Vahle f Seri̇si̇ Bara

8/12/2019 Vahle f Sers Bara

1/24

COPPERHEAD

CONDUCTOR SYSTEMS


2/24

VAHLE RAIL SYSTEMS

2

19 12

INDEXPage

Basic Description, Advantages 2

Selection of Conductorsand Engineering Data 3

Steel Copperhead Rails

and Accessories 4-6

Aluminium Copperhead Rails

and Accessories 8, 9

Hollow Aluminium Copperhead Rails

and Accessories 10

Fibreglass Copperhead Rails

and Accessories 11

Solid Copper Rails and Accessories 12

Page

Railholders and Ground Supports 13

Insulators up to 1000 V 14

High Voltage Insulators 15

Current Collectors 16, 17

Spare Parts for Current Collectors 18

Installation Information 19

Heating Systems 20, 21

Questionnaire 22

Vahle Rails in Action 7, 23

All Vahle Electrification Systems back cover

BASIC DESCRIPTION

The Copperhead Conductor Rail was invented by PAUL VAHLE

in the year 1912, and from this beginning the VAHLE COMPA-

NY continuously improved and developed the many Rail Sys-

tems, detailed in this catalogue.

The T or hollow T section and the extruded copperhead is

drawn through a special die, which compresses the copper

flanges around the dovetail head of the rail, connecting the two

components to a 100 % rigid unit.

The well-known VAHLE Copperhead Conductor Rails represent

a neat and compact arrangement and have proven an out-

standing success for safe power feeding of:

Travelling cranes, Loading bridges, Container handling

equipment, Monorails, Hoists, Coking machinery and

many other applications.

The VAHLE Copperhead Conductor Rails are available in sizesto meet individual current requirements from 200 to 1,500 Amps.

SOME ADVANTAGES OF VAHLE RAIL SYSTEMSWith VAHLE-Systems you eliminate all drawbacks inherent in

the conventional design of trolley wires, steel angles and steel

rails.

Copperhead Rails ensure an efficient and continuous contact.

There is no sparking.

The easy maintenance is a proven low factor.

No losses due to interruption of service, no downtime.

Negligible wear - almost unlimited life of conductors.

Much lower resistance between copperhead and carbon pick-

up shoe.

The main users are:

Steel mills, Coking plants, Gas works, Cement indus-

tries, Ship yards and Dockside enterprises.

Fibreglass-Copperhead Rails are preferably used for applica-

tions in corrosive atmospheres and in locations with high

humidity.

Aluminium-Copperhead Rails are very economical due to the

light weight of the Aluminium and its high conductivity.

Solid-Copper Rails are recommended for heavy duty current

rating and for humid locations.

The rails are supplied in 7 m (23) and 14 m (46) standard

lengths, drilled at either end for joint plates or expansion

connectors. Shorter lengths are available to coincide with your

run way lengths requirements.

We produce a complete range of Accessories, Insulators andCurrent Collectors.

Low weight of rails and saving of steel superstructure and

space.

Variation in temperature and resulting expansion and contrac-

tion is compensated by standard expansion joints.

If required, VAHLE Copperhead Rails can also be supplied bent

to your specification.

Heating systems are available for all VAHLE Rails.

For Ducting Systems and Housings incorporating VAHLE Rails

and Accessories see separate catalogue No. 5 -

Heavy Enclosed Conductor Systems.


3/24

19 12SELECTION OF CONDUCTORS

3

Adequate Ampere Capacity must be providedto carry the anticipated electrical loads:The total Ampere load is determined from the nominal ratedfull load current reduced by the duty cycle (fED) and by adiversity factor for non-simultaneous operation.

The average crane motor duty cycle is usually between 40%and 60%, depending on the type of application.

A diversity factor of 0.4 to 0.7 can be used when there aremore than one crane on the same runway.

Example:3 cranes, each In = 300 Amps.

Length of runway: 100 m (330)

Assumed duty cycle: 60% (ED)

Assumed diversity factor: 0.7

Ampere load per crane: In x fED = 300 A x 0.78 = 234 A

Ampere load for 3 cranes: 234 A x 3 = 702 A

Total Ampere load when using

a diversity factor of 0.7: 702 A x 0.7 = 491.4 A

Selected conductors: F 35/100or: F 45/50

Formula for Voltage Drop Calculation:

AC: u = 3 x I x l x Z

DC: u = 2 l x I x R

u = Voltage drop [V] R = Resistance [Ohm/m]

I = Ampere load [A] l = Length from power feedto end of conductor [m]

Z = Impedance [Ohm/m] L = System length [m]

Effectice Length:

l =L power feed located at the end of the system

l =L/2 power feed located at the mid-point of the system

l =L/4 power feed located at both ends of the system

l =L/6 power feed located atL/6 from each end ofthe system

Engineering data

ConductorType

MaximumContinuous

Amps.

