Technical data

Demag Compact Line DCL

42211044.eps

070606 EN/PDF 070606

203 387 44

714 IS 962.2

Manufacturer

Demag Cranes & Components GmbH Drives P.O. Box 67 D-58286 Wetter Telephone (0 23 35) 92-0 Telefax (0 23 35) 92 72 98 E-mail drives@demagcranes.com www.demagcranes.com

Table of contents

1 1.1 1.2 2 2.1 2.1.1 2.1.2 3 3.1 3.1.1 3.1.2 3.1.3 3.2 4 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.3 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.8.1 6.9 6.9.1 6.9.2 6.10 6.10.1 6.11 7 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.2 7.2.1 8

General Symbols DCL installation Design and installation notes Definitions Arms length Protection against indirect contact Calculating and selecting the conductor cross-section Calculating the conductor cross-section Calculation method Graphical method DCL maximum permissible current I35 [A] for an ambient temperature of 35C DCL basic structure General layout Suspension arrangements DCL suspension with C-rail bracket Sliding suspension/fixed suspension Mounting and operating dimensions DCL suspension with M8 threaded pin Mounting and operating dimensions, sliding suspension/fixed suspension Further fitting information Technical data DCL straight section 4, 5, 6 und 7 poles DCL curved section 4, 5, 6 und 7 poles DCL line power feed 4, 5, 6 und 7 poles DCL connector end cap as end power feed DCL connector end cap as track end cap End cap Entry/transfer section DCL current collector trolley 4, 5, 6 und 7 poles Current collector technical data Towing arm for DCL current collector trolley Standard towing arm Towing arm for free transfer sections Profile sealing lip Assembly tool for fitting the profile sealing lip Isolating section Component parts Straight sections and accessories Component set for sliding suspension with C-rail bracket Component set for sliding suspension with threaded pin Component set for conductor connector Isolating sections Current collectors and current collector trolleys Sliding contact set Resistance to acids, chemicals and fuels Fax: Enquiry Fax: Order

3 3 3 4 4 4 4 5 6 6 7 8 9 10 11 11 11 12 14 14 14 15 15 17 19 21 22 23 24 26 27 28 28 29 30 30 31 32 32 32 32 32 32 33 33 34 35 36
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General

1.1 Symbol description

The following symbols and recommendations indicate potential safety hazards or causes of damage or provide useful information. Warning against dangerous electrical voltage Contact with live parts can result in immediate death. Protective covers (e.g. covers and enclosures) marked with this sign may only be opened by qualified electricians. Before opening, all relevant operating, control, feed or other voltages must be disconnected. Operating hazard for the installation This symbol in the operating instructions indicates all warnings which, if not complied with, may result in damage to the product.

1.2 DCL installation

The DCL is a conductor bar system with PVC-housing. The uniform housing can be effected with 4, 5, 6 or 7 conductors / poles acc. to the 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 in the table below.

Conductor line Enclosure material Standard length Number of conductors / poles Distance between suspensions max. 2 ) Voltage UN Size 1 ) Permissible current (100% CDF to 35 C) 1 ) Conductor cross section Conductor material copper Conductor material stainless steel plated5) Ambient temperature / Enclosure temparature Protection class DIN VDE 0470 T.1/EN 60529 Curve section minimum radius Fire protection C IP-Code mm A mm mm V AC 35 64 10 X X 60 78 15 X mm PVC 4000 4...7 1000 2 ) / 2000 24 bis 690 100 100 25 X -30 bis +70 IP 23 / IP 24 with sealing lip $ 800 mm UL94 / VO; not halogen-free 140 140 38 X 200 160 56 X -

Current collector trolley Number of poles Sliding contact material Rated current IN (80% ED) Connection cross section for power connection (1, 2, 3, 4) Connection cross section for control cable (5, 6, 7) Connecting cable length (standard) 4 ) Fuse protection max. Travel speed max. max. mm max. mm mm A m/min bronze 40 A 6 2,5 2000 100 100 3 ) / 200 graphite 20 A 4 4...7 silver-graphite 20 A

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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.

Design and installation notes

Please note:

Conductor lines must be operated in accordance with generally accepted engineering principles. Ensure compliance with DIN VDE/EN, SEV, CSA and UL regulations. We make special reference to the DIN VDE regulations, particularly to DIN VDE 0100.

Of the many regulations, we refer to the following definitions: see DIN VDE 0106, Part 200.

2.1 Definitions
2.1.1 Arms length Arms length is the area which a persons hand may reach in all directions from normal locations without any special equipment. Measured from the position where a person is standing, this area ranges up to at least 2,5 m upwards and at least 1,25 m to the side and downwards (see DIN 31 001 Sheet 1). Wherever large or long objects which are not insulated for the operating voltage are moved, the minimum arms length must be correspondingly increased.

2.1.2 Protection against indirect contact

Protection against direct contact constitutes all measures to protect people from hazards resulting from contact with live parts of electrical equipment. This may be partial or full protection. Partial protection only provides protection against accidental contact. Protection against accidental contact does not mean any protection against deliberate contact. Enclosure type IP 2X to DIN VDE 0470 Part 1 offers protection against accidental contact. Complete protection starts from IP 5X to DIN VDE 0470 Part 1.

