bus bar selection 20338744_0606073419

Technical data Demag Compact Line DCL

42211044.eps

070606 EN/PDF 070606

203 387 44

714 IS 962.2

Manufacturer

Demag Cranes & Components GmbH Drives P.O. Box 67 · D-58286 Wetter Telephone (0 23 35) 92-0 · Telefax (0 23 35) 92 72 98 E-mail [email protected] www.demagcranes.com

2

1 1.1 1.2

General Symbols DCL installation

3 3 3

2 2.1 2.1.1 2.1.2

Design and installation notes Definitions Arm’s length Protection against indirect contact

4 4 4 4

3 3.1 3.1.1 3.1.2 3.1.3

5 6 6 7

3.2

Calculating and selecting the conductor cross-section Calculating the conductor cross-section Calculation method Graphical method DCL maximum permissible current I35 [A] for an ambient temperature of 35°C DCL basic structure

4

General layout

10

5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.3

Suspension arrangements DCL suspension with C-rail bracket Sliding suspension/fixed suspension Mounting and operating dimensions DCL suspension with M8 threaded pin Mounting and operating dimensions, sliding suspension/fixed suspension Further fitting information

11 11 11 12 14 14 14

6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.8.1 6.9 6.9.1 6.9.2 6.10 6.10.1 6.11

Technical data DCL straight section 4, 5, 6 und 7 poles DCL curved section 4, 5, 6 und 7 poles DCL line power feed 4, 5, 6 und 7 poles DCL connector end cap as end power feed DCL connector end cap as track end cap End cap Entry/transfer section DCL current collector trolley 4, 5, 6 und 7 poles Current collector technical data Towing arm for DCL current collector trolley Standard towing arm Towing arm for free transfer sections Profile sealing lip Assembly tool for fitting the profile sealing lip Isolating section

15 15 17 19 21 22 23 24 26 27 28 28 29 30 30 31

7 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.2 7.2.1

Component parts Straight sections and accessories Component set for sliding suspension with C-rail bracket Component set for sliding suspension with threaded pin Component set for conductor connector Isolating sections Current collectors and current collector trolleys Sliding contact set

32 32 32 32 32 32 33 33

8

Resistance to acids, chemicals and fuels

34

Fax: Enquiry Fax: Order

35 36

8 9

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Table of contents

1

General

1.1 Symbol description

The following symbols and recommendations indicate potential safety hazards or causes of damage or provide useful information. Warning against dangerous electrical voltage Contact with live parts can result in immediate death. Protective covers (e.g. covers and enclosures) marked with this sign may only be opened by qualified electricians. Before opening, all relevant operating, control, feed or other voltages must be disconnected. Operating hazard for the installation This symbol in the operating instructions indicates all warnings which, if not complied with, may result in damage to the product.

1.2 DCL installation

The DCL is a conductor bar system with PVC-housing. The uniform housing can be effected with 4, 5, 6 or 7 conductors / poles acc. to the customer’s requests. The standard material for conductors is copper. Alternatively, a stainless steel-plated copper bar is available. The special characteristic is the insensitive stainless steel-contact surface compared to copper. The stainless steel-plated copper bar is predestined for the use near the sea, outdoors, with chemicals or for systems with low application time. An oxidising of the sliding contact surface is excluded. The available conductor bar cross sections and conductor materials can be found in the table below.

Conductor line Enclosure material

PVC

Standard length

mm

4000

mm

1000 2 ) / 2000

Number of conductors / poles

4...7

Distance between suspensions max. 2 )

V AC

Voltage UN Size 1 )

24 bis 690 35

60

100

140

200

A

64

78

100

140

160

mm²

10

15

25

38

56

Conductor material copper

X

X

X

X

X

Conductor material stainless steel plated5)

X

-

-

-

-

Permissible current (100% CDF to 35 °C) 1 ) Conductor cross section

Ambient temperature / Enclosure temparature

°C

-30 bis +70

Protection class DIN VDE 0470 T.1/EN 60529

IP-Code

IP 23 / IP 24 with sealing lip

Curve section minimum radius

$ 800 mm

mm

Fire protection

UL94 / VO; not halogen-free

Current collector trolley Number of poles

4...7

Sliding contact material Rated current IN (80% ED)

graphite

40 A

20 A

silver-graphite 20 A

Connection cross section for power connection (1, 2, 3, 4)

max. mm²

Connection cross section for control cable (5, 6, 7)

max. mm²

2,5

mm

2000

Connecting cable length (standard) 4 ) Fuse protection max. Travel speed max.

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bronze

6

4

A

100

m/min

100 3 ) / 200

1) The voltage drop must be checked for installations with large power feed sections and high currents. Refer to calculation from chapter 3. 2) With single-sided thermal effect. 3) For straight sections with entry/transfer section. 4) Other line lengths possible. 5) Copper conductor 10 mm2 on the contact surface plated with stainless steel. Applications and further notes cf. chapter 6.

3

2

Design and installation notes

Please note:

Conductor lines must be operated in accordance with generally accepted engineering principles. Ensure compliance with DIN VDE/EN, SEV, CSA and UL regulations. We make special reference to the DIN VDE regulations, particularly to DIN VDE 0100.

Of the many regulations, we refer to the following definitions: see DIN VDE 0106, Part 200.

2.1 Definitions 2.1.1 Arm’s length

Arm’s length is the area which a person’s hand may reach in all directions from normal locations without any special equipment. Measured from the position where a person is standing, this area ranges up to at least 2,5 m upwards and at least 1,25 m to the side and downwards (see DIN 31 001 Sheet 1). Wherever large or long objects which are not insulated for the operating voltage are moved, the minimum arm’s length must be correspondingly increased.

2.1.2 Protection against indirect contact

Protection against direct contact constitutes all measures to protect people from hazards resulting from contact with live parts of electrical equipment. This may be partial or full protection. Partial protection only provides protection against accidental contact. Protection against accidental contact does not mean any protection against deliberate contact.