ResistanceOhm/ 000 m

Impedance*Ohm/ 000 m

L 20/ 14 220 0.506 0.573

L 20/ 25 256 0.386 0.458

L 20/ 50 327 0.25 0.336

L 20/100 444 0. 48 0.253

F 35/ 30 320 0.264 0.345

F 35/ 50 4 0 0.204 0.293

F 35/100 529 0. 30 0.238

F 35/150 632 0.096 0.2 4

F 35/200 724 0.076 0.203

F 45/ 50 495 0. 78 0.266

F 45/100 620 0. 9 0.223

F 45/150 728 0.089 0.203

F 45/200 826 0.072 0. 94

F 45/300 000 0.05 0. 82

F 45/400 56 0.040 0. 74

F 45/500 299 0.033 0. 69

F 45/600 432 0.028 0. 65

A 2 0/ 14 445 0. 83 0.255

A 3 5/ 30 600 0. 0 0.227

A 3 5/ 50 675 0.09 0.220

A 35/100 795 0.072 0.207

A 45/ 50 790 0.07 0.20

A 45/100 9 5 0.060 0. 93

A 45/150 025 0.05 0. 88

A 45/200 0 0.045 0. 84

A 45/300 295 0.036 0. 77

A 45/400 45 0.030 0. 72

AC 45/ 60 000 0.053 0. 87

AC 45/110 080 0.046 0. 84

AC 45/150 60 0.042 0. 8AC 45/200 225 0.038 0. 79

AC 45/300 370 0.032 0. 74

K 45/ 60 220 0.300 0.364

K 45/110 380 0. 64 0.248

K 45/150 480 0. 20 0.2 7

K 45/200 575 0.090 0. 99

K 45/300 740 0.060 0. 82

C 20/200 720 0.088 0.227

C 35/400 080 0.045 0. 97

C 45/500 2 0 0.036 0. 87

C 45/600 365 0.03 0. 69

C 45/800 580 0.023 0. 68

Up to 4000 Amp. Special conductor rails are available.

* Impedance data based on 50 mm spacing between phases and 50 Hz.Current ratings are based on a temperature rise of 30C over 30C ambient.

ConductorType

MaximumContinuous

Amps.

ResistanceOhm/ 000 m

Impedance*Ohm/ 000 m

Other Criterion:

a) Select the conductor cross section to carry the calculated

total Ampere load and consider the voltage drop calcula-

tion to maintain the limits established by the motor manu-

facturers. The conductor size and/or number of feed

points should be increased in case the drop is exceeding

the limitations. For very high Ampere loads it may be

necessary to provide booster cables.

b) Specify the correct VAHLE-conductor by considering the

type of application and environment, such as heavy or light

duty service, corrosion, heat, humidity, internal standards.

duty cycle fED

100 % 1.00

80 % 0.90

60 % 0.78

50 % 0.7140 % 0.63


4/24

STEEL-COPPERHEAD RAILS

4

19 12

Type

Coppercross

section

mm2

Steelcross

section

mm2

Equival.total

coppercon-

ductor

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

L 20/ 14-7 4 50 36 3 6,5 20 .24 220 00 007

L 20/ 25-7 25 50 47 33 8 20 .34 256 00 0 7

L 20/ 50-7 50 50 72 34 0 20 .57 327 00 027

L 20/100-7 00 50 22 38.5 2 20 2.02 444 00 037

Standard lengths:

7 m (23)

Best applicable collectors: DVD 1 and DVD

Main application:

conductor system for hoists and monorails, down-shopand cross travel supply for light cranes

Type

Copper

crosssection

mm2

Steel

crosssection

mm2

Equival.

totalcoppercon-

ductor

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

F 35/ 30-7 30 265 69 32 4.2 35 2.34 320 04 3 7

F 35/ 50-7 50 265 89 33. 4.6 35 2.52 4 0 00 047

F 35/100-7 00 265 39 36.0 5.3 35 2.97 529 00 057

F 35/150-7 50 265 89 38.3 7.3 35 3.42 632 00 067

F 35/200-7 200 265 239 40.8 7.3 35 3.87 724 00 077

Standard lengths:7 m (23)

Best applicable collectors: GSV 1, GSV 2, GSV 4 and GSV 8

Main application:conductor system for heavy monorails, down-shop andcross travel supply for medium duty cranes

Type

Coppercross

section

mm2

Steelcross

section

mm2

Equival.total

coppercon-

ductor

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

F 45/ 50-7 50 355 02 43. 4.6 45 3.23 495 00 087

F 45/100-7 00 355 52 46.0 5.3 45 3.68 620 00 097

F 45/150-7 50 355 202 48.3 7.3 45 4. 3 728 00 07

F 45/200-7 200 355 252 50.8 7.3 45 4.58 826 00 7

F 45/300-7 300 355 352 56.3 7.6 45 5.48 000 00 27

F 45/400-7 400 355 452 59.3 9.6 45 6.38 56 00 37

F 45/500-7 500 355 552 64.3 9.6 45 7.28 299 00 47

F 45/600-7 600 355 652 65.0 23.2 45 8. 8 432 00 57

Standard lengths:

7 m (23)


The steel sections can be supplied galvanized or with anticorrosion paint.

Main application:

down-shop and cross travel supply for heavy cranes,loading bridges, coking machinery, rapid transit systems etc.

Scale :


5/24

ACCESSORIES

5

19 12

Expansion Joints

Type MaterialWeight

kgCatalog-No.

