KBSL KSL - VAHLE

ENCLOSED CONDUCTOR SYSTEMSKBSL KSL

POWERAILS KBSL – KSLINDEXPowerail versions (Photos)Basic descriptionTechnical dataPowerail, Cat.-Nos. and WeightsStandard sections and curvesJointing materialBracketsHangersEnd feedsLine feedsEnd capsConductor dead sectionsContact sections, turntables and switchesTransfer guides, straightTransfer guides, obliquePage22, 334, 567891010, 111111121313Transfer funnelsAnti-condensation sectionRemoving sectionExpansion joint sectionCollectorsDouble collectorsTow armsSpare partsExamples for orderingKTW System incl. KBSLFlexible tow arm configurationApplication photoQuestionnaireProduct linePage141516171818191920, 2122, 23242425, 2628Powerail versions (drawings see page 5).Type KBSL(1)color: greenType KSLcolor: greenGeneralApporovalsThe Powerail types KBSL and KSL are totally enclosed,touch-proven conductor systems for safe mobile power feeding of:Overhead Cranes, Monorail Systems, Electric Hoists, AutomatedStorage and Retrieval Systems, Electric Power Tools, Machine Tools,Assembly and Test Lines, Hanger Door Motors, Studio & StationLightingSystems and many other applications.KSL: UL-approved, CSA-approved.Please contact us before ordering.Main characteristics are minimum space requirement, easy installation and resistance against corrosion.VAHLE Powerails fully meet all VDE safety requirements.Other combinations of cross sections, as shown on page 5, arepossible. Regulation VDE 0100,part 430 has to be consideredwhen using an N-conductor. Powerail KSLT can be equippedwith sealing strip „D“ (IP 24) or with plastic shielding „FP“.2(1)KBSL is w/o stiffener clamps.KSL will be equipped with stiffener clamps.HousingThe compact insulating housing holds from 4-5 pure copperconductors. Suitable for indoor applications.Standard sections are 1, 2, 3 or 4 m long.Other sections and curves are available.Type KSL is equipped with stiffener clamps.The ground conductor is identified by international color code. Longand short lip housing profiles (see page 6) and collector safety keysavoid phase reversing.Any number of conductors can be accomplished by installingvarious Powerails side by side.

BASIC DESCRIPTION OF POWERAILS AND COMPONENTSThe KBSL and KSL can be supplied from 40 - 100 A alternativelywith bolted joints or plug-in joints. With 140 and 200 A bolted jointsare always needed. The sections for plug-in and bolted joints areidentically constructed.Available in air gap version (5mm), where the collector carbon bridges the gap, e.g. for mains.Also available in insulating piece version (30 mm). In this case theinsulating piece is longer than the carbon and each Powerailsection can be separated electrically, e.g. for control.Joint coverCollector:The housing of the Powerail types KBSL and KSL areconnected by plastic joint covers.The current collectors are made of re-inforced polyester, for highstrength and light weight. Spring loaded carbon brushes maintainuniform contact. Connecting cables or terminal boxes and hinged orflexible towing arms included.Couplings:Main power supply:The Powerail systems can be fed either by line feeds or end feeds.End caps:The open ends of Powerail are closed by end caps.Hangers:Bracket at the crane track (see page 8).Max. support distance with the following ambient temperatures ofthe conductor:울 35 C 2,00 m 35 C 1,33 mExpansion during temperature fluctuation:The extensions can be compensated for the KBSL and KSL byexpansion joint sections (without electrical separation).Anti-condensation sections:With following system requirements double collectors have tobe used:- Transfers with switches and turntables- low voltages, frequency controlled drives- Transmission of data- and/or emergency stop signals- high electrical loadsThe length of the collector cable may not exceed 3 m if the addedovercurrent protection device is not designed for the load capacityof this cable. Please refer also to regulations VDE 0100, part 430and EN 60204-32.(Note: this might happen in case of several collector running in onesystem).The connecting cables are sufficiently dimensioned for the indicatedcontinuous current ratings.These sections are used for transfer of the Powerail to outdoor areasto avoid condensation. The Powerail is not separated electrically.Contact sections, turntables and switches:Powerail for working areas and transfer applications see page 12.Sectionalizing:Conductor dead sections are electrical interrupts of the conductor.Under normal operating conditions a cross over with collectors toswitch the voltage off or on is only allowed with low power ratings(control current).Consider reduction factors for different kinds of installation as per VDE 0298-4.Please note: For use in galvanizing and pickling plants,under agressive conditions and low voltage applications we would appreciate receiving detailled information, especially of the environmental conditions. Forquotations and order processing including Powerailsystems with curves, dead sections, turntables,switches etc. we require your drawings or sketches.Please use our questionnaire, page 25/26.All steel parts and hardware of Powerails can be supplied in stainless steel version (version K)Technical Data of Powerail KBSL · KSLElectrical properties:AmpacityNennspannung(UL)Dielectric strengthSpecific resistanceSurface resistanceLeakage resistance200 A (at 80% ED)690 V (600 V)IEC 60243-1-3IEC 60093IEC 60093IEC 60112Flame test proof:no flaming particles,self extinguishingDIN 41 02 –30–40 kV/mm5 x 1015 Ohm/cm1013 OhmCTI 600–2,7Mechanical properties:Flexible strengthTensile strength75 N/mm2 10 %40 N/mm2 10 %Temperature range (ambient):– 30 C to 60 CHousing Resistance GasolineSulphuric acid 50 %to chemicals:Mineral Oil Caustic soda 25 % & 50 %Hydro-chloric acid,at 45 CGreaseconcentratedClass B 1Part 1Consider the voltage drop calculation to maintain the limits established by the motor manufacturers:AC:DC: U 앀3 x I x l x Z U1 2l x I x R U1 Voltage drop [V] U2 Voltage drop [%]I Ampere load [A] U2 U1 · 100VR Resistence [Ohm/m]l Power feed length [m]L System length [m]Effective length:l Lpower feed located at the end of the systeml L/2 power feed located at the mid-point of the systeml L/4 power feed located at both ends of the systeml L/6 power feed located at L/6 from each end of the systemZ Impedance Ohm/1000 mV Voltage rating [V]The total ampere load is determined from the nominal rated current of all motors working simultaneously on the same feedsection of your electrification system. A diversity factor of 0.5 – 0.9 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 isexceeding the limitations.3

