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.
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- 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
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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
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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.
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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