DLM 20/ 14 0.32 00 60

DLM 20/ 25brass

0.35 00 70

DLM 20/ 50 0.38 00 80

DLM 20/100 0.42 00 90

Rigid Joints

Type MaterialWeight

kgCatalog-No.

SMDV 35/ 30 . 5 04 340

SMDV 35/ 50 . 5 00 300

SMDV 35/100 brass .25 00 3 0

SMDV 35/150 .39 00 320

SMDV 35/200 .48 00 330

SMDV 45/ 50 .46 00 340SMDV 45/100 .56 00 350

SMDV 45/150 .69 00 360

SMDV 45/200brass

.80 00 370

SMDV 45/300 3.06 00 380

SMDV 45/400 3.29 00 390

SMDV 45/500 3.5 00 400

SMDV 45/600 3.78 00 4 0

Type MaterialWeight

kgCatalog-No.

KLM 20/ 14-100 0.35 00 500

BLM 20/ 14-100 0. 8 00 5 0

MFV 35/ 30-200 0.4 05 893

MFV 45/ 50-200 0.46 05 897

MFV 45/300-600 .28 00 540

brass

brass

brass

brass

brass

Scale : 5

Type MaterialWeight

kgCatalog-No.

KBV 45/ 50 3.6 00 420KBV 45/100 3.98 00 430

KBV 45/150 4.70 00 440

KBV 45/200brass

4.90 00 450

KBV 45/300 7.59 00 460

KBV 45/400 7.76 00 470

KBV 45/500 7.94 00 480

KBV 45/600 8.0 00 490


6/24

ACCESSORIES

6

19 12

Feeder Clamps

Type MaterialWeight

kgCatalog-No.

LM 20/ 14-100 brass 0. 7 00 590

Cu 20/ 14 0.06 00 600Cu 20/ 25 0.08 04 840

Cu 20/ 50copper

0.08 04 850

Cu 20/100 0.09 04 860

Cu 35/ 30 0. 6 04 360

Cu 35/ 50 0. 7 00 6 0

Cu 35/100 copper 0. 8 00 620

Cu 35/150 0. 9 00 630

Cu 35/200 0.20 00 640

Cu 45/ 50 0.20 00 650

Cu 45/100 0.2 00 660

Cu 45/150copper

0.22 00 670

Cu 45/200 0.22 00 680

AM 35/ 30-200brass

0.44 05 050

AM 45/ 50-200 0.60 05 080

BK 45/ 50-200brass

.29 00 700

BK 45/300-600 .29 03 460

KK 45/300 .26 00 7 0

KK 45/400brass

.89 04 760

KK 45/500 .89 04 770

KK 45/600 .89 04 780

Locating clamps

Type MaterialWeight

kgCatalog-No.

LK 20 0.04 00 550

SK 35 0. 00 560

SK 45 0. 2 00 570

SKK 45 polyamid 0.23 00 580

galvanized

galvanized

galvanized


7/24

VAHLE RAILS IN ACTION

7

19 12

Bridge CraneConductor Transfer Ends

Coking Plant


8/24

ALUMINIUM-COPPERHEAD RAILS

8

19 12

Type

Coppercross

section

mm2

Alu-miniumcross

section

mm2

Equival.total

coppercon-

ductor

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

A 20/14-7 4 50 90 3 6.5 20 0.52 445 03 647

Standard lengths:

7 m (23)

Best applicable collectors: DVD 1 and DVD

Main application:

conductor system for hoists and monorails, down-shopand cross travel supply for light cranes

Type

Coppercross

section

mm2

Alu-miniumcross

section

mm2

Equival.total

coppercon-

ductor

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

A 35/ 30-7 30 265 60 32 4.2 35 .00 600 04 327

A 35/ 50-7 50 265 80 33. 4.6 35 . 8 675 03 657

A 35/100-7 00 265 230 36 5.3 35 .63 795 03 667

Standard lengths:

7 m (23)

Best applicable collectors: GSV 1 and GSV 2

Main application:

conductor system for heavy monorails, down-shop andcross travel supply for medium duty cranes

Type

Coppercross

section

mm2

Alu-miniumcross

section

mm2

Equival.total

coppercon-

ductor

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

A 45/ 50-7 50 355 225 43. 4.6 45 .42 790 03 677

A 45/100-7 00 355 275 46.0 5.3 45 .87 9 5 03 687

A 45/150-7 50 355 325 48.3 7.3 45 2.32 025 03 697

A 45/200-7 200 355 375 50.8 7.3 45 2.77 00 03 587

A 45/300-7 300 355 475 56.3 7.6 45 3.67 295 03 707

A 45/400-7 400 355 575 59.3 9.6 45 4.57 45 03 7 7

Standard lengths:

7 m (23)


Main application:

down-shop and cross travel supply for heavy cranes,

loading bridges, coking machinery, rapid transit systems etc.

Extra protection paint for rails is available.Rail supports must be of polyamid or of aluminium for heavy duty & high-temp.

Locating Clamps

Type MaterialWeight

kgCatalog-No.