4

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Enclosure type IP 2X to DIN VDE 0470 Part 1 offers protection against accidental contact. Complete protection starts from IP 5X to DIN VDE 0470 Part 1.

3

Calculating and selecting the conductor cross-section

Voltage drop 1. and permissible current 2. must be considered when calculating power supply cross-sections. 1. - Calculate the cross-section considering the max. permissible voltage drop of 2,5 % for crane runways + 2,5 % for crane bridge. - The relevant value is the starting current · cosϕA of the largest motor + the rated current · cosϕN of the next smaller motor. - The currents must be added for motors connected in parallel. The calculated cross-sections must be halved for power supplies to solo hoists. 2. - Calculate the cross-section considering the max. permissible current for cables to DIN VDE 100 Part 430/523. - The relevant value is the sum of all rated currents of all drives. The currents indicated in diagram 1, section 3.1.2 must not be exceeded. Permissible voltage drop The voltage drop is determined by current IG. Current IG results from adding the starting - (IA · cosϕA) and rated currents (IN · cosϕN) (see table 1 below). The conductor cross-section may be determined according to the calculation method described in section 3.1.1 or diagram 1, section 3.1.2. Table 1 indicates the number of consumers to be considered for calculating IG depending on the number of cranes fed by a conductor line. Table 1 Number of cranes fed by a conductor line

Of all cranes taken together (in order of output) 1st motor

2nd motor

3rd motor

4th motor

1

I A · cos ϕA

I N · cos ϕN

-

-

2

I A · cos ϕA

I N · cos ϕN

I N · cos ϕN

-

3

I A · cos ϕA

I A · cos ϕA

-

-

4

I A · cos ϕA

I A · cos ϕA

I N · cos ϕN

-

5

I A · cos ϕA

I A · cos ϕA

I N · cos ϕN

I N · cos ϕN

For double drive arrangements correspondingly: 2 · IA · cosϕA or 2 · IN · cosϕN.

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Exception:

For double hoist units with delayed starting IA · cosϕA + IN · cosϕN.

5

3.1 Calculating the conductor cross-section Abbreviations used in the equations: A

= Conductor cross-section of the DCL

[mm²]

L

= cable length

[m]

I

= starting current (IA · cosϕA) or rated current (IN · cosϕN)

[A]

IG

= sum of the currents according to table 1

[A]

f

= frequency in Hertz

[Hz]

χ

= conductibility (for χCu = 56)

[m²/Ωm]

∆U = permissible voltage drop

[V]

U

[V]

= voltage in volts

1. Conductor cross-section of the DCL

2. Required conductor length

A

=

L1 =

[mm2]

∆U x χ

∆U x χ x A

X

f2

I2

4. Conversion for conductor crosssection A2 for non-standard conductor length L2

A2 =

5. Permissible voltage drop

∆U = 2,5 % = 10 V (for 400 V)

=

6. Conversion from 400 V, 50 Hz to a new voltage and frequency

[m]

f1

1,73 x IG

3. Conversion for starting current IA · cosϕA or rated current IN · cosϕN fornon-standard voltage U

∆U =

6

1,73 x L x IG

U 1 x I1

[A]

U2

L 2 x A1

[mm2]

L1

U x 2,5 % [V] 100 %

400 V Inew = Iold X

X Unew

fnew 50 Hz

[A]

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3.1.1 Calculation method

3.1.2 Graphical method

Calculating the conductor cross-section for the permissible voltage drop. The DCL conductor line cross-section and/or voltage drop may be reduced by the position and quantity of power feeds.

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Diagram 1

for ∆ 42226444.eps

7

Check the maximum permissible current for the conductor cross-section as a function of the cyclic duration factor (CDF) at an ambient temperature of 35 °C.

3.1.3 DCL maximum permissible current I35 [A] for an ambient temperature of 35°C

For other ambient temperatures, the current (IJ) must be calculated with the conversion factor (fu) according to the table below. The same or the next largest conductor cross-section must be selected.

Diagram 2

300

I35 [A]

292

275

Permissible current [A] at 35°C ambient temperature

250

270 253 241

238 226

225

225

216

211 200

200

194 178

175 150

184

207 177

165

157

125

191

155 143 133

129 118

109

100

124 102

147 117 96

139 111 91

133 106 87

200 171

128

83

25

30

35

40

45

50

55

60

187

165

123

101 97

75 50

193

80

65

161

181

176

172 167 163 160 DCL 200 (56mm 2 ) 156 152 149 146 142 140 DCL 140 (38mm 2 )

119 115 111 108 105 103 94 91 88 85 83 80 80 77 74 72 70 68 66

70

75

80

85

90

95

100 100 DCL 100 (25mm 2 ) 78 64

DCL 60 (15mm2 ) DCL 35 (10mm2 )

100

ED [%] Cyclic Duration Factor 42226544.eps

Calculating the maximum permissible current Iϑ [A] for other ambient temperatures ϑ [°C]

Conversion factor

fu

Maximum permissible current

8

20

25

30

35

40

45

50

55

60

65

1,20

1,14

1,07

1,00

0,92

0,84

0,74

0,64

0,51

0,35

Iϑ = I35 · fu

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Ambient temperature

3.2 DCL basic structure

Straight section, section 6.1

Standard length, section 6.1

Remaining length < 4 m, section 6.1

Curve section, section 6.2

Profile sealing lip, section 6.10

Connector cap / End power feed, section 6.5

Line power feed, section 6.3

End cap, section 6.6

Sliding suspension / Fixed suspension, section 5.1.1 C-rail mounting bracket, section 5.1

Threaded pin bracket, section 5.2 Entry funnel / Transfer funnel, section 6.7

Isolating section, section 6.11

Current collector trolley, section 6.8

Model code:

Bronze contact 40 A, section 6.8.1 1)

Graphite contact 20 A, section 6.8.1 1)

