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Technical dataDemag Compact Line DCL
42211044.eps
070606 EN/PDF 070606 203 387 44 714 IS 962.2
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1 General 31.1 Symbols 31.2 DCL installation 3
2 Design and installation notes 42.1 Definitions 42.1.1 Arms length 42.1.2 Protection against indirect contact 4
3 Calculating and selecting the conductor cross-section 53.1 Calculating the conductor cross-section 6
3.1.1 Calculation method 63.1.2 Graphical method 73.1.3 DCL maximum permissible current I
35[A] for an ambient temperature
of 35C 83.2 DCL basic structure 9
4 General layout 10
5 Suspension arrangements 115.1 DCL suspension with C-rail bracket 115.1.1 Sliding suspension/fixed suspension 115.1.2 Mounting and operating dimensions 125.2 DCL suspension with M8 threaded pin 145.2.1 Mounting and operating dimensions, sliding suspension/fixed suspension 14
5.3 Further fitting information 146 Technical data 156.1 DCL straight section 4, 5, 6 und 7 poles 156.2 DCL curved section 4, 5, 6 und 7 poles 176.3 DCL line power feed 4, 5, 6 und 7 poles 196.4 DCL connector end cap as end power feed 216.5 DCL connector end cap as track end cap 226.6 End cap 236.7 Entry/transfer section 246.8 DCL current collector trolley 4, 5, 6 und 7 poles 266.8.1 Current collector technical data 276.9 Towing arm for DCL current collector trolley 286.9.1 Standard towing arm 28
6.9.2 Towing arm for free transfer sections 296.10 Profile sealing lip 306.10.1 Assembly tool for fitting the profile sealing lip 306.11 Isolating section 31
7 Component parts 327.1 Straight sections and accessories 327.1.1 Component set for sliding suspension with C-rail bracket 327.1.2 Component set for sliding suspension with threaded pin 327.1.3 Component set for conductor connector 327.1.4 Isolating sections 327.2 Current collectors and current collector trolleys 337.2.1 Sliding contact set 33
8 Resistance to acids, chemicals and fuels 34
Fax: Enquiry 35Fax: Order 36
Table of contents
Manufacturer Demag Cranes & Components GmbHDrives
P.O. Box 67 D-58286 WetterTelephone (02335) 92-0 Telefax (0 2335) 92 7298E-mail drives@demagcranes.comwww.demagcranes.com
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1 General
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.
The following symbols and recommendations indicate potential safety hazards orcauses of damage or provide useful information.
Warning against dangerous electrical voltageContact with live parts can result in immediate death. Protective covers (e.g. coversand enclosures) marked with this sign may only be opened by qualified electricians.Before opening, all relevant operating, control, feed or other voltages must be dis-connected.
Operating hazard for the installation
This symbol in the operating instructions indicates all warnings which, if not compliedwith, may result in damage to the product.
1.1 Symbol description
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. tothe customers 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 inthe table below.
enilrotcudnoC
lairetamerusolcnE CVP
htgneldradnatS mm 0004
selop/srotcudnocforebmuN 7...4
.xamsnoisnepsusneewtebecnatsiD )2 mm 0001 )2 0002/
UegatloV N CAV 096sib42
eziS )1 53 06 001 041 002
)C53otFDC%001(tnerrucelbissimreP )1 A 46 87 001 041 061
noitcesssorcrotcudnoC mm 01 51 52 83 65
reppoclairetamrotcudnoC X X X X X
detalpleetssselniatslairetamrotcudnoC )5 X - - - -
erutarapmeterusolcnE/erutarepmettneibmA C 07+sib03-
92506NE/1.T0740EDVNIDssalcnoitcetorP edoC-PI pilgnilaeshtiw42PI/32PI
suidarmuminimnoitcesevruC mm $ mm008
noitcetorperiF eerf-negolahton;OV/49LU
yellortrotcelloctnerruC
selopforebmuN 7...4
lairetamtcatnocgnidilS eznorb etihparg etihparg-revlis
ItnerrucdetaR N )DE%08( A04 A02 A02
)4,3,2,1(noitcennocrewoprofnoitcesssorcnoitcennoC mm.xam 6 4
)7,6,5(elbaclortnocrofnoitcesssorcnoitcennoC mm.xam 5,2
)dradnats(htgnelelbacgnitcennoC )4 mm 0002
.xamnoitcetorpesuF A 001
.xamdeepslevarT nim/m 001 )3 002/
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2 Design and installation notes
Conductor lines must be operated in accordance with generally accepted engineer-ing 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.
Arms length is the area which a persons hand may reach in all directions fromnormal locations without any special equipment. Measured from the position where aperson is standing, this area ranges up to at least 2,5 m upwards and at least 1,25 mto the side and downwards (see DIN 31 001 Sheet 1).
Wherever large or long objects which are not insulated for the operating voltage aremoved, the minimum arms length must be correspondingly increased.