LK 20 galvanized 0.04 00 550

SK 35 galvanized 0. 00 560

SK 45 galvanized 0. 2 00 570


Scale :


9/24

LA 20/14 LM 20

AMA 35 AM 35/45

KKA 45/ 50150 KK 45/300

KKA 45/200400 KK 45/400600

ACCESSORIES

9

19 12

Feeder Clamps

Type MaterialWeight

kgCatalog-No.

LA 20/14 brass 0. 4 03 540

AMA 35/ 30 0.44 05 00AMA 35/ 50 brass 0.44 05 0

AMA 35/100 0.44 05 20

KKA 45/ 50 .26 04 790

KKA 45/100 .26 04 800

KKA 45/150 brass .89 04 8 0

KKA 45/200 .89 05 30

KKA 45/300 .89 04 820

KKA 45/400 .89 04 830

Expansion Joints

Type MaterialWeight

kgCatalog-No.

DMA 20/14 brass 0.43 03 720

SMDA 35/ 30 .42 04 350

SMDA 35/ 50 brass .52 03 780

SMDA 35/100 .7 03 790

SMDA 45/ 50 .9 03 800

SMDA 45/100 2.79 03 8 0

SMDA 45/150 brass 3. 8 03 820

SMDA 45/200 6.86 05 679SMDA 45/300 3.8 03 830

SMDA 45/400 3.87 03 840

KBA 45/ 50 3.86 03 850

KBA 45/100 4.00 03 860

KBA 45/150 brass 6.94 03 870

KBA 45/200 6.86 05 680

KBA 45/300 7.93 03 880

KBA 45/400 8.0 03 890

Rigid JointsType Material

Weightkg

Catalog-No.

ALM 20/14 brass 0.26 0 020

MFVA 35/ 30-100 brass 0.59 05 903

MFVA 45/ 50-200 brass 0.66 05 50

MFVA 45/300-400 brass .28 05 60

Drawings see page 6

Scale : 5


10/24

HOLLOW-ALUMINIUM-COPPERHEAD RAILS AND ACCESSORIES

0

19 12

Type

Coppercross

section

mm2

Equival.total

coppercon-

ductormm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

AC 45/ 60-7 60 360 4 22 45 2. 5 000 00 777

AC 45/110-7 0 4 0 42 23 45 2.60 080 00 787

AC 45/150-7 50 450 43 24 45 2.96 60 00 797

AC 45/200-7 200 500 43 25 45 3.4 225 00 807

AC 45/300-7 300 600 49 24 45 4.3 370 00 8 7

Standard lengths: 7 m (23)


Type MaterialWeight

kgCatalog-No.

ADV 45/ 60 7. 8 04 680

ADV 45/110 7. 8 04 690

ADV 45/150 brass 7.60 04 700

ADV 45/200 7.60 04 7 0

ADV 45/300 7.60 04 720

AFV 45/ 60brass

.98 05 60

AFV 45/110-300 .90 0 000


KA 45/ 60brass

2.03 05 649

KA 45/110-300 .95 0 0 0

Expansion Joints

Rigid Joints

Locating Clamps

Feeder Clamps

Extra protection paint for rails is available.Rail supports must be of polyamid or of aluminium for heavy duty & high-temp.

Scale 1 : 1

Scale : 5


11/24

FIBREGLASS-COPPERHEAD RAILS AND ACCESSORIES 19 12

Type

Coppercross

section

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

K 45/ 60-7 60 4 22 45 .6 220 00 727

K 45/110-7 0 42 23 45 2.06 380 00 737

K 45/150-7 50 43 24 45 2.4 480 00 747

K 45/200-7 200 43 25 45 2.86 575 00 757

K 45/300-7 300 49 24 45 3.75 740 00 767

Type MaterialWeight

kgCatalog-No.

KDV 45/ 60 5.24 00 860

KDV 45/110 5.4 00 870

KDV 45/150 brass 5.64 00 880

KDV 45/200 5.89 00 890

KDV 45/300 6. 00 900

KFV 45/ 60brass

.98 05 60

KFV 45/110-300 .90 0 000


KA 45/ 60brass

2.03 05 649

KA 45/110-300 .95 0 0 0

Expansion Joints

Rigid Joints

Locating Clamps

Feeder Clamps

Standard lengths:

7 m (23)


Main application:

down-shop and cross travel supply for medium and

heavy duty cranes, loading bridges etc. in locations withvery high humidity and very corrosive atmosphere.

Rail supports must be of polyamid.

Scale :

Scale : 5


12/24

SOLID-COPPER RAILS AND ACCESSORIES

2

19 12

Type

Coppercross

section

mm2

H

mm

a

mm

b

mm

Weight

kg/m

Max.conti-nuous

A

Catalog-No.

C 20/200-7 200 32 2 20 .86 720 00 827

C 35/400-7 400 45 2 35 3.55 080 00 837

C 45/500-7 500 50 6 45 4.45 2 0 00 937

C 45/600-7 600 50 25 45 5.32 365 00 847

C 45/800-7 800 50 27 45 7. 2 580 00 857

Standard lengths:

7 m (23)

Best applicable collectors: for C 20/200: DVD, SO and BVSfor C 35/400, C 45/500, C 45/600, C 45/800: GSV 1, GSV 2,

GSV 4, GSV 8

Main application:

C 20/200 and C 35/400 in conjunction with heavy enclosedconductor systems.