Standard towing arm, section 6.9.1

Transfer towing arm, section 6.9.2

DCL - GS 4 - 60 - PE - 4000

(Example for ordering a straight section) Section - installation length [mm] With protective earth conductor Size Number of poles Component (GS = straight section) Line Compact

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Demag

1) The sliding contacts of the control lines (poles 5, 6, 7) optionally are also available as silver-graphite-sliding contact. Technical data and other notes cf. chapter 6. 9

4

General layout

400

2000

2000

1600

EK

A AK

2000

400 3) min.250

GA GA

GA B S

4000

65

2000

2000 1600

4

4003) min.250

2000 1600

1)

GA

GA

FA

5

S

3

GA

1600

400

400 3) min.250

GA

GA

S 4000

4000

2000

2000

2000

400 3) min.250

GA

AK

EK

S 4000

4000

Clearance ≥ 150

Clearance ≥ 250 6

1 2

7 or 8

8

In place of an AK connector end cap an entry/transfer funnel may be fitted. To do this, an additional suspension must be fitted at 200 mm.

Section A - B Steel structure etc.

(PE)

or 7

42109645.eps

Item

Designation

1

DCL straight section

GS

Dimensions 4000 mm R $ 800 mm

2

DCL curve section

BS

3

Joint connector

S

4

Sliding suspension

GA

5

Fixed suspension

FA

6

Line power feed

ES

7

Connector end cap as end power feed Connector end cap as track end cap

AK

End cap

EK

8

4000 mm

Current collector trolley 2)

Profile rib (orientation rib)

Towing arm 2) Towing arm for transfer sections 2) Entry / transfer funnel 2)

42106144.eps

Please note In place of an AK connector end cap, • a track extension, • an entry section, • or a transfer section may be fitted. DCL installations - with a line power feed are supplied with an end cap item (8) at both ends. A track cannot be extended when an end cap is fitted. An installation with an end cap is exactly 74 mm shorter than the rated length. On request also available with connector end cap as track end cap so that the track can be extended. An installation with a connector end cap is exactly 130 mm longer than the rated length. Allow for clearance to connect the end power feed (approx. 250 mm).

10

1) When large cable cross-sections (from size PG42) are used with a DCL section with a line power feed, a third additional sliding suspension must be fitted close to the power feed enclosure. 2) Not shown 3) The 400 mm dimension must not be exceeded.

20338744.p65/070606

- with an end power feed are supplied with a connector end cap (7) at both ends.

5

Suspension arrangements

5.1 DCL suspension with C-rail bracket 5.1.1 Sliding suspension/fixed suspension Attachment to upper flange I

42211444.eps

Flange clamp

Part no.

Clamping range 8 to 16 mm Clamping range 16 to 30 mm

974 548 44 974 549 44

Adjusting range

min. 120, max.180

25 or 40

42211144.eps

Attachment to lower flange II

C-rail 40 x 25 min. 100 max. 165 C-rail 40 x 40 min. 90 max. 150

Adjusting range

42211544.eps

42206244.eps

25 or 40

20338744.p65/070606

Part no. for C-rail 40 x 25

42226044.eps

L=

300

968 427 44

L=

500

850 184 44

L=

1000

974 554 44

L=

600

974 550 44

L=

1270

650 275 44

L=

700

974 551 44

L=

1500

650 274 44

L=

920

974 553 44

L=

1820

958 521 44

L = 6000

213 600 44

L = 6000

213 601 44

Part no for C-rail 40 x 40

11

42106344.eps

min. max.

30 90

Adjusting range

5.1.2 Mounting and operating dimensions

42211344.eps

C-rail 40 x 25 min. 10 max. 75 C-rail 40 x 40

Adjusting range

42206344.eps

12

42211244.eps

20338744.p65/070606

min. 0 max. 60

Mounting arrangement I Fixed point 1)

C-rail clamp section Mounting bracket

42106344.eps

Mounting arrangement II

Sliding supension

C-rail clamp section Fixed point 1)

Mounting bracket

42211344.eps

Component set for sliding suspension with C-rail bracket

Bestell-Nr.

1 off C-rail clamp section 1 off mounting bracket

876 638 44

1 off sliding suspension

The following information is required for ordering C-rails and flange clamps to fit DCL to I-beams: • C-rail type and length (see table on page 12). • Flange clamps for Ι-beams (see below).

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Girder width

Clamping range

Part no.

Ι 160 - Ι 400

8 - 16 mm

974 548 44

Ι 425 - Ι 600

16 - 30 mm

974 549 44

1) Only for fixed suspension. The fixed suspension is a sliding suspension which is fixed on the profile section by means of a self-tapping screw. Self-tapping screw 3,5 x 9,5 to DIN 7981.

13

5.2 DCL suspension with M8 threaded pin 5.2.1 Mounting and operating dimensions, sliding suspension/fixed suspension

Mounting angle

M8 lock nut

max. 43

Adjusting range

Fixed point 1)

Sliding suspension 42106444.eps

42207444.eps

Component set for sliding suspension with M8 threaded pin

Part no.

1 off threaded pin fitting 1 off countersunk screw M8 x 70 876 637 44 2 off lock nut M8 1 off sliding suspension

5.3 Further fitting information

• Straight sections feature plastic sliding suspensions for connection to C-rail or threaded pin fittings.. • Line power feeds feature an additional sliding suspension. • For C-rail fittings: - The mounting brackets are clipped into the sliding suspensions. - The C-rail clamp section is fitted according to mounting arrangement I or II (see section 5.1.2). • For threaded pin fittings: - The threaded pin fitting with countersunk screw is clipped into the sliding suspensions. • The max. distance between DCL sliding suspensions is 2000 mm for straight sections (see chapter 4).

• The centre of every DCL installation must be secured by a fixed suspension. To do this, screw the enclosed 3,5 x 9,5 self-tapping screw into the sliding suspension. For DCL installations with entry/transfer sections, the funnels must be arrested.