Protection against direct contact constitutes all measures to protect people fromhazards resulting from contact with live parts of electrical equipment. This may bepartial or full protection.
Partial protection only provides protection against accidental contact. Protectionagainst accidental contact does not mean any protection against deliberate contact.
Enclosure type IP 2X to DIN VDE 0470 Part 1 offers protection against accidentalcontact. Complete protection starts from IP 5X to DIN VDE 0470 Part 1.
Please note:
2.1 Definitions2.1.1 Arms length
2.1.2 Protection against indirectcontact
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3 Calculating and selecting the conductor cross-section
Voltage drop 1. and permissible current 2. must be considered when calculatingpower supply cross-sections.
1. - Calculate the cross-section considering the max. permissible voltage drop of2,5 % for crane runways + 2,5 % for crane bridge.
- The relevant value is thestarting current cos
Aof the largest motor + the rated current cos
Nof 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 cablesto 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
cosA) and rated currents (I
N cos
N)
(see table 1 below).The conductor cross-section may be determined according to the calculationmethod 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
For double drive arrangements correspondingly: 2 IA
cosA
or 2 IN
cosN.
Exception: For double hoist units with delayed startingIA
cosA
+ IN
cosN.
ybdefsenarcforebmuN
enilrotcudnoca
rehtegotnekatsenarcllafO
)tuptuoforedroni(
rotomts1 rotomdn2 rotomdr3 rotomht4
1 IA
soc A
IN
soc N
- -
2 I A soc A I N soc N I N soc N -
3 I A soc A I A soc A - -
4 I A soc A I A soc A I N soc N -
5 I A soc A I A soc A I N soc N I N soc N
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Abbreviations used in the equations:
A = Conductor cross-section of the DCL [mm]
L = cable length [m]
I = starting current (IA
cosA) or rated current (I
N cos
N) [A]
IG
= sum of the currents according to table 1 [A]
f = frequency in Hertz [Hz]
= conductibility (for Cu
= 56) [m/ m]
U = permissible voltage drop [V]
U = voltage in volts [V]
1. Conductor cross-section of the DCL
2. Required conductor length
3. Conversion for starting current IA
cos
Aor rated current I
N cos
N
fornon-standard voltage U
4. Conversion for conductor cross-section A
2for non-standard
conductor length L2
5. Permissible voltage drop
6. Conversion from 400 V, 50 Hz to anew voltage and frequency
3.1 Calculating the con-ductor cross-section
3.1.1 Calculation method
A =IxLx37,1 G
mm[ 2] xU
L1 = xU Ax
Xf2
]m[Ix37,1 G f1
I2 =U1 Ix 1
]A[U2
A2 =L2 Ax 1
mm[ 2]L1
U = )V004rof(V01=%5,2
U =%5,2xU
]V[%001
I wen = I dlo XV004
Xf wen
]A[U wen zH05
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Diagram 1
Calculating the conductor cross-section for the permissible voltage drop.
The DCL conductor line cross-section and/or voltage drop may be reduced by theposition and quantity of power feeds.
3.1.2 Graphical method
42226444.eps
for
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I35 [A]
25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 10050
75
100
125
150
175
200
225
250
275
300
ED [%]
DCL 35 (10mm )2DCL 60 (15mm )2DCL 60 (15mm )2
DCL 100 (25mm )2
DCL 140 (38mm )2
DCL 200 (56mm )2
292
270
253
238
226
216207
200 193187
181176
172 167 163 160
140
100100
78
64
142
103
80
6668707274
77808387
9196
102109
118
129
80838588
919497101
106111
117124
133
143
157
194
105108111115
119123
128133
139147
155
165
178
146149152
156161
165171
177184
191200
211
225
241
Check the maximum permissible current for the conductor cross-section as afunction of the cyclic duration factor (CDF) at 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
3.1.3 DCL maximum permissiblecurrent I
35[A] for an ambient
temperature of 35C
42226544.eps
Cyclic Duration
Factor
Perm
iss
iblecurren
t[A]a
t35Cam
bien
ttemp
era
ture
Maximum permissible current I
= I35
fu
Calculating the maximum permissible current I
[A] for other ambient temperatures
erutarepmettneibmA ]C[ 02 52 03 53 04 54 05 55 06 56
rotcafnoisrevnoC fu 02,1 41,1 70,1 00,1 29,0 48,0 47,0 46,0 15,0 53,0
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3.2 DCL basic structure
Model code:
(Example for ordering a straight section)
DCL - GS 4 - 60 - PE - 4000
Section - installation length [mm]
With protective earth conductor
Size
Number of poles
Component (GS = straight section)
Line
Compact
Demag
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
End cap, section 6.6
Sliding suspension /Fixed suspension,
section 5.1.1
Isolating section, section 6.11
Current collector trolley,
section 6.8
Standard towing arm,section 6.9.1
Transfer towing arm,section 6.9.2
Bronze contact 40 A,section 6.8.1 1)
Graphite contact 20 A,section 6.8.1 1)
C-rail mounting bracket,section 5.1
Threaded pin bracket,section 5.2
Entry funnel / Transfer funnel,section 6.7
Connector cap / End power feed,section 6.5
Line power feed,section 6.3
1) The sliding contacts of the control lines (poles 5, 6, 7) optionally are also availableas silver-graphite-sliding contact. Technical data and other notes cf. chapter 6.