C 45/- series for heavy duty current ratings.

Expansion Joints

Type MaterialWeight

kgCatalog-No.

DP 20/200 .0 00 960

DP 35/400 2.56 00 970

DP 45/500 brass 7.00 00 940

DP 45/600 7.80 00 980

DP 45/800 8.50 00 990

Rigid JointsType Material

Weightkg

Catalog-No.

CP 20/200 0.20 0 00

CP 35/400 0.50 0 0

CP 45/500 copper . 5 00 950

CP 45/600 . 5 0 20

CP 45/800 .33 0 30

Locating Clamps

Type MaterialWeight

kgCatalog-No.

LK 20 steel 0.04 00 550

SK 35 steel 0. 00 560

SK 45 steel 0. 2 00 570

Feeder Clamps

Type MaterialWeight

kgCatalog-No.

CKK 20/200 copper 0.25 0 40

CKK 35/400 copper .50 0 50

CKK 45/500 copper .95 0 500

CKK 45/600 brass .95 0 60CKK 45/800 brass .95 0 70

Scale : 5


13/24

RAIL HOLDERS AND GROUND SUPPORTS

3

19 12

* Bolt 50 mm

Rail Holders

Type MaterialWeight

kgCatalog-No.

SD 20 steel 0. 5 0 80

SD 35 steel 0.20 0 90

SH 35 steel 0.36 0 200

SKD 35 polyamid 0.05 0 220

SC 35 steel 0.57 0 230

SA 45 aluminium 0.23 04 600

SD 45 steel 0.2 0 240

SH 45 steel 0.36 0 250

SKD 45 polyamid 0.07 0 270

SC 45 steel 0.57 0 280

SSR 45 steel 0.45 04 730

Rail Supports for Ground

Type MaterialWeight

kg

Catalog-No.for bolt lengths

20 mm

Catalog-No.for bolt lengths

80 mm

STD 20 steel 0.26 0 290

STD 35 0.47 05 68 0 300

STH 35 steel 0.64 05 682 0 3 0

STC 35 0.94 05 683 0 320 *

STD 45 0.49 05 684 0 330

STH 45 steel 0.64 05 685 0 340

STC 45 0.94 05 686 0 350 *

STKD 35 0.33 05 687 03 380STKD 45

polyamid0.35 05 688 03 390

Fr A-Schienen nur Schienenhalter Typ SKD oder SA verwen-den. Fr K-Schienen nur SKD-Schienenhalter verwenden.

Scale : 5

Scale : 5


14/24

INSULATORSUP TO 1000 V

4

19 12

Typefor

Railbase

Material Weightkg

Catalog-No.for bolt lengths 3040 mm

Phase Ground

Catalog-No.for bolt lengths 70 mm

Phase Ground

Leakage-Distance

mm

RailMounting

Possibilities

Mechanical Strengths (kp)

Tension Compress. Cantilever

white brownD 80 20 mm 60 800 800 450 0.6 0 380 0 390

all white brownVO rails 60 800 800 700 .02 05 667 05 668 0 400 0 4 0VDO 35 35 mm 60 800 800 700 .20 05 669 05 670 0 580 0 590VDO 45 45 mm 60 800 800 700 .22 05 67 05 672 0 660 0 670

VAB all 00 2 00 2 00 770 .5 05 673 05 674 0 440 0 450VHB rails 00 2 00 2 00 770 .5 0 520 0 530 2 900 05 572VDB 35 35 mm 00 2 00 2 00 770 .49 05 675 05 676 0 620 0 630VDB 45 45 mm 00 2 00 2000 770 .55 05 677 05 678 0 700 0 7 0

light yellowVDK 20 20 mm 60 300 0.04 0 780 0 790VDK 35 35 mm 60 600 0. 7 0 800 0 8 0

brown yellowGH 45 70 600 500 600 0.26 0 820 0 830GH 50 80 800 2000 900 0.56 0 840 0 850GH 80 all 20 2 00 2000 950 0.82 0 860 0 870GHH 30 rails 65 000 500 450 0. 6 06 090 06 09GHA 75 5 600 2000 650 0.64 0 900 0 9 0

GHH 75 5 600 2000 650 0.64 0 880 0 890GHA 80 25 2 00 2000 950 0.87 04 650 04 660GHH 80 25 2 00 2000 950 0.87 04 630 04 640

porcelain

porcelain

polyamid

resin

Scale 1 : 5


15/24

HIGH VOLTAGE INSULATORS

5

19 12

Type Voltage Materialmax.

TemperaturC

Weightkg

Catalog-No.

Phase Ground

LeakageDistance

mm

RailMounting

Possibilities

Mechanical Strengths (kp)

Tension Compress. Cantilever

brown yellow

GH 130 6 kV 2 0 5000 7000 2000 90 .25 04 670 04 750

white brown

VAM 6 kV 220 2500 3000 550 3.28 0 920 0 930

VHM 6 kV 220 2500 3000 55040

3.28 0 940 0 950

brown brown

VAK 20 kV 400 2000 2500 500 7.09 02 000 02 000

VHK 20 kV 400 2000 2500 50040

7.09 02 020 02 020

resin

porcelain

porcelain

Scale : 5


16/24

HEAVY DUTY CURRENT COLLECTORS

6

19 12

Type

Capa-city

A

Pick-up Shoes

Material Dimensions mm

Weight

kg

Catalog-No.

