bus bar selection 20338744_0606073419

7/27/2019 bus bar selection 20338744_0606073419

1/40

Technical dataDemag Compact Line DCL

42211044.eps

070606 EN/PDF 070606 203 387 44 714 IS 962.2


2/40

20338744

.p65/070606

2

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 [email protected]


3/40

20338744

.p65/070606

3

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/


4/40

20338744

.p65/070606

4

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


5/40

20338744

.p65/070606

5

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


6/40

20338744

.p65/070606

6

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


7/40

20338744

.p65/070606

7

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


8/40

20338744

.p65/070606

8

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


9/40

20338744

.p65/070606

9

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.


10/40

20338744

.p65/070606

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

yellortrotcelloctnerruC )2

mragniwoT )2

snoitcesrefsnartrofmragniwoT )2

lennufrefsnart/yrtnE )2


11/40

20338744

.p65/070606

11

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


12/40

20338744

.p65/070606

12

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


13/40

20338744

.p65/070606

13

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


14/40

20338744

.p65/070606

14

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


15/40

20338744

.p65/070606

15

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.


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.


16/40

20338744

.p65/070606

16

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)


17/40

20338744

.p65/070606

17

6.2 DCL curved section 4, 5, 6 and 7 poles

This diagram shows an inside curve


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.


42210444.eps


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.


18/40

20338744

.p65/070606

18

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)


Radius (mm)

Angle (degrees)

Curve I or curve A 2)

Model code


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.


19/40

20338744

.p65/070606

19

6.3 DCL line power feed 4, 5, 6 and 7 poles


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


1)


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.


20/40

20338744

.p65/070606

20

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)


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)


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.


Line power feed DCL-ES-4-140-PE

or DCL-ES-7-60 (no PE)


21/40

20338744

.p65/070606

21

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.


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


DCL connector end cap as end power feed DCL-AK-16

Rubber sleeve PG 21


22/40

20338744

.p65/070606

22

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


AK = Connector end cap clipped together with the joint connector.



42052444.eps

Connector end cap

42210744.eps

Clearance


DCL connector end cap as track end cap DCL-AK


23/40

20338744

.p65/070606

23

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


EK = End cap screwed together with the conductor enclosure.


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


End cap DCL-EK


24/40

20338744

.p65/070606

2441761944.eps

6.7 Entry/transfer section



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


25/40

20338744

.p65/070606

25

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.


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):


TR Transfer section

Type (L = left-hand or R = right-hand)

Number of poles ( 4,5, 6, or 7 conductors)



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.


26/40

20338744

.p65/070606

26

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(



04-7-WAS-LCD )1 44785678 7 4 3 RB/A04 RB/A04 mm)5,2x3+6x4(




27/40

20338744

.p65/070606

27

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):


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.


DCL-SAW-4-40-PE

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

lairetamtcatnocgnidilS eznorB etihparG )1 etihparG-revliS )1

egnarnoitacilppA ylppusygrenEylppusygrenE

noissimsnartataDnoissimsnartataD

egataloVelbissimreP V096ot42 .

tnerrucsuounitnoC )2

FDC%08htiw A04 A02 A02



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)


28/40

20338744

.p65/070606

28

6.9 Towing arm for DCL current collector trolley6.9.1 Standard towing arm (not for transfer sections)

42225844.eps

42206144.eps

Detail X


Towing arm DCL-MIT


29/40

20338744

.p65/070606

29

6.9.2 Towing arm for free transfer sections

42225944.eps

42226344.eps


Towing arm for transfer section DCL-MIT


30/40

20338744

.p65/070606

30

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


31/40

20338744

.p65/070606

31

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


Isolating section U 876 676 44

Isolating section S 876 678 44


32/40

20338744

.p65/070606

32

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


33/40

20338744

.p65/070606

33

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


stestcatnocgnidilS

-7+6/5+4-WAS-LCD etihparg,A02 )2

noitangiseD .ontraP



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


34/40

20338744

.p65/070606

34

+ 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

dicA .cnoC

dicacimorhC %04 .tcatnoctceriddiovAdicaciruflus-cimorhC %02

dicacirtiN %01 +

stcatnocgnidilsforaewdesaercnI

dicacirufluS %01 +

dicacionahtE %5 +

dicacinobraC %01 +

dicacielO +

dicaciratrat-D %01 +

dicacimroF %02 +

C03+erutarepmet.xaM

C06+otC03+morf

srotcelloctnerrucforaewdesaercnI

dicacinesrA %02 +

dicaciroB %01 +

dicaciroulfordyH +

dicacitcaL %01 +

dicacirohpsohP %05 +

dicacilaxO %01 +

dicacirolhcordyH %02

dicacirtiC %01 +

muideM krameR

tiripsmuelorteP

tcatnoctceriddiovA

lortepralugeR

lortepedargrepuS

enisoreK

tiripsmuelortepetihW

lioleseiD

elozneB -

)scitamoramorfeerf(esaerg,liO +

tcatnoctceriddiovAliognillirD

lioekarbETA

sffutsdooF +

retawaeSmk5ecnatsid +

muideM krameR

snoitulosenilaklA%1< +

%1> / m5ecnatsidmuminiMretawainommA -

lohoclA +

snobracordyHcitahppila -

citamora -

stnevloscirolhC -

retsE -

enoteK -

enelyhterolhcirT -

stnevlosenilaclA .yawlareneganiderewsnaebtonnaC

etatecalyhtE

lonatuB -

etatecalytuB -

lonahteM -

louluT -

enelyX -

edirolhcartetnobraC

enotecA -

eylgnihcaelB


35/40

20338744

.p65/070606

35

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)


36/40

20338744

.p65/070606

36

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)

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not l iable for errors or omissions. Subject to change.Prin

tedinGermany

DZS/120

0/2T/PDF080704


37/40

20338744

.p65/070606

37

Notes


38/40

20338744

.p65/070606

38

Notes


39/40

20338744

.p65/070606

39

Notes


40/40

Demag Cranes & Components GmbHAntriebstechnik

Documents

bus bar selection 20338744_0606073419