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10
EKmin.250
B
A
65
EK
min.250
GAFA
400 2000
400
2000 2000 400
4000 4000 4000
4001600
2000 2000
AKGAGAGAGAAK
S
GAGAGA GA
SS S
1600
2000 2000 2000
400
4000 4000
2000
1600
min.250
4001600
min.250
Please note
In place of an AK connector end cap, a track extension, an entry section, or a transfer sectionmay 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 endcap is exactly 74 mm shorter than the rated length.
On request also available with connector end cap as track end cap so that thetrack can be extended.
- with an end power feed are supplied with a connector end cap (7) at both ends.
An installation with a connector end cap is exactly 130 mm longer than the ratedlength. Allow for clearance to connect the end power feed (approx. 250 mm).
4 General layout
42109645.eps
1)
1) When large cable cross-sections (from size PG42) are used with a DCL section with a line power feed, athird additional sliding suspension must be fitted close to the power feed enclosure.
2) Not shown
3) The 400 mm dimension must not be exceeded.
61
2
3
45
87 or
8
or 7
42106144.eps
(PE)
Steel structure etc.
Profile rib(orientationrib)
Section A - B
Clearance 250 Clearance 150
3) 3) 3) 3)
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.
metI noitangiseD snoisnemiD
1 noitcesthgiartsLCD SG mm0004
2 noitcesevrucLCD SB R $ mm008
3 rotcennoctnioJ S
4 noisnepsusgnidilS AG
5 noisnepsusdexiF AF
6 deefrewopeniL SE mm0004
7
pacdnerotcennoCdeefrewopdnesa
KApacdnerotcennoC
pacdnekcartsa
8 pacdnE KE
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mragniwoT )2
snoitcesrefsnartrofmragniwoT )2
lennufrefsnart/yrtnE )2
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5.1 DCL suspension with C-rail bracket5.1.1 Sliding suspension/fixed suspension
Flange clamp Part no.
Clamping range 8 to 16 mm 974 548 44Clamping range 16 to 30 mm 974 549 44
C-rail 40 x 25min. 100max. 165
C-rail 40 x 40min. 90max. 150
liar-Crof.ontraP 52x04
=L 003 44724869=L 005 44481058
=L 006 44055479
=L 007 44155479
=L 029 44355479
=L 0006 44006312
Attachment to upper flange I
Attachment to lower flange II
42206244.eps
42211144.eps
42211544.eps
42211444.eps
25 or 40
min.
120,m
ax.1
80
Adjusting
range
5 Suspension arrangements
Adjus
tingrange
42226044.eps
25
or40 04x04liar-CrofontraP
=L 0001 44455479
=L 0721 44572056
=L 0051 44472056
=L 0281 44125859
=L 0006 44106312
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5.1.2 Mounting and operating dimensions
42206344.eps
42211344.eps
42106344.eps
42211244.eps
min. 30max. 90
C-rail40 x 25
min. 10max. 75
C-rail40 x 40
min. 0max. 60
Adjus
tingrange
Adjus
tingrange
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Mountingarrangement I
Mounting ar-rangement II
Mountingbracket
C-rail clamp section
Fixed point 1)
The following information is required for ordering C-rails and flange clamps to fit DCLto I-beams:
C-rail type and length (see table on page 12). Flange clamps for -beams (see below).
tekcarbliar-ChtiwnoisnepsusgnidilsroftestnenopmoC .rN-lletseB
noitcespmalcliar-Cffo1
44836678tekcarbgnitnuomffo1
noisnepsusgnidilsffo1
42106344.eps
42211344.eps
Fixed point 1)
Mountingbracket
C-rail clamp section
Sliding supension
1) Only for fixed suspension. The fixed suspension is a sliding suspension which is fixed on the profile sectionby means of a self-tapping screw. Self-tapping screw 3,5 x 9,5 to DIN 7981.
htdiwredriG egnargnipmalC .ontraP
-061 004 mm61-8 44845479
-524 006 mm03-61 44945479
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Mounting angle
Adjus
tingrange
max.
43
M8 lock nut
42207444.eps
42106444.eps
Straight sections feature plastic sliding suspensions for connection to C-rail orthreaded 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 straightsections (see chapter 4).
Sliding suspensions must be fitted every 500 mm (along the curve) for curvedsections.
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 slidingsuspension.For DCL installations with entry/transfer sections, the funnels must be arrested.