Ground

Phase insul. uninsul.

GSV 1 00 graphite 50 x 00 x 20 5.20 02 080 02 090 03 920carbon

GSV 1/mi 00 met.-impr. 50 x 00 x 20 5.33 02 00 02 0 03 930carbon

GSV 1/S 00 graphite 80 x 00 x 30 5.82 02 20 02 30 03 940carbon

GSV 1/Smi 00 met.-impr. 80 x 00 x 30 6.0 02 40 02 50 03 950carbon

GSV 1/Ms 00 brass 60 x 00 x 2 5.52 02 60 02 70 03 960

Type

Capa-city

A

Pick-up Shoes


Weight

kg

Catalog-No.

Ground


GSV 2 200 graphite 80 x 40 x 30 9.30 02 200 02 2 0 03 980carbon

GSV 2/mi 200 met.-impr. 80 x 40 x 30 9.55 02 220 02 230 03 990carbon

GSV 2/Nmi 200 met.-impr. 80 x 40 x 30 8.86 02 240 02 250 04 000carbon

GSV 2/Ms 200 brass 90 x 25 x 5 9.56 02 260 02 270 04 0 0

GSV 2/GG 200 cast iron 90 x 40 x 5 9.22 02 280 02 290 04 300

Type

Capa-city

A

Pick-up Shoes


Weight

kg

Catalog-No.

Ground


GSV 4 400 graphite 00 x 40 x 30 .72 02 300 02 3 0 04 020carbon

GSV 4/mi 400 met.-impr. 00 x 40 x 30 2. 0 02 320 02 330 04 030carbon

GSV4/Nmi 400 met.-impr. 00 x 40 x 30 .58 02 340 02 350 04 070carbon

GSV4/Smi 400 met.-impr. 40 x 40 x 30 3. 6 04 040 04 050 04 060carbon

GSV 4/Ms 400 brass 90 x 25 x 5 .57 02 360 02 370 04 080

TypeCapa-city

A

Pick-up Shoes


Weight

kg

Catalog-No.Ground


GSV 8 800 graphite 00 x 40 x 30 5.34 02 380 02 390 04 090carbon

GSV 8/mi 800 met.-impr. 00 x 40 x 30 5.79 02 400 02 4 0 04 00carbon

GSV 8/Nmi 800 met.-impr. 00 x 40 x 30 5.43 02 420 02 430 04 40carbon

GSV 8/Smi 800 met.-impr. 40 x 40 x 30 8. 6 04 0 04 20 04 30carbon

GSV 8/Ms 800 brass 90 x 25 x 5 5.05 02 440 02 450 04 50

All malleable iron parts are galvanized. They can be plastic-coated for a smallsurcharge.

Insulators are high quality cast resin.height of GSV 8/N : 270 70

Scale : 0

height of GSV 2/N : 23555

height of GSV 4/N : 25070


17/24

DVD 00 graphite 60 x 65 05 2.56 02 480 02 490 04 70carbon

CURRENT COLLECTORS

7

19 12

Type

Capa-city

A

Pick-up Shoes


Width

mm

Weight

kg

Catalog-No.

Ground


Type DVD for medium duty

metal-SO 20 impr. 05 x 36 x 25 50 .56 02 540 02 550

carbon

Type

Capa-city

A

Pick-up Shoes


Width

mm

Weight

kg

Catalog-No.

Phase Ground

Type SO for enclosed Conductors (FK System)

BVS/1 20 metal- 90 x 34 x 42 60 .40 02 560 impr.

BVS/1 20 carbon 30 x 34 x 42 60 .30 02 570

BVS/2 80 high 90 x 34 x 42 60 .96 05 89 dens.

BVS/2 80 carbon 30 x 34 x 43 60 .80 05 892

Type

Capa-city

A

Pick-up Shoes


Width

mm

Weight

kg

Catalog-No.

Phase Ground

Type BVS for enclosed Conductors (CP System)

KSKS 2/ 600 7.0 05 70 05 320

metal-KSKS 2/ 800

200impr. 30 x 220 x 40 05 7.55 05 80 05 330

carbon

KSKS 2/1000 8.24 05 90 05 340

KSKS 4/ 600 22.53 02 5 0 02 530

2 metal-KSKS 4/ 800 400 impr. 2 x 30 x 220 x 40 05 23. 2 05 590 05 594

carbons

KSKS 4/1000 23.85 05 59 05 595

TypeCapa-city

A

Pick-up Shoes


Width

mm

Weight

kg

Catalog-No.

Phase Ground

Type KSKS for Coking Plants*

** Dont use on less than 50 sq. mm copperhead rails.

Dimensions c Dimensions a

min. normal max.

600 340 650 950800 340 750 50000 340 850 350

The following KS collector heights a will result from the

different contact arm dimensions c:

Scale : 0

BVS for Ground

DVD


18/24

SPARE PARTS FOR CURRENT COLLECTORS

8

19 12

DescriptionPart.

No.