14

1) Only for fixed suspension. The fixed suspension is a sliding suspension which is fixed on the profile section by means of a self-tapping screw. Self-tapping screw 3,5 x 9,5 to DIN 7981.

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• Sliding suspensions must be fitted every 500 mm (along the curve) for curved sections.

6

Technical data

6.1 DCL straight section 4, 5, 6 und 7 poles Suspension method Protective earth symbol (only for conductor line with PE)

Attached to C-rail or suspended from threaded pin(must be ordered separately, see sections 5.1.1 and 5.2.1)

Profile sealing lip: fitted as required. May be added to order per meter. 42212444.eps

Profile rib (orientation rib) 42207544.eps

S

= Joint connectors are pre-assembled on the conductor enclosures.

GA = Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly. - Additional sliding suspensions may be fitted. - Specify suspension method and order separately. - Suspension diagram with dimensions see chapter 4. Please observe! Steel structure etc.

Unless the installation is designed otherwise, it must be ensured that all DCL straight and curve sections are fitted in such a way that the protective earth conductor (PE) and the profile rib of the enclosure face towards the track support resp. the steelwork. Version without protective conductor (PE) Systems and current collecting trolleys without protective conductor connection (PE) will be supplied as follows.

(PE) Systems Profile rib (orientation rib)

42106144.eps

The green-yellow marking of the protective conductor is not applicable. The conductor / pole is equipped resp. processed and can be used for the power- or for the control signal transmission. The cross section then corresponds to the conductor cross section of the power transmission (valid for sizes starting at 140). Current collecting trolley In this version the green-yellow core is replaced by a black core. The protective marking (PE) is not applied. The sliding contacts are equipped in accordance with the conductor- / poles-quantity. When all DCL straight and curve sections have been fitted, one sliding suspension must be fixed with a DCL straight section in the middle of the track (fixed point) to prevent the DCL installation moving to the side. Fixed point or fixed suspension:

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Screw the enclosed 3,5 x 9,5 self-tapping screws to DIN7981 as there is a risk of accidental contact with live parts if longer screws are used. Use only the enclosed 3,5 x 9,5 self-tapping screws to DIN7981 as there is a risk of accidental contact with live parts if longer screws are used. 1) Standard length 4000 mm. Indicate reduced length in order text for part no. Minimum reduced length 500 mm. For complete conductor line installations, the entire conductor line length including the power feed(s) must be specified in the order text.

15

Part number table (conductor material copper) Size 35

60

64

78

10

15

100

140

200

Permissible current (A) at 100 % CDF up to 35 °C 2) Number of poles 100

140

160

38

56

L1 - L3 conductor cross-section mm² 25

4

876 640 44

876 606 44

876 607 44

876 608 44

876 609 44

Phase L1 - L3 PE conductor Control cable

3 x 10 mm² 1 x 10 mm² -

3 x 15 mm² 1 x 15 mm² -

3 x 25 mm² 1 x 25 mm² -

3 x 38 mm² 1 x 25 mm² -

3 x 56 mm² 1 x 38 mm² -

5

876 641 44

876 610 44

876 611 44

876 612 44

876 613 44

Phase L1 - L3 PE conductor Control cable

3 x 10 mm² 1 x 10 mm² 1 x 10 mm²

3 x 15 mm² 1 x 15 mm² 1 x 10 mm²

3 x 25 mm² 1 x 25 mm² 1 x 10 mm²

3 x 38 mm² 1 x 25 mm² 1 x 10 mm²

3 x 56 mm² 1 x 38 mm² 1 x 10 mm²

6

876 642 44

876 614 44

876 615 44

876 616 44

876 617 44

Phase L1 - L3 PE conductor Control cable

3 x 10 mm² 1 x 10 mm² 2 x 10 mm²

3 x 15 mm² 1 x 15 mm² 2 x 10 mm²

3 x 25 mm² 1 x 25 mm² 2 x 10 mm²

3 x 38 mm² 1 x 25 mm² 2 x 10 mm²

3 x 56 mm² 1 x 38 mm² 2 x 10 mm²

7

876 643 44

876 618 44

876 619 44

876 623 44

876 624 44

Phase L1 - L3 PE conductor Control cable

3 x 10 mm² 1 x 10 mm² 3 x 10 mm²

3 x 15 mm² 1 x 15 mm² 3 x 10 mm²

3 x 25 mm² 1 x 25 mm² 3 x 10 mm²

3 x 38 mm² 1 x 25 mm² 3 x 10 mm²

3 x 56 mm² 1 x 38 mm² 3 x 10 mm²

The combinations of conductor quantity / number of poles and size indicated in the order table can be purchased as components. As a standard material for the conductor copper is used. Alternatively, the conductor cross section 10 mm2 can be ordered in stainless steel plated version. The above mentioned part numbers are only valid for the conductor material copper. A version with stainless steel plated copper bar (10 mm2) has to be especially mentioned in the order. For straight sections not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with “no PE”. Suspensions DCL with C-rail installation or threaded bolts M8 have to be ordered separately. Component sets for sliding suspensions with C-rail installation or threaded bolts M8 have to be selected with the corresponding quantity (cf. chapter 7.1). Sliding suspensions are pre-mounted for the suspension distance 2000 mm. The following information is required for ordering a straight section (see model code order text): ⇒ Conductor line type, component DCL-GS ⇒ Number of poles (4, 5, 6, or 7 conductors) ⇒ Size (35, 60, 100, 140, 200) ⇒ protective earth conductor PE (with or without) ⇒ Section and installation length in mm 1)

Model code

Order text, e.g.: DCL-GS-6-100-PE-4000 or

16

DCL-GS-7-60-3500 (no PE, 3500 mm long)

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1) Standard length 4000 mm. Indicate reduced length in order text for part no. Minimum reduced length 500 mm. For complete conductor line installations, the entire conductor line length including the power feed(s) must be specified in the order text. 2) The permissible current for the conductors must be checked. Calculation or tables see chapter 3. 3) 10 mm2 (L1-L3, PE and / or control line) available upon request as stainless steel plated copper bar.