5.3 Further fittinginformation
Fixed point 1)
1) Only for fixed suspension. The fixed suspension is a sliding suspension which is fixed on the profile sectionby means of a self-tapping screw. Self-tapping screw 3,5 x 9,5 to DIN 7981.
5.2 DCL suspension with M8 threaded pin5.2.1 Mounting and operating dimensions, sliding suspension/fixed suspension
Sliding suspension
nipdedaerht8MhtiwnoisnepsusgnidilsroftestnenopmoC .ontraP
gnittifnipdedaerhtffo1
4473667807x8Mwercsknusretnuocffo1
8Mtunkcolffo2
noisnepsusgnidilsffo1
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S = Joint connectors are pre-assembled on the conductor enclosures.
GA = Sliding suspensions: are fitted to the conductor enclosures and have to bepositioned during assembly.
- Additional sliding suspensions may be fitted.
- Specify suspension method 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 straightand 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.
Systems
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- orfor 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 protectivemarking (PE) is not applied. The sliding contacts are equipped in accordance with theconductor- / poles-quantity.
When all DCL straight and curve sections have been fitted, one sliding suspensionmust be fixed with a DCL straight section in the middle of the track (fixed point) toprevent the DCL installation moving to the side.
Fixed point or fixed suspension:
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.
6.1 DCL straight section 4, 5, 6 und 7 poles
42106144.eps
(PE)
Steel structureetc.
Profile rib(orientationrib)
6 Technical data
Protective earth symbol(only for conductor line with PE)
42207544.eps
Profile rib (orientation rib)
Suspension method
Attached to C-rail or suspended fromthreaded pin(must be ordered separate-ly, see sections 5.1.1 and 5.2.1)
Profile sealing lip: fitted as required.
May be added to order per meter.42212444.eps
1) Standard length 4000 mm. Indicate reduced length in order text for part no. Minimum reduced length500 mm. For complete conductor line installations, the entire conductor line length including the powerfeed(s) must be specified in the order text.
Use only the enclosed 3,5 x 9,5 self-tapping screws to DIN7981 as thereis a risk of accidental contact with live parts if longer screws are used.
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selopforebmuN
eziS
53 06 001 041 002
)2C53otpuFDC%001ta)A(tnerrucelbissimreP
46 87 001 041 061
mmnoitces-ssorcrotcudnoc3L-1L
01 51 52 83 65
4 44046678 44606678 44706678 44806678 44906678
3L-1LesahP
rotcudnocEP
elbaclortnoC
mm01x3
mm01x1
-
mm51x3
mm51x1
-
mm52x3
mm52x1
-
mm83x3
mm52x1
-
mm65x3
mm83x1
-
5 44146678 44016678 44116678 44216678 44316678
3L-1LesahP
rotcudnocEP
elbaclortnoC
mm01x3
mm01x1
mm01x1
mm51x3
mm51x1
mm01x1
mm52x3
mm52x1
mm01x1
mm83x3
mm52x1
mm01x1
mm65x3
mm83x1
mm01x1
6 44246678 44416678 44516678 44616678 44716678
3L-1LesahP
rotcudnocEP
elbaclortnoC
mm01x3
mm01x1
mm01x2
mm51x3
mm51x1
mm01x2
mm52x3
mm52x1
mm01x2
mm83x3
mm52x1
mm01x2
mm65x3
mm83x1
mm01x2
7 44346678 44816678 44916678 44326678 44426678
3L-1LesahP
rotcudnocEP
elbaclortnoC
mm01x3
mm01x1
mm01x3
mm51x3
mm51x1
mm01x3
mm52x3
mm52x1
mm01x3
mm83x3
mm52x1
mm01x3
mm65x3
mm83x1
mm01x3
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)
Part number table (conductor material copper)
The combinations of conductor quantity / number of poles and size indicated in theorder table can be purchased as components. As a standard material for theconductor copper is used. Alternatively, the conductor cross section 10 mm2 can beordered 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 especiallymentioned in the order.
For straight sections not fitted with a protective earth conductor (PE), this must beindicated 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 orderedseparately. Component sets for sliding suspensions with C-rail installation or threadedbolts M8 have to be selected with the corresponding quantity (cf. chapter 7.1).
Sliding suspensions are pre-mounted for the suspension distance 2000 mm.
1) Standard length 4000 mm. Indicate reduced length in order text for part no. Minimum reduced length500 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.
Model code Order text, e.g.:
DCL-GS-6-100-PE-4000
or DCL-GS-7-60-3500 (no PE, 3500 mm long)
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6.2 DCL curved section 4, 5, 6 and 7 poles
This diagram shows an inside curve
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.- 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 straightand 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.
42106144.eps
(PE)
Steel structure etc.
Profile rib(orientationrib)
42210444.eps
Profile rib (orientation rib)
Profile sealing lip: fitted as required.May be added to order per meter.
stra
ight straight
Suspension method
Attached to C-rail or suspended
from threaded pin (must beordered separately, see sections5.1.1 and 5.2.1)
For designing of systems with straight and curve sections the following has to beobserved:
The straight ends of the curve sections with 178 mm are fixed values and if necessaryhave to be deducted from the total length of the connecting straight section.