POWERAIL TYPES, ENGINEERING DATA AND CAT.-NOS.Type(1)HS c/w PESS w/o PEKBSL 4/ 40 HSKBSL 4/ 40 SSKBSL 4/ 60 HSKSBL 4/ 60 SSKBSL 4/100 HSKBSL 4/140 HSKBSL 4/200 HSKBSL 5/ 40 HSKBSL 5/ 40 SSKBSL 5/ 60 HSKBSL 5/ 60 SSKBSL 5/100 HSKBSL 5/140 HSKBSL 5/200 HSKSLKSLKSLKSLKSLKSLKSL4/ 40 HS4/ 40 SS4/ 60 HS4/ 60 SS4/100 HS4/140 HS4/200 HSKSLKSLKSLKSLKSLKSLKSL5/ 40 HS5/ 40 SS5/ 60 HS5/ 60 SS5/100 HS5/140 HS5/200 HS4control linecontrol linecontrol linecontrol linecontrol linecontrol linecontrol linecontrol lineContinuousNo. ofcurrent A atConductors 35 C and100% EDPhaseCopper cross srctionmm2N/5(3)L1 L2 L3Control lineNominalvoltage 5101569069069069069069069030303030303030- Suffix types e.g. 2 m KSL 4/60 with PE R KSL 4/60 - 2 HS Order. - No. 250 002, shorter lengths are made up from the next larger standart lengths.(1)KBSL is w/o stiffener clamps. KSL and KSG are c/w stiffener clamps (see page 6).(2) 80% intermittent.Ground PE(3)Please refer to page 2 for use as N -conductor see page 2.For mounting configurations also see pages 8, 10, 11,13, 14, 20, 23, 25(4)Nominal voltage UL 600 V

Impedanceat50 Hertz20 CW / 1000 mResistanceat20 CW / 1000 ,7781,7782,1342,4553,060252 96 256 55 253 21 253 25 253 23 252 68 252 69 530,361,7341,7341,9031,9032,3482,6683,274256 13 256 56 253 22 253 26 253 24 252 70 252 71 KBSL 4 pole, 40-200 A color greenKSL 4 pole, 40-200 A color green( 0,530,361,7531,7531,8881,8882,2442,5653,170257 36 257 64 250 00 251 46 250 01 250 69 254 04 530,361,8441,8442,0132,0132,4582,7783,384256 93 257 65 250 02 251 47 250 03 250 73 254 05 Add last number (1, 2, 3, 4 length suffix)in accordance to bars requred.KBSL 5 pole, 40-200 A color greenKSL 5 pole, 40-200 A color greenDescription in brackets for control.case of using a conductor as N.( ) In*5