6.2 DCL curved section 4, 5, 6 and 7 poles Suspension method Attached to C-rail or suspended from threaded pin (must be ordered separately, see sections 5.1.1 and 5.2.1)

This diagram shows an inside curve

a str

igh

str

t

aig

ht

Profile rib (orientation rib)

Profile sealing lip: fitted as required. May be added to order per meter.

42210444.eps

S Steel structure etc.

= Joint connectors are pre-assembled on the conductor enclosures.

GA = Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly. - Suspensions spaced at a distance of 500 mm along the curve. - Specify suspensions and order separately. - Suspension diagram with dimensions see chapter 4. Please observe! Unless the installation is designed otherwise, it must be ensured that all DCL straight and curve sections are fitted in such a way that the protective earth conductor (PE) and the profile rib of the enclosure face towards the track support resp. the steelwork.

(PE)

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Profile rib (orientation rib)

42106144.eps

For designing of systems with straight and curve sections the following has to be observed: The straight ends of the curve sections with 178 mm are fixed values and if necessary have to be deducted from the total length of the connecting straight section. 17

For curved sections not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with “no PE”.

The following information is required for ordering a curved section (see model code order text): ⇒ Conductor line type, component DCL-BS ⇒ Number of poles (4, 5, 6, or 7 conductors) ⇒ Size (35, 60, 100, 140, 200)

1)

⇒ protective earth conductor PE (with or without) ⇒ Radius (mm) ⇒ Angle α (degrees) ⇒ Curve I or curve A 2)

Model code

Order text, e.g.: DCL-BS 5-100- PE- R = 1500, α = 45, curve A

18

3)

3) Profile sealing lip may be added to order per meter. Please specify in the order.

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1) The permissible current for the conductors must be checked. Calculation or tables see chapter 3. 2) Definition of curve type I and curve type A: On curve I the protective earth conductor and the profile rib are on the inside of the curved section. On curve A the protective earth conductor and the profile rib are on the outside of the curved section. On curved sections which do not feature a protective earth conductor, the profile rib is only for orientation. The view refers to the centre of the radius.

6.3 DCL line power feed 4, 5, 6 and 7 poles M6 slot-head screws Prepared opening 1)

Connecting terminal

Connecting bar only for 100 A, 140 A and 200 A DCL conductor

42109044.eps

2)

Profile sealing lip: fitted as required. May be added to order per meter.

Profile rib (orientation rib) 42212444.eps

S

42210544.eps

= Joint connectors are pre-assembled on the conductor enclosures.

20338744.p65/070606

GA = Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly. Line power feeds feature an additional sliding suspension. - Additional sliding suspensions may be fitted. - Specify suspension method and order separately, see chapter 5. - Suspension diagram with dimensions see chapter 4.

1) Cut off the rubber sleeves to the required cable diameters. - dia. 48 PG 42 only with rubber sleeve max. 43 mm cable diameter, PG 36 for PG screw fitting. - dia. 29 PG 21 with rubber sleeve max. 24 mm cable diameter, The rubber sleeves are supplied loose inside the line power feed enclosure. 2) Standard length 4000 mm. Indicate reduced length in order text for part no. Minimum reduced length 1000 mm.

19

Part number table (conductor material copper) Size 35

60

64

78

10

15

100

140

200

Permissble current (A) at 100 % CDF up to 35 °C 1) Number of poles 100

140

160

38

56

L1 - L3 conductor cross-section mm² 25

4

876 646 44

876 650 44

876 651 44

876 652 44

876 653 44

L1 - L3 + PE Control cable

4 x 1,5 - 16 mm² -

4 x 1,5 - 16 mm² -

4 x 25 - 70 mm² -

4 x 25 - 70 mm² -

4 x 25 - 70 mm² -

5

876 647 44

876 654 44

876 655 44

876 656 44

876 657 44

L1 - L3 + PE Control cable

4 x 1,5 - 16 mm² 1 x 1,5 - 16 mm²

4 x 1,5 - 16 mm² 1 x 1,5 - 16 mm²

4 x 25 - 70 mm² 1 x 1,5 - 16 mm²

4 x 25 - 70 mm² 1 x 1,5 - 16 mm²

4 x 25 - 70 mm² 1 x 1,5 - 16 mm²

6

876 648 44

876 658 44

876 659 44

876 660 44

876 661 44

L1 - L3 + PE Control cable

4 x 1,5 - 16 mm² 2 x 1,5 - 16 mm²

4 x 1,5 - 16 mm² 2 x 1,5 - 16 mm²

4 x 25 - 70 mm² 2 x 1,5 - 16 mm²

4 x 25 - 70 mm² 2 x 1,5 - 16 mm²

4 x 25 - 70 mm² 2 x 1,5 - 16 mm²

7

876 649 44

876 662 44

876 663 44

876 664 44

876 665 44

L1 - L3 + PE Control cable

7 x 1,5 - 16 mm² 3 x 1,5 - 16 mm²

7 x 1,5 - 16 mm² 3 x 1,5 - 16 mm²

4 x 25 - 70 mm² 3 x 1,5 - 16 mm²

4 x 25 - 70 mm² 3 x 1,5 - 16 mm²

4 x 25 - 70 mm² 3 x 1,5 - 16 mm²

The combinations of conductor quantity / number of poles and size indicated in the order table can be purchased as components. As a standard material for the conductor copper is used. Alternatively, the conductor cross section 10 mm2 can be ordered in stainless steel plated version. The above mentioned part numbers are only valid for the conductor material copper. A version with stainless steel plated copper bar (10 mm2) has to be especially mentioned in the order. For line power feeds not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with “no PE”. Suspensions DCL with C-rail installation or threaded bolts M8 have to be ordered separately. Component sets for sliding suspensions with C-rail installation or threaded bolts M8 have to be selected with the corresponding quantity (cf. chapter 7.1). Sliding suspensions are pre-mounted for the suspension distance 2000 mm.