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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 (degrees)
Curve I or curve A 2)
Model code
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 curvedsection.
On curved sections which do not feature a protective earth conductor, the profile rib is only fororientation.
The view refers to the centre of the radius.
Order text, e.g.:
DCL-BS 5-100- PE- R = 1500, = 45, curve A 3)
3) Profile sealing lip may be added to order per meter. Please specify in the order.
For curved sections not fitted with a protective earth conductor (PE), this mustbe indicated in the order section and specified as a part no. with no PE.
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6.3 DCL line power feed 4, 5, 6 and 7 poles
S = Joint connectors are pre-assembled on the conductor enclosures.
GA = Sliding suspensions: are fitted to the conductor enclosures and haveto 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.
M6 slot-head screws
Prepared
opening
Connecting bar
only for 100 A,140 A and 200 ADCL conductor
Connecting terminal
42210544.eps
42109044.eps
Profile rib (orientation rib)
1)
Profile sealing lip: fitted as required.May be added to order per meter.
42212444.eps
2)
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.
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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)
selopforebmuN
eziS
53 06 001 041 002
)1C53otpuFDC%001ta)A(tnerrucelbssimreP
46 87 001 041 061
mmnoitces-ssorcrotcudnoc3L-1L
01 51 52 83 65
4 44646678 44056678 44156678 44256678 44356678
EP+3L-1L
elbaclortnoC
mm61-5,1x4
-
mm61-5,1x4
-
mm07-52x4
-
mm07-52x4
-
mm07-52x4
-
5 44746678 44456678 44556678 44656678 44756678
EP+3L-1L
elbaclortnoC
mm61-5,1x4
mm61-5,1x1
mm61-5,1x4
mm61-5,1x1
mm07-52x4
mm61-5,1x1
mm07-52x4
mm61-5,1x1
mm07-52x4
mm61-5,1x1
6 44846678 44856678 44956678 44066678 44166678
EP+3L-1L
elbaclortnoC
mm61-5,1x4
mm61-5,1x2
mm61-5,1x4
mm61-5,1x2
mm07-52x4
mm61-5,1x2
mm07-52x4
mm61-5,1x2
mm07-52x4
mm61-5,1x2
7 44946678 44266678 44366678 44466678 44566678
EP+3L-1L
elbaclortnoC
mm61-5,1x7
mm61-5,1x3
mm61-5,1x7
mm61-5,1x3
mm07-52x4
mm61-5,1x3
mm07-52x4
mm61-5,1x3
mm07-52x4
mm61-5,1x3
Part number table (conductor material copper)
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.
The combinations of conductor quantity / number of poles and size indicated in theorder table can be purchased as components. As a standard material for theconductor copper is used. Alternatively, the conductor cross section 10 mm2 can beordered 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 especiallymentioned in the order.
For line power feeds not fitted with a protective earth conductor (PE), this must beindicated 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 orderedseparately. Component sets for sliding suspensions with C-rail installation or threadedbolts M8 have to be selected with the corresponding quantity (cf. chapter 7.1).Sliding suspensions are pre-mounted for the suspension distance 2000 mm.
Model code Order text, e.g.:
Line power feed DCL-ES-4-140-PE
or DCL-ES-7-60 (no PE)
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The following information is required for ordering or selecting a connector end cap asa power feed (see model code order text):
Conductor line type, DCL AK connector end cap
Connection cross-section 16 mm (IN 60 A)
Prepared openings
Open as required andfit rubber sleeve(s).
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.
Rubber sleeves for cabledia. up to 24 mm 1)
Straight /curved section
AK = Connector end cap clipped together with the joint connector.
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.
6.4 DCL connector end cap as end power feed
42110444.eps
Connecting point on the conductor lug
Attach cable lugs to cables up to 16 mm 2)
Attach the cable lugs to the conductor lugs using M6 nuts andbolts.Clip
42210644.eps
Clearance
Model code Order text, e.g.:
DCL connector end cap as end power feed DCL-AK-16
Rubber sleeve PG 21
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6.5 DCL connector end cap as track end cap(for DCL conductor line with end power feed or with extended track)
The following information is required for ordering or selecting a connector end cap astrack end cap (see model code order text):
Conductor line type, DCL AKconnector end cap
Straight /curved section
AK = Connector end cap clipped together with the joint connector.
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.
42052444.eps
Connector end cap
42210744.eps
Clearance
Model code Order text, e.g.:
DCL connector end cap as track end cap DCL-AK
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6.6 End cap(for DCL installations with line power feed or sections subsequently cut to length on site)
The following information is required for ordering or selecting an end cap (see modelcode order text):
Conductor line type, DCL
EKend cap
Clearance
Straight /curved section
EK = End cap screwed together with the conductor enclosure.