GSV 1 SCatalog-

No.

GSV 1Catalog-

No.

GSV 2Catalog-

No.collector spring 02 640 02 640 02 800

spring bolt 2 02 650 02 650 02 8 0

lever w/thread, mod. 6 6 3 04 490 04 490 02 660

lever w/boring, mod. 6 5 4 04 500 04 500 02 670

insulator w/o bolts phase 02 680 02 680 02 820ground 05 380 05 380 05 492

insulator for N-series phase 5 02 830w/o bolts ground 05 49spacer tubes, set 6 02 690 02 690 02 840

copper shunt lead, set 7 02 7 0 02 7 0 02 860

carbon brush, graphite 02 720 02 770 02 870carbon brush, metal-impr. 8 02 730 02 780 02 880

carbon holder w/clamps 9 02 740 02 790 02 890

pick-up shoe, (brass) 0 02 750 02 900

pick-up shoe, (GG-20) 02 760 02 9 0

DescriptionPart.No.

GSV 4Catalog-

No.

GSV 8Catalog-

No.collector spring 02 920 03 0 0

spring bolt 2 02 930 02 930

lever w/thread, mod. 6 6 3 02 660 02 660

lever w/boring, mod. 6 5 4 02 670 02 670

insulator w/o bolts phase 02 820 02 820ground 05 492 05 492

insulator for N-series phase 5 02 830 02 830w/o bolts ground 05 49 05 49

spacer tubes, set 6 02 940 03 020

copper shunt lead, set 7 02 960 03 040carbon brush, graphite 02 970 02 970carbon brush, metal-impr. 02 980 02 980carbon brush, metal-impr. 8

( 40 x 40 x 30) 04 90 04 90

carbon holder w/clamps 02 990 02 990carbon holder w/clamps 9( 40 x 40 x 30) 04 200 04 200pick-up shoe (brass) 0 03 000 03 000

swing, set 2 03 050

Description Part.No.

DVDCatalog-No.

base plate 03 90

bow 2 03 200

lever 3 03 2 0

lever 5 05 690

clip, phase 06 0 9ground 6 06 020

copper shunt lead, set 8 03 250

tension spring 9 03 260

spacer tube 0 03 270

insulator phase 03 50ground 05 370

triangular carbon, graphite 2 03 280

triangular side plate 3 03 80

Type GSV

Type DVD

0

2

6

8

9

6

2

5

7

2

2

3

3

0

5

9

3

2

8

6

6

4

3

.

.

.

..

.

.

. ..

.. .

..

.

..

..

.

.

.

.

..

.

.

.


19/24

INSTALLATION INFORMATION

9

19 12

1.Install brackets to I beam or girder, weld or bolt on 2 m (6 6 )centers for L 20, A 20, C 20 Rails; 2.5 m (8 3) centers for all

other rails.

Spacing between VAHLE Rails is 150 mm std. (6), min. 100 mm

(4) for L 20, A 20, C 20 Rails; 150 mm std. (6), min. 120 mm(5) for all other Types.

For high voltage installations: approx. 250 mm (10)

Check alignment.

2.Secure insulators/rail supports to brackets (in accordance with the

mounting instructions see pages 1315) leaving bolts hand tight.

For general Arrangement see Fig. A.

When placing the conductors into the insulators, make sure that

the bayonett clamp (incorporated in most VAHLE insulators) sup-

ports the rail sliding tight to allow for expansion and contraction.

Do not change the position (dont turn rail holders) when tightening

support bolts against steel brackets.

3.Connect the VAHLE Rails by rigid- or expansion joints using the

holes provided at the ends of the 7 m (23) sections. For systems

up to 100 m (330) no expansion joints required. With longer runs

use an expansion joint after every 6 standard lengths of 7 m (23)

intervals. For special heat environment and strong temperaturefluctuations reduce these intervals to 28 m (92). For gap setting

see adjacent diagram and example.

Provide an extra insulator/Rail support close to each expansion

joint approx. 250 mm.

4.Anchor VAHLE Rails for controlled sliding in both directions, by

fitting two locating clamps close to the center insulator of the run

or in the center between two expansion joints (see Fig. B + C).

5.Install feeder clamps at feed points. Bolt to web of rail and braise

to copperhead.

6.Prepare Collector Bracket to suite normal working height and fixing

studs of Current Collectors (See page 16 and 17) and install

Collectors securely.

Symbols:

Rigid Joint

Expansion Joint

Insulator

Insulator with Locating Clamps

Expansion diagram

Expansion diagramThe chart shows orientation lines for the different conductorrails, considering 42 m expansion joint intervals.

For gap setting move the orientation line in parallel up to thepoint presenting the anticipated max. ambient temperature.

Then connect point of actual ambient temperature duringinstallation to the right until intersecting with the orientationline. Follow the vertical axis downward to read the air gapdimension in mm.

Example:

Ambient temperature 25 CAir gap F-Rail = 19 mmAir gap C-Rail = 24 mmAir gap A-Rail = 33 mm

Fig. A

Fig. B

Fig. C


20/24

50

45

40

35

30

25220 V

N[W/m]

l [m]

20 30 40 50 60 70 80 90 100

50

45

40

35

30

25380 V

N[W/m]

l [m]

20 30 40 50 60 70 80 90 100

H2,0

H1,4

4

H0,9

H0,7

H0,4

8

H2,0

H1,44

H0,9

H0,7

H0,48

HEATING SYSTEMS FOR ICING CONDITIONS

20

19 12

Determine a heating cable of 30 to 45

W/m capacity.