The following information is required for ordering a line power feed (see model code order text): ⇒ Conductor line type, component DCL-ES ⇒ Power feed, number of poles (4, 5, 6, or 7 conductors) ⇒ Size (35, 60, 100, 140, 200) ⇒ protective earth conductor PE (with or without)

Model code

20

Order text, e.g.: Line power feed

DCL-ES-4-140-PE

or

DCL-ES-7-60 (no PE)

20338744.p65/070606

1) The permissible current for the conductors must be checked. Calculation see tables in chapter 3. 2) 10 mm2 (L1-L3, PE and / or control line) available upon request as stainless steel plated copper bar.

6.4 DCL connector end cap as end power feed Prepared openings Open as required and fit rubber sleeve(s).

Straight /curved section

Rubber sleeves for cable dia. up to 24 mm 1)

Connecting point on the conductor lug Attach cable lugs to cables up to 16 mm² 2) Attach the cable lugs to the conductor lugs using M6 nuts and bolts.

Clip

42110444.eps

Clearance

AK S GA

= = =

Connector end cap clipped together with the joint connector. Joint connectors are pre-assembled on the conductor enclosures. Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly. 42210644.eps

The following information is required for ordering or selecting a connector end cap as a power feed (see model code order text): ⇒ Conductor line type, DCL ⇒ AK connector end cap ⇒ Connection cross-section ≤ 16 mm² (IN ≤ 60 A)

20338744.p65/070606

1) Not included in the scope of supply. Cut off the rubber sleeves to the required cable diameters. 2) Cable lugs are not included in the scope of supply.

Model code

Order text, e.g.: DCL connector end cap as end power feed DCL-AK-16 Rubber sleeve

PG 21 21

6.5 DCL connector end cap as track end cap (for DCL conductor line with end power feed or with extended track)

Connector end cap

Straight /curved section

42052444.eps

Clearance

AK S GA

= = =

Connector end cap clipped together with the joint connector. Joint connectors are pre-assembled on the conductor enclosures. Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly.

42210744.eps

The following information is required for ordering or selecting a connector end cap as track end cap (see model code order text): ⇒ Conductor line type, DCL

Model code

Order text, e.g.: DCL connector end cap as track end cap

22

DCL-AK

20338744.p65/070606

⇒ AK connector end cap

6.6 End cap (for DCL installations with line power feed or sections subsequently cut to length on site)

Straight /curved section

Oval flat head screw 3,5 x 10 DIN7981 42109544.eps

Clearance

EK GA

= =

End cap screwed together with the conductor enclosure. Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly. 42210844.eps

Use only the enclosed 3,5 x 10 oval flat head screws to DIN7981 as there is a risk of accidental contact with live parts if longer screws are used.

The following information is required for ordering or selecting an end cap (see model code order text): ⇒ Conductor line type, DCL

20338744.p65/070606

⇒ EK end cap

Model code

Order text, e.g.: End cap

DCL-EK

23

6.7 Entry/transfer section Suspension method Attached to C-rail or suspended from threaded pin(must be ordered separately, see sections 5.1.1 and 5.2.1)

View “X”

Orientation rib Funnel left-hand

View “X”

Orientation rib Funnel right-hand

42279444.eps

Dead funnel area Conductor line

Dimension mm

1 2 3

243

4 5 6

Profile sealing lip: fitted as required. May be added to order per meter. 24

42212444.eps

7 PE

352 243 134 41761944.eps

20338744.p65/070606

Profile rib (orientation rib)

For transfers left-hand and right-hand funnels are required. Entry/transfer speed 100 m/min. Min. distance between transfer funnels 10 mm. Max. lateral misalignment between the funnels ± 10 mm. Max. vertical misalignment between the funnels ± 8 mm. S = Joint connectors are pre-assembled on the conductor enclosures. F

= Fixed suspension slides on funnel enclosure to be positioned and secured with self-tapping screw during assembly.

Use only the enclosed 3,5 x 9,5 self-tapping screws to DIN7981 as there is a risk of accidental contact with live parts if longer screws are used.

Part number table

Number of poles

Type

Conductor line assignment

right-hand

Part no. 876 695 44

4

1-3,7 (PE) left-hand

876 700 44

right-hand

876 696 44

5

1-3,7 (PE) 5 left-hand

876 701 44

right-hand

876 697 44

6

1-3,7 (PE) 4,6 left-hand

876 702 44

right-hand

876 698 44

7

1-3,7 (PE) 4-6 left-hand

876 703 44

The combinations of conductor quantity / number of poles and size indicated in the order table can be purchased as components. As a standard material for the conductor copper is used. Alternatively, the conductor cross section 10 mm2 can be ordered in stainless steel plated version. The above mentioned part numbers are only valid for the conductor material copper. A version with stainless steel plated copper bar (10 mm2) has to be especially mentioned in the order. For transfer sections not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with “no PE”. Note The current collector trolley must be prepared for DCL with entry/transfer setions or profile sealing lip. Open the terminal box on the current collector trolley and separate the upper terminal box enclosure half on the prepared openings (prepared openings see figure in section 6.8). The following information is required for ordering or selecting transfer sections (see model code order text): ⇒ Conductor line type, DCL ⇒ ÜTR Transfer section ⇒ Type (L = left-hand or R = right-hand) ⇒ Number of poles ( 4,5, 6, or 7 conductors)

20338744.p65/070606

⇒ protective earth conductor PE (with or without)

Model code

Order text, e.g.: Transfer section (funnel right-hand)

DCL-ÜTR-4-PE

or (funnel left-hand)

DCL-ÜTL-7 (no PE) 25

6.8 DCL current collector trolley 4, 5, 6 and 7 poles Guide wheel

5 6

4

Travel wheel

2

3

7

1

Guide roller

The current collector trolley must be prepared for DCL with entry/ transfer setions or profile sealing lip. Open the terminal box on the current collector trolley and separate the upper terminal box enclosure half on both terminal box halves along the prepared opening.