GA = Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly.
Use only the enclosed 3,5 x 10 oval flat head screws to DIN7981 as there is a risk ofaccidental contact with live parts if longer screws are used.
42109544.eps
Oval flat head screw 3,5 x 10 DIN7981
42210844.eps
Model code Order text, e.g.:
End cap DCL-EK
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6.7 Entry/transfer section
Profile rib (orientation rib)
Profile sealing lip: fitted as required.May be added to order per meter.
View X View X
Orientation ribFunnel right-handOrientation rib
Funnel left-hand
42279444.eps
Suspension method
Attached to C-rail or suspended from threaded pin(must be
ordered separately, see sections 5.1.1 and 5.2.1)
aeralennufdaeDenilrotcudnoC mmnoisnemiD
1
3422
3
4
5 253
6342
7
EP 431
42212444.eps
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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 withself-tapping screw during assembly.
Use only the enclosed 3,5 x 9,5 self-tapping screws to DIN7981 as there is a risk ofaccidental contact with live parts if longer screws are used.
Part number table selopforebmuN epyT enilrotcudnoC
tnemngissa
.ontraP
4dnah-thgir
)EP(7,3-144596678
dnah-tfel 44007678
5dnah-thgir
5)EP(7,3-144696678
dnah-tfel 44107678
6dnah-thgir
6,4)EP(7,3-144796678
dnah-tfel 44207678
7dnah-thgir
6-4)EP(7,3-144896678
dnah-tfel 44307678
For transfer sections not fitted with a protective earth conductor (PE), this must beindicated 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 orprofile sealing lip.
Open the terminal box on the current collector trolley and separate the upper termi-nal box enclosure half on the prepared openings (prepared openings see figure insection 6.8).
The following information is required for ordering or selecting transfer sections(see model code order text):
Conductor line type, DCL
TR Transfer section
Type (L = left-hand or R = right-hand)
Number of poles ( 4,5, 6, or 7 conductors)
protective earth conductor PE (with or without)
Model code Order text, e.g.:
Transfer section (funnel right-hand) DCL-TR-4-PE
or (funnel left-hand) DCL-TL-7 (no PE)
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 theconductor copper is used. Alternatively, the conductor cross section 10 mm2 can beordered 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 especiallymentioned in the order.
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6.8 DCL current collector trolley 4, 5, 6 and 7 poles
42210944.eps
Guide wheel
Travel wheel
Guide roller
The current collector trolley mustbe prepared for DCL with entry/transfer setions or profile sealing lip.
Open the terminal box on the cur-rent collector trolley and separatethe upper terminal box enclosurehalf on both terminal box halvesalong the prepared opening.
41762044.eps
1
3
6
5
7
2
4
Preparedopening
(separate on
both sides)
1) Bronze sliding contact material,connecting conductor cross-sectionsL1 - L3 + PE max. 6,0 mm.
Control conductor connecting cable cross-section 1,5 mm.
Other cross-sections on request.
2) Graphite sliding contact material, connectingconductor cross-sections L1 - L3 + PE max.4,0 mm.
Control conductor connecting cable cross-
section 2,5 mm.Other cross-sections on request.
3) Sliding contact materials bronze and silver-graphite, connecting conductors L1 L3 + PE(bronze) max. 6.0 mm2. Connecting conductorsof the control conductors (silver-graphite)2.5 mm2. Other cross section on request.
noitangiseD .ontraP
seloP
I ,N /DE%08
lairetamtcatnocgnidilS
elbaccirteM
/noinu
ebutdetagurroc
elbacgnitcennoC
srotcudnoclatoT EP-2L-1L
lortnoC
rotcudnoc
04-4-WAS-LCD )1 44185678 4 4 0 RB/A04 -
71WN/52M
mm6x4
02-4-WAS-LCD )2 44285678 4 4 0 RB/A02 - mm4x4
04-5-WAS-LCD )1 44385678 5 4 1 RB/A04 RB/A04 mm)5,2x1+6x4(
02-5-WAS-LCD )2 44485678 5 4 1 RG/A02 RG/A02 mm)5,2x1+4x4(
M-04-5-WAS-LCD )3 44777678 5 4 1 RB/A04 RGIS/A02 mm)5,2x1+6x4(
04-6-WAS-LCD)1
44585678 6 4 2 RB/A04 RB/A04 mm)5,2x2+6x4(
02-6-WAS-LCD )2 44685678 6 4 2 RG/A02 RG/A02 mm)5,2x2+4x4(
M-04-6-WAS-LCD )3 44877678 6 4 2 RB/A04 RGIS/A02 mm)5,2x2+6x4(
04-7-WAS-LCD )1 44785678 7 4 3 RB/A04 RB/A04 mm)5,2x3+6x4(
02-7-WAS-LCD )2 44885678 7 4 3 RG/A02 RG/A02 mm)5,2x3+4x4(
M-04-7-WAS-LCD )3 44977678 7 4 3 RB/A04 RGIS/A02 mm)5,2x3+6x4(
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1) Current collector trolleys with graphite sliding contacts must be used in DCL installations operated close tothe sea, outdoors and in chemical environments. Use a higher number of current collector trolleys to ensurecontact 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 of3 - 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.