STANDARD SECTIONS, CURVESSections max. 4 m(1) standardStiffener clampKBSLKSLAKBSLKSLBKBSL without stiffener clamps.KSLstiffener clamps.shortwithlip50short lipSections for plug-in joints and bolted joints are equal.BAleftPic. shows 4000 mm standard section, view on short lip siderightExtra finish of KBSL and KSL surcharge Cat.-No.:Index Kstainless steelclamps & hardwareType4-poleKSLIndex K:Index I:Index I (60 A)copper conductorswith stainless steel cap5-pole4-pole250 830}258 3015-pole258 302for special environmental conditionsCurves(2)Production corresponding to customer drawingL3(4)L1(2)KSLe.g. 4 polesContact surfaceof the collector(3)HR forLLAHR for LLIVRUVROL2(1)long lipSupport spacing750 up to max. 2000 mm,depending on the radiusmax. L 3600 mm,max. ) 120 Minimum bendingKSL 1800 mmSurcharge 4-polefor bendingOrder-No.horizontal curvevertical curveMin. bending radius horizontal in mmradiusverticalforKSL251 500251 490KSL4-pole5-pole6(1)(2)60 A100 A140 A200 ASurcharge 5-polefor bending600750600750900900900900horizontal curvevertical curveOrder-No.Shorter sections see page 4. and 5.Long lip side of Powerails should always be mounted facing the track (see page 8).Notify exceptions for replacements and/or extensions and determine correct curves.KSL259 424259 426

JOINT MATERIAL(1)Plug-in joints 40-100 ABolted joints 40-200 Aready installedready installed15015020209292Joint cap4 or 5 Bolted joints4 or 5 Plug-in jointsfor KBSL & KSL 4 poleTypVBK 4for KBSL & KSL 4 poleWeight kgCat.- No.0,215257 907for KBSL & KSL 5 poleTypVBK 5(1)Joint capTypVBS 4Weight kgCat.- No.0,285258 818for KBSL & KSL 5 poleWeight kgCat.- No.0,225257 908Identically constructed for main current and control lineTypVBS 5Weight kgCat.- No.0,310258 8197

BRACKETS KBSL KSLThese brackets are easily bolted to any type of standard -beam.View without -beamClaw suitablefor D 6-15 mmKBSL – KSLPowerail TypeCollectorSKRSKN161 -157Dim. a165SKNT 7-15 7175 -15For KBSL and KSL dimensions "a" also for double collectors.View without-beamClaw suitablefor D 15-25 mmEHK small claw versionØ9TypeXmmLmmB maxmmWeightkgOrder-No.for std.bracketsOrder-No.with smallclawEHK 250EHK 300EHK 400EHK 500EHK 600EHK 700EHK 750EHK 1,7501,8201,900251 600251 610251 620251 630251 640251 650251 660251 670251 720251 730251 740251 750251 760251 770251 780251 790Ø 11Dsmall clawplease declare measure DAttention:Make sure that hoist wheels have enough clearance. Usesmall claw if necessary. Check -beam dimension D.rail of EHK is identical to type S 1, Cat. 8a.8(1)Max. width at joint caps with KSL, see page 7.Select next larger size bracket when I-beam dimension B isbetween 170 mm and 300 mm.

SLIDING HANGERS, FIXPOINT HANGERSSliding hangermax. 35M8145(2)6630Sliding hangermounted to Powerail-section.Sliding hangermounted to Powerail-section.for KBSL & KSLfor KBSL only (one-piece bracket)TypeKGBWeight kgOrder-No.Typ0,225259 001KSHKSH/K(1)Weight kgOrder-No.0,2510,220252 894250 660Fixpoint hanger75Fixpoint hanger mounted to Powerail section.Hanger consists of steel clamp and bolt M 8.for KBSL & KSLTypKFKF/K(1)(1)(2)Weight kgOrder-No.0,2150,215258 806258 807stainless steelFlat washers only be used in slotted holes.9