If no suitable result from adjacent dia-

grams, devide the length of the system

into two or more heating sections.

Supply lower voltage via a transformerin case of shorter heating sections.

Heating[Watt/ m] : N =

U2

capacity R L2

U = Supply voltage [Volt]R = Resistance of heating cable [Ohm/m]L = Length of heating sections [m]

Composition of heating cable: Conductor: resistor material CrNi, stranded

Insulation: TFE-(Teflon-)insulation, natural colour,glass silk sheath

Sheath: V2A wire

Wire Resistance data:

heating cable: H 0.48 0.48 Ohm/mheating cable: H 0.70 0.70 Ohm/mheating cable: H 0.90 .00 Ohm/mheating cable: H .44 .44 Ohm/mheating cable: H 2.00 2.00 Ohm/m

Tolerance: 2.5%Outside diameter: ca. 4 mm

Selection of heating cable:

Scheme of heating system formore than one section


21/24

HEATING SYSTEMS FOR ICING CONDITIONS

2

19 12

Heating system for steel and aluminium copper head rails:

Heating system for fibre glass and aluminium copper head rails:

Our supply includes:

Heating cable of adequate sizeCopper protection tube

Fixing clips

Glass fibre hose for expansion joints

Insulated terminal clamps

Material for end connections(cable lugs etc.)

Mounting instructions

All switches, fuses, cable etc.by others!

Our supply includes:

Heating cable of adequate type

Feeder terminals

Material for end connnections(cable lugs etc.)

Mounting instructions

All switches, fuses, cable etc. by others.

The heating cable is protected by a copper tube.

The fixing, easily arranged by galvanized steel clips.

Rigid and expansion joints are bridged as above sketches.

The ends of heating cable are connected by insulated terminal clamps.

Scheme for automatic

thermostat operation

The heating cable is installed in the hollow web of the VAHLE rails,holes for feed cable drilled at terminal-feed points.


22/24

QUESTIONNAIRE FOR VAHLE CONDUCTOR SYSTEMS

22

19 12

Adress:

Attention of:

Date:

. Type of crane/machine to be electrified:

2. Voltage: Volts ~/=: Phases: c/s:

3. Length of conductor system:

4. Number of conductors required: power lines: control lines: neutral (ground):

5. Indoor: Outdoor:

6. Special site conditions (humidity, dust, chemical influence etc.):

7. Temperature conditions: C min., C max.

8. Type of conductors preferably wanted:

9. Number and position of feeder points:

0. Mounting position envisaged:(prints and sketches should be submitted whenever obtainable)

. Number of cranes / machines fed from the one system:

2. Ampere load of each crane / machine:

3. Other pertinent data:

For curved tracks, breaks in system etc. please submit prints and sketches.

Motor data Questionnaire Ref. 12 (to determine conductor size)

Motor Gen. Set.

Main Hoisting

Aux. Hoisting

Main Traverse

Aux. Traverse

Main Travel

Aux. Travel

SlewingLuffing and any other Service

Crane

Current

HP / kW A % ED

Crane 2

Current

HP / kW A % ED

Crane 3

Current

HP / kW A % ED

To our nearest local agency:


23/24

VAHLE RAILS IN ACTION

23

19 12

In accordance with our companys policy of continued improvement, we reserve the right to amend specifications and details at any time.


24/24

Catalog No. 1a/E 2001

0108Printedin

Germany2004-099410004/04

Catalog No.

Copperhead Conductor Systems 1 a

Battery Charging Systems 1 b

Insulated Conductor Systems U 10 2 a

Insulated Conductor Systems U 20 U 30 U 40 2 b

Insulated Conductor Systems U 15 U 25 U 35 2 c

Aluminium Enclosed Conductor Systems LSV LSVG 3 aPowerail Enclosed Conductor Systems KBSL KSL KSLT KSG 4 a

Powerail Enclosed Conductor Systems VKS VKL 4 b

Powerail Enclosed Conductor System MKLD MKLF MKLS 4 c

Heavy Enclosed Conductor Systems 5

Trolley Wire and Accessories 6

Cable Tenders 7

Cable Carriers for -tracks 8 a

Cable Carriers for Flatform Cable on -beams 8 bF

Cable Carriers for Round Cable on -beams 8 bR

Cable Carriers for -tracks 8 c

Conductor Cables and Fittings 8 L

Spring Operated Cable Reels 9 a

VAHLE POWERCOM Data Transmission Systems 9 c

CPS Contactless Power Supply 9 d

SMG Slotted Microwave Guide 9 e

WCS Position Encoding System 9 f

Motor Powered Cable Reels on request

DQS - zertifiziert nach

DIN EN ISO 9001:2000

OHSAS 18001

(Reg.-Nr. 003140 QM OH)

MANAGEMENTSYSTEM

Documents

Vahle f Seri̇si̇ Bara