The following information is required for ordering a current collector trolley (see mod-el 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)
6.8.1 Current collector technicaldata
For current collecting trolleys not fitted with protective earth conductor (marking PEis 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. Themarking (PE) is not applied.
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 copperbars is recommended.If necessary, the use of at least 2 current collecting trolleys can be reasonable.
Model code Order text, e.g.:
DCL-SAW-4-40-PE
or DCL-SAW-7-20-3500 (no PE, 3500 mm connecting cable)
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egnarnoitacilppA ylppusygrenEylppusygrenE
noissimsnartataDnoissimsnartataD
egataloVelbissimreP V096ot42 .
tnerrucsuounitnoC )2
FDC%08htiw A04 A02 A02
FDC%06htiw A54 A02 A02
FDC%04htiw A05 A52 A52
elbacgnitcennoC )3EP+3L-1L mm0002xmm6 mm0002xmm4
elbaClortnoC DE%08,A52.xam,mm5.2
deepslevarT
noitcesthgiartS nim/m002.xam
noitcesevruCnim/m001.xam
srefsnarT
Rrofgnitaitogen-evruC $ mm008
Connecting cable length (mm)
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6.9 Towing arm for DCL current collector trolley6.9.1 Standard towing arm (not for transfer sections)
42225844.eps
42206144.eps
Detail X
Model code Order text, e.g.:
Towing arm DCL-MIT
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6.9.2 Towing arm for free transfer sections
42225944.eps
42226344.eps
Model code Order text, e.g.:
Towing arm for transfer section DCL-MIT
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6.10 Profile sealing lip
42212444.eps
Order text, e.g.:DCL profile sealing lip 876 508 44 1)DCL assembly tool for profile sealing lip 876 509 44Cyacrylat glue (super glue), 20 gr. 000 383 44 2)
6.10.1 Assembly tool for fitting theprofile sealing lip Disconnect the DCL installation from the power supply before fitting the
profile sealing lip.
Cable slider
42262144.eps
Handle
Roller pair
DCL assembly tool
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 fittogether.
Profile sealing lip length = 2 x DCL installation length
The profile sealing lips are individually pushed into both sides of the DCL conductorenclosure (see also assembly instructions 214 399 44, section 3.11.1).
If profile sealing lips are used with the DCL, the teminal box enclosure halveson the current collector trolley must be prepared. (see note in section 6.8).
1) Profile sealing lip may be added to order per meter. Please specify in the order.2) Order, if required.
Model code
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6.11 Isolating section
98
5,5
5
,5
5,5
5,5
5,5
205
5,5
5,5
5,5
42145244.eps
For control purposes, the DCL conductor line can be interrupted by means ofisolating 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 isrequired:
- postition of the isolating section/sections in the installation
- conductor no.
- length of each isolating section
Isolating
sectionU
off,isolatin
gsection
S
Isolatingsecti
onS
Cucondu
ctor
100A
Cucondu
ctor
100A
Cucondu
ctor
100A
Cucondu
ctor
100A
Model code Order text, e.g.:
Isolating section U 876 676 44
Isolating section S 876 678 44
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7 Component parts
7.1 Straight sections andaccessories
7.1.1 Component set for slidingsuspension with C-rail bracket
noitangiseD .ontraP
noisnepsusgnidilS
44736678gnittifnipdedaerhT
)ffo2(8MtunkcoL
07x8MwercsknusretnuoC
noitangiseD .ontraP
noisnepsusgnidilS
44836678tekcarbgnitnuoM
noitcesgnipmalcliar-C
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).
7.1.2 Component set for slidingsuspension with M8 threadedpin
noitangiseD ytitnauQ .ontraP
noitcesUrotcennocrotcudnoC 1
44396678
gulrotcennocrotcudnoC 2
02x6MwercsdaehdnuoR 2
6MtunkcoL 2
noitcespmalC )1 2
22x6MwercsdaehdnuoR 2
7.1.3 Component set for conductorconnector
noitangiseD .ontraP
UnoitcesgnitalosI )2 44676678
I noitcesgnitalos S )2 44876678
7.1.4 Isolating sections
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stestcatnocgnidilS
7+6/5-WAS-LCD
etihparg-revlis,A02/eznorb,A04 )3
noitangiseD .ontraP
A02/A04elop-5testcatnocgnidilS
)WASelop-5rof( 33627678A02/A04elop-7testcatnocgnidilS
)WASelop-7+6rof(33727678
7.2.1Current collector andcurrent collector trolley
The parts listed below are subject to a greater or lesser amount of wear while acurrent collector trolley is in operation.
