows insulated section 30 mm insulated section Please indicate which conductors are to be interrupted (see page 4). Factory assembled. 5 mm air gap 30 mm insulated section MSTL MSTI MSTL MSTI MSTL MSTI MSTL MSTI MSTL MSTI MSTL MSTI MSTL MSTI MSTL MSTI MSTL MSTI MSTL MSTI Heating system Arrangement of heating cables Heating systems are recommended for outdoor Powerail installations with icing conditions and for extremely humid environments. The heating is accomplished by heating conductors being arranged inside the Powerail housing as shown in the adjacent drawing. Attention! Heating system to be used only when temperature is + 5 C or lower. Selection of heating cables N (W/m) N (W/m) 400 V Composition of heating cable: V H 3,00 H 2,00 H 1,44 H 3,00 H 2,00 H 1,44 Conductor: material resistor CrNi, stranded Insulation: PTFE-(Teflon) tinned copper braid Sheath: PTFE-insulation OD: 3,7 mm - 4,3 mm Layout of one heating section with feeder boxes at both ends Temperature control units on request. H 1,00 H 0,81 H 0,60 H 0,48 H 1,00 L (m) H 0,38 H 0,81 H 0,60 H 0, L (m) H 0,32 H 0,20 H 0,15 Determine a heating cable between 24 and 30 watt/m capacity. For longer runs, not covered by the adjacent diagrams, divide the length of the system into two or more heating sections. Supply lower voltage via a transformer in case of shorter heating sections. Heating capacity [Watt/m]: N = U = supply voltage [Volt] R = resistance of heating cable [Ohm/m] L = length of heating section [m] Wire resistance data: heating cable: H 0,15 0,15 Ohm/m heating cable: H 0,20 0,20 Ohm/m heating cable: H 0,32 0,32 Ohm/m heating cable: H 0,38 0,38 Ohm/m heating cable: H 0,48 0,48 Ohm/m heating cable: H 0,60 0,60 Ohm/m heating cable: H 0,81 0,81 Ohm/m heating cable: H 1,00 1,00 Ohm/m heating cable: H 1,44 1,44 Ohm/m heating cable: H 2,00 2,00 Ohm/m heating cable: H 3,00 3,00 Ohm/m tolerance ± 2,5 % Example for ordering heating system for 60 m Powerail 1) 122 m heating cable type H 1,44 (incl. safety lengths) Supply voltage 400 V, 2 heating sections Heating capacity per above diagram approx. 2 x 31 W/m with 60 m 2 x 31 W/m approx W = 3,72 kw. 2) Two terminal boxes for heating system 3) Four sets of connecting material 4) Threading tool for heating cable All switches, fuses, cable etc. by others! U 2 R L 2 20

21 EXAMPLE FOR ORDERING SPARE PARTS System length 64 m X = 300 mm end section = expansion section for copper conductor for (w/o cond.). Not for and. Example for ordering System length 64 m MKL 8/100-HS (see page 5) Qty. Description 15 Flat copper strip 4 m -4 HS Flat copper strip 3 m -3 HS Powerail 4 m 8/100-4 HS /100-4 HS Powerail 3 m 8/100-3 HS /100-4 HS Line feed MNGD 8/ HS MNGF 8/100-HS MNGS 8/100-HS End section, right MSED/R End section, left MSED/L End caps MSES MSES Joint caps MVMD Joint caps MVMS MVMS Fixpoint hanger MFN MFN MFN Sliding hangers MGA MGA MGA m Flat copper strip, 3 coils à 65 m 26 mm m Flat copper strip, 1 coil à 65 m 17 mm m Flat copper strip, 2 coils à 65 m 10 mm m Flat copper strip, 2 coils à 65 m 11 mm Collector MSW 8/50-1 HS MSW 8/50-1 HS MSW 8/50-1 HS Tow arm MGR MGR MGR Copper cassette EZK Laying mechanism RV Conductor threading tool EZR Spare parts for Powerail Plug in joint for (11 mm Cu; 40 A) Plug in joint for (13 mm Cu; A) Bolted joint for (11 mm Cu; 40 A) Bolted joint for (13 mm Cu; A) Joint Cap for transfer guide and transfer funnel, pair (, and ) Sealing strip Spare parts for collectors Carbon brush phase, incl. brush holder (lateral) Carbon brush PE, incl. brush holder (lateral) Carbon brush 7th and 8th pole (above) Carbon brush 9th and 10th pole (below) Carbon pressure spring, standard for phase and PE Carbon pressure spring, reinforced for phase and PE Throat part Trolley wheel Connecting bar for double collector

22 19 12 QUESTIONNAIRE CUSTOMER ATTENTION OF ADDRESS TELEPHONE TELEFAX INTERNET 1. of crane/machine to be electrified 2. Voltage Volts~/=: Phases, c/s 3. Length of conductor system 4. Number of power conductors: control lines: ground: neutral: 5. Indoor Outdoor 6. Special site conditions (humidity, dust, chemical influences etc.) 7. Temperature conditions C min. C max. 8. Number of cranes/machines supplied by the one system 9. Ampere load of each crane/machine (use table on page 30) 10. Permissible voltage drop 11. Number and position of feed points 12. Number and position of isolating sections 13. Installation position envisaged 14. Brackets required (see page 8) yes no c/c distance beam/powerail: 15. Max. travelling speed of machinery 16. Other important data: 22 Please submit prints or sketches, also for curved tracks.

23 QUESTIONNAIRE To the nearest local VAHLE agency: Date: Motordata Power kw Crane 1 Nominal current Starting current A cos ϕ N % ED A cos ϕ A of motor Power kw Crane 2 Nominal current Starting current A cos ϕ N % ED A cos ϕ A of motor Hoist motor Auxiliary hoist Long travel Cross travel Motordata Power kw Crane 3 Nominal current Starting current A cos ϕ N % ED A cos ϕ A of motor Power kw Crane 4 Nominal current Starting current A cos ϕ N % ED A cos ϕ A 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: In accordance with our company s policy of continued improvement, we reserve the right to amend specifications and details at any time. 23

24 Catalog No. 4c/E 2005 MANAGEMENTSYSTEM DQS certified in accordance with DIN EN ISO 9001:2000 OHSAS (Reg. no 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 30 U 40 2 b Insulated Conductor Systems U 15 U 25 U 35 2 c Aluminium Enclosed Conductor Systems LSV LSVG 3 a Powerail Enclosed Conductor Systems KBSL KSL KSLT 4 a Powerail Enclosed Conductor Systems VKS VKL 4 b Powerail Enclosed Conductor System 4 c Powerail Enclosed Conductor System KS 10 4 d Powerail Enclosed Conductor System KBH 4 e 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 Printed in Germany DS /05 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/

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