Prepared opening (separate on both sides)

41762044.eps

26

Poles Designation

Part no. Total

L1-L2-PE

Control conductor

IN, 80 % ED / Sliding contact material

Metric cable union / corrugated tube

Connecting cable conductors

DCL-SAW-4-40 1)

876 581 44

4

4

0

40 A / BR

-

DCL-SAW-4-20 2)

876 582 44

4

4

0

20 A / BR

-

4 x 4 mm²

DCL-SAW-5-40 1)

876 583 44

5

4

1

40 A / BR

40 A / BR

(4 x 6 + 1 x 2,5) mm²

DCL-SAW-5-20 2)

876 584 44

5

4

1

20 A / GR

20 A / GR

(4 x 4 + 1 x 2,5) mm²

DCL-SAW-5-40-M 3)

876 777 44

5

4

1

40 A / BR

20 A / SIGR

(4 x 6 + 1 x 2,5) mm²

DCL-SAW-6-40 1)

876 585 44

6

4

2

40 A / BR

40 A / BR

DCL-SAW-6-20 2)

876 586 44

6

4

2

20 A / GR

20 A / GR

DCL-SAW-6-40-M 3)

876 778 44

6

4

2

40 A / BR

20 A / SIGR

(4 x 6 + 2 x 2,5) mm²

DCL-SAW-7-40 1)

876 587 44

7

4

3

40 A / BR

40 A / BR

(4 x 6 + 3 x 2,5) mm²

DCL-SAW-7-20 2)

876 588 44

7

4

3

20 A / GR

20 A / GR

(4 x 4 + 3 x 2,5) mm²

DCL-SAW-7-40-M 3)

876 779 44

7

4

3

40 A / BR

20 A / SIGR

(4 x 6 + 3 x 2,5) mm²

4 x 6 mm²

M 25 / NW 17

(4 x 6 + 2 x 2,5) mm² (4 x 4 + 2 x 2,5) mm²

20338744.p65/070606

1) Bronze sliding contact material, connecting conductor cross-sections L1 - L3 + PE max. 6,0 mm². Control conductor connecting cable crosssection 1,5 mm². Other cross-sections on request. 2) Graphite sliding contact material, connecting conductor cross-sections L1 - L3 + PE max. 4,0 mm². Control conductor connecting cable crosssection 2,5 mm². Other cross-sections on request. 3) Sliding contact materials bronze and silvergraphite, connecting conductors L1 – L3 + PE (bronze) max. 6.0 mm2. Connecting conductors of the control conductors (silver-graphite) 2.5 mm2. Other cross section on request.

42210944.eps

6.8.1 Current collector technical data

Sliding contact material Application range

Bronze

Graphite1)

Silver - Graphite 1)

Energy supply

Energy supply Data transmission

Data transmission

24 to 690 V .

Permissible Volatage

Continuous current 2)

Connecting cable 3)

Travel speed

with 80 % CDF

40 A

20 A

20 A

with 60 % CDF

45 A

20 A

20 A

with 40 % CDF

50 A

25 A

25 A

L1 - L3 + PE

6 mm² x 2000 mm

4 mm² x 2000 mm

Control Cable

2.5 mm², max. 25 A, 80% ED

Straight section

max. 200 m/min

Curve section max. 100 m/min Transfers $ 800 mm

Curve-negotiating for R

For the transmission of control signals and at low voltages (24 – 48 V, IN # 1 A) the use of silver-graphite-sliding contacts in connection with stainless steel plated copper bars is recommended. If necessary, the use of at least 2 current collecting trolleys can be reasonable. The following information is required for ordering a current collector trolley (see model code order text): ⇒ Conductor line type, DCL ⇒ Current collector trolley ⇒ Number of poles ( 4,5, 6, or 7 sliding contacts) ⇒ Permissible current (20 or 40 A) ⇒ Protective earth conductor PE (with or without) ⇒ Connecting cable length (mm) For current collecting trolleys not fitted with protective earth conductor (marking PE is not applied) this must be indicated in the order section and specified as a part no. with “no PE”. In this version the green-yellow core is replaced by a black core. The marking (PE) is not applied.

20338744.p65/070606

1) Current collector trolleys with graphite sliding contacts must be used in DCL installations operated close to the sea, outdoors and in chemical environments. Use a higher number of current collector trolleys to ensure contact reliability. 2) If 2 current collector trolleys are connected in parallel, twice the rated current can be expected to occur. If 3 current collector trolleys are connected in parallel, the rated current will be increased by a factor of 3 - 10%. 3) Single conductors in the corrugated tube. Maximum cable length 2000 mm Other lengths on request. Minimum length: 500 mm / maximum length: 10000 mm.

Model code

Order text, e.g.: DCL-SAW-4-40-PE or

DCL-SAW-7-20-3500 (no PE, 3500 mm connecting cable) 27

6.9 Towing arm for DCL current collector trolley 6.9.1 Standard towing arm (not for transfer sections)

Detail X

42225844.eps

Model code

Order text, e.g.: Towing arm

28

DCL-MIT

20338744.p65/070606

42206144.eps

6.9.2 Towing arm for free transfer sections

42225944.eps

20338744.p65/070606

42226344.eps

Model code

Order text, e.g.: Towing arm for transfer section

DCL-MITÜ

29

6.10 Profile sealing lip

42212444.eps

6.10.1 Assembly tool for fitting the profile sealing lip

Disconnect the DCL installation from the power supply before fitting the profile sealing lip.

DCL assembly tool Cable slider

Roller pair

Handle

42262144.eps

The profile sealing lip is supplied on rolls in lengths measuring 40 m. Profile sealing lip sections have to be bonded together using cyanoacrylate glue (super glue)2) for longer DCL tracks. Ensure the bonding surfaces are clean and fit together.

Profile sealing lip length = 2 x DCL installation length The profile sealing lips are individually pushed into both sides of the DCL conductor enclosure (see also assembly instructions 214 399 44, section 3.11.1).