Wear depends on various factors and is not determined by the current collector trolleyoperating period alone.Preventive maintenance is therefore required.
Worn current collector trolleys or other components must be replaced immediately.
stestcatnocgnidilS
-7+6/5+4-WAS-LCD eznorb,A04 )1
noitangiseD .ontraP
)WASelop-5+4rof(A04elop-5testcatnocgnidilS 33517678
)WASelop-7+6rof(A04elop-7testcatnocgnidilS 33617678
stestcatnocgnidilS
-7+6/5+4-WAS-LCD etihparg,A02 )2
noitangiseD .ontraP
)WASelop-5+4rof(A02elop-5testcatnocgnidilS 33717678
)WASelop-7+6rof(A02elop-7testcatnocgnidilS 33817678
Sliding contact set Bronze or Graphite
7.2 DCL Spare part-sets
Line power feed set
noitangiseD .ytQ .ontraP
LCD07edisnoitcennoC
)straptnorferusolcne(2
33235678
)strapediserusolcne(trapretneC 2
12GPtuopsyrtnE 1
24GPtuopsyrtnE 1
6Mtun.xeH 2
21x6Mwercs.lyC 2
End power feed set
Sliding contact set Bronze / Silver-Graphite
noitangiseD .ytQ .ontraP
pacdnE 2
3343567861-KA-LCDpacnoitcennoC 2
12GPtuopsyrtnE 4
5.9x5.3TSwercsgnippat-fleS 6
1) Sliding contacts power + control conductor: bronze
2) Sliding contacts power + control conductor: graphite
3) Sliding contacts power: bronzeSliding contacts control conductor: silver-graphite
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+ resistant resitant to a limited extent
- not resistant
8 Resistance to acids, chemicals and fuels
8.1 Acids
8.2 Fuels, oil, grease etc.
8.3 Chemicals
Applies to all chemicals:
Conductors (Cu) subject to increasedoxidation (corrosion)
Resistance information only valid forroom temperature (20 C).
muideM krameR
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dicacirtiN %01 +
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dicacirufluS %01 +
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dicacinobraC %01 +
dicacielO +
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dicacimroF %02 +
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C06+otC03+morf
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dicacitcaL %01 +
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dicacilaxO %01 +
dicacirolhcordyH %02
dicacirtiC %01 +
muideM krameR
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lortepedargrepuS
enisoreK
tiripsmuelortepetihW
lioleseiD
elozneB -
)scitamoramorfeerf(esaerg,liO +
tcatnoctceriddiovAliognillirD
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muideM krameR
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%1> / m5ecnatsidmuminiMretawainommA -
lohoclA +
snobracordyHcitahppila -
citamora -
stnevloscirolhC -
retsE -
enoteK -
enelyhterolhcirT -
stnevlosenilaclA .yawlareneganiderewsnaebtonnaC
etatecalyhtE
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etatecalytuB -
lonahteM -
louluT -
enelyX -
edirolhcartetnobraC
enotecA -
eylgnihcaelB
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EnquiryDemag Compact Line
Demag-Compact-Line O DCL - _____ - _____ PE - PVC
Selected/dimensioned by O Customer O Demag Wetter / Deutschland
Type _____ Number of poles _____ A (rated current)
Length _____ m
Rated voltage/frequency _____ V _____ Hz
Control voltage _____ V
Protective earth conductor PE O Yes O No
Complete DCL track O Yes _____ number of DCL tracks
O No O Spare parts see remark
Track layout O straight O curved
according to enclosed drawing
Electrical power feed point O Line power feed _____ number of
O End power feed _____ number of
Current collector trolley _____ number of _____ mm cable length
O Bronze sliding contacts
O Graphite sliding contacts
O Including standard towing arm (not for transfer sections)
Suspension method O C-rail O M 8 threaded pin
Accessories O Yes, the following: O No
Address and reference of the customer
_______________________________________________________________________
Remarks:
Project no.
Page 11 page(s)
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OrderDemag Compact Line
Demag-Compact-Line O DCL - _____ - _____ PE - PVC
Selected/dimensioned by O Customer O Demag Wetter / Deutschland
Type _____ Number of poles _____ A (rated current)
Length _____ m
Rated voltage/frequency _____ V _____ Hz
Control voltage _____ V
Protective earth conductor PE O Yes O No
Complete DCL track O Yes _____ number of DCL tracks
O No O Spare parts see remark
Track layout O straight O curved
according to enclosed drawing
Electrical power feed point O Centre power feed section _____ number of
O End power feed _____ number of
Current collector trolley _____ number of _____ mm cable length
O Bronze sliding contacts
O Graphite sliding contacts
O Including standard towing arm (not for transfer sections)
Suspension method O C-rail O M 8 threaded pin
Accessories O Yes, the following: O No
Address and reference of the customer
_______________________________________________________________________
Remarks:
Project no.
Page 11 page(s)
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Demag Cranes & Components GmbHAntriebstechnik
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