Model code

30

Order text, e.g.: DCL – profile sealing lip DCL assembly tool for profile sealing lip Cyacrylat glue (super glue), 20 gr.

876 508 44 1) 876 509 44 000 383 44 2)

1) Profile sealing lip may be added to order per meter. Please specify in the order. 2) Order, if required.

20338744.p65/070606

If profile sealing lips are used with the DCL, the teminal box enclosure halves on the current collector trolley must be prepared. (see note in section 6.8).

6.11 Isolating section

For control purposes, the DCL conductor line can be interrupted by means of isolating sections on straigth sections or line feeds. The isolating sections can only be combined with 100 A copper conductors. The isolating section can be fitted in the factory or on site. If the isolating sections are fitted in the factory, the following detailed information is required: - postition of the isolating section/sections in the installation - conductor no. - length of each isolating section

ctor ondu Cu c A 100

5,5

5, 5

205 ctor ondu Cu c A 100 5,5

5, 5

ting

Isola

nS sectio ting la o off, is

ion U

sect

5,5 5,

98

5

ctor ondu Cu c A 100

5,5 5, 5

ctor ondu Cu c A 100

ion S sect ting Isola

20338744.p65/070606

42145244.eps

Model code

Order text, e.g.: Isolating section U

876 676 44

Isolating section S

876 678 44 31

7

Component parts

7.1 Straight sections and accessories 7.1.1 Component set for sliding suspension with C-rail bracket

Designation

Part no.

Sliding suspension Mounting bracket

876 638 44

C-rail clamping section

7.1.2 Component set for sliding suspension with M8 threaded pin

Designation

Part no.

Sliding suspension Threaded pin fitting 876 637 44 Lock nutM8 (2 off) Countersunk screw M8 x 70

7.1.3 Component set for conductor connector

Designation

Quantity

Conductor connector U section

1

Conductor connector lug

2

Round head screw M6 x 20

2

Lock nut M6

2

Clamp section 1)

2

Round head screw M6 x 22

2

Part no.

876 693 44

32

Designation

Part no.

Isolating section U 2)

876 676 44

Isolating section S 2)

876 678 44

1) Clamp section not required for 100 A, 140 A and 200 A conductors. 2) off, isolating section S = 97 mm isolating distance off, isolating section S + off, isolating section U = 205 mm isolating distance The isolating distance can be extended by adding further isolating sections (isolating section U) (see assembly instructions 214 399 44, section 4.12).

20338744.p65/070606

7.1.4 Isolating sections

7.2 DCL Spare part-sets

7.2.1 Current collector and current collector trolley

The parts listed below are subject to a greater or lesser amount of wear while a current collector trolley is in operation. Wear depends on various factors and is not determined by the current collector trolley operating period alone. Preventive maintenance is therefore required. Worn current collector trolleys or other components must be replaced immediately.

Sliding contact set Bronze or Graphite Sliding contact sets DCL - SAW - 4 + 5 / 6 + 7 - 40 A, bronze1 ) Designation

Part no.

Sliding contact set 5-pole 40 A (for 4 + 5-pole SAW)

876 715 33

Sliding contact set 7-pole 40 A (for 6 + 7-pole SAW)

876 716 33

Sliding contact sets DCL - SAW - 4 + 5 / 6 + 7 - 20 A, graphite2 ) Designation

Part no.

Sliding contact set 5-pole 20 A (for 4 + 5-pole SAW)

876 717 33

Sliding contact set 7-pole 20 A (for 6 + 7-pole SAW)

876 718 33

Sliding contact set Bronze / Silver-Graphite Sliding contact sets DCL - SAW - 5 / 6 + 7 40 A, bronze / 20 A, silver-graphite3 ) Designation

Part no.

Sliding contact set 5-pole 40 A / 20 A (for 5-pole SAW) Sliding contact set 7-pole 40 A / 20 A (for 6 + 7-pole SAW)

876 726 33 876 727 33

Line power feed set Designation

Qty.

Connection side 70 DCL (enclosure front parts)

2

Center part (enclosure side parts)

2

Entry spout PG 21

1

Entry spout PG 42

1

Hex. nut M6

2

Cyl. screw M6 x 12

2

Part no.

876 532 33

End power feed set Designation End cap

Qty.

Part no.

2

Connection cap DCL-AK-16

2

Entry spout PG 21

4

Self-tapping screw ST 3.5x9.5

6

20338744.p65/070606

876 534 33

1) Sliding contacts power + control conductor: bronze 2) Sliding contacts power + control conductor: graphite 3) Sliding contacts power: bronze Sliding contacts control conductor: silver-graphite

33

Resistance to acids, chemicals and fuels

8.1 Acids

Medium Acid

Remark Conc.

Chromic acid

40 %

⊕

Chromic-sulfuric acid

20 %

⊕

Nitric acid

10 %

+

Sulfuric acid

10%

+

Ethanoic acid

5%

+

Carbonic acid

10 %

+

D-tartaric acid

10 %

+

Formic acid

20 %

+

Arsenic acid

20 %

+

Boric acid

10 %

+

Lactic acid

10 %

+

Phosphoric acid

50 %

+

Oxalic acid

10 %

+

Hydrochloric acid

20 %

⊕

Citric acid

10 %

+

Oleic acid

+

Medium ⊕

Regular petrol

⊕

Supergrade petrol

⊕

Kerosine

⊕

White petroleum spirit

⊕

Diesel oil

⊕

Benzole

-

Oil, grease (free from aromatics)

+

Drilling oil

⊕

ATE brake oil

⊕

Foodstuffs

8.3 Chemicals

+

distance > 5km

+

+

>1%

⊕/−

Conductors (Cu) subject to increased oxidation (corrosion) Resistance information only valid for room temperature (20 °C).

34

Use double current collectors

Minimum distance 5 m

-

Alcohol

Applies to all chemicals:

Avoid direct contact

Remark