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Calculating and selecting the conductor cross-section

Voltage drop 1. and permissible current 2. must be considered when calculating power supply cross-sections. 1. - Calculate the cross-section considering the max. permissible voltage drop of 2,5 % for crane runways + 2,5 % for crane bridge. - The relevant value is the starting current cosA of the largest motor + the rated current cosN of the next smaller motor. - The currents must be added for motors connected in parallel. The calculated cross-sections must be halved for power supplies to solo hoists. 2. - Calculate the cross-section considering the max. permissible current for cables to DIN VDE 100 Part 430/523. - The relevant value is the sum of all rated currents of all drives. The currents indicated in diagram 1, section 3.1.2 must not be exceeded. Permissible voltage drop The voltage drop is determined by current IG. Current IG results from adding the starting - (IA cosA) and rated currents (IN cosN) (see table 1 below). The conductor cross-section may be determined according to the calculation method described in section 3.1.1 or diagram 1, section 3.1.2. Table 1 indicates the number of consumers to be considered for calculating IG depending on the number of cranes fed by a conductor line. Table 1
Number of cranes fed by a conductor line 1 2 3 4 5 Of all cranes taken together (in order of output) 1st motor I A cos A I A cos A I A cos A I A cos A I A cos A 2nd motor I N cos N I N cos N I A cos A I A cos A I A cos A 3rd motor I N cos N I N cos N I N cos N 4th motor I N cos N

For double drive arrangements correspondingly: 2 IA cosA or 2 IN cosN. Exception: For double hoist units with delayed starting IA cosA + IN cosN.

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3.1 Calculating the conductor cross-section

3.1.1 Calculation method Abbreviations used in the equations: A L I IG f U = Conductor cross-section of the DCL = cable length = starting current (IA cosA) or rated current (IN cosN) = sum of the currents according to table 1 = frequency in Hertz = conductibility (for Cu = 56) = voltage in volts [mm] [m] [A] [A] [Hz] [m/m] [V] [V]

U = permissible voltage drop

1. Conductor cross-section of the DCL

1,73 x L x IG U x

[mm2]

2. Required conductor length

L1 =

U x x A 1,73 x IG

f2 f1

[m]

3. Conversion for starting current IA cosA or rated current IN cosN fornon-standard voltage U

I2

U 1 x I1 U2

[A]

4. Conversion for conductor crosssection A2 for non-standard conductor length L2

A2 =

L 2 x A1 L1

[mm2]

5. Permissible voltage drop

U = 2,5 % = 10 V (for 400 V) U = U x 2,5 % [V] 100 %

Inew = Iold X

X Unew

[A]

50 Hz

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6. Conversion from 400 V, 50 Hz to a new voltage and frequency

400 V

fnew

3.1.2 Graphical method

Calculating the conductor cross-section for the permissible voltage drop. The DCL conductor line cross-section and/or voltage drop may be reduced by the position and quantity of power feeds.

Diagram 1

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for
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3.1.3 DCL maximum permissible current I35 [A] for an ambient temperature of 35C

Check the maximum permissible current for the conductor cross-section as a function of the cyclic duration factor (CDF) at an ambient temperature of 35 C. For other ambient temperatures, the current (IJ) must be calculated with the conversion factor (fu) according to the table below. The same or the next largest conductor cross-section must be selected.

Diagram 2

300

I35 [A]

292 270 253 241 225 211 194 178 157 165 155 143 129 118 133 109 124 102 147 117 96 139 111 91 200 238 226 216 191 207 177 200 171

275 250

Permissible current [A] at 35C ambient temperature

225 200 175 150 125 100 75 50

184

193 165

187 161

181

133 106 87

172 167 163 160 DCL 200 (56mm 2 ) 156 152 149 146 142 140 DCL 140 (38mm 2 )

176

128

123

101 97 83 80

119 115 111 108 105 103 94 91 88 85 83 80 80 77 74 72 70 68 66 75 80 85 90 95

100 100 DCL 100 (25mm 2 ) 78 64

DCL 60 (15mm2 ) DCL 35 (10mm2 ) ED [%] Cyclic Duration

Factor
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25

30

35

40

45

50

55

60

65

70

100

Calculating the maximum permissible current I [A] for other ambient temperatures
Ambient temperature Conversion factor [C] fu 20 1,20 25 1,14 30 1,07 35 1,00 40 0,92 45 0,84 50 0,74 55 0,64 60 0,51 65 0,35

Maximum permissible current

I = I35 fu

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3.2 DCL basic structure

Straight section, section 6.1

Standard length, section 6.1

Remaining length < 4 m, section 6.1

Curve section, section 6.2

Profile sealing lip, section 6.10

Connector cap / End power feed, section 6.5

Line power feed, section 6.3

End cap, section 6.6

Sliding suspension / Fixed suspension, section 5.1.1 C-rail mounting bracket, section 5.1 Entry funnel / Transfer funnel, section 6.7 Threaded pin bracket, section 5.2

Isolating section, section 6.11

Current collector trolley, section 6.8 Bronze contact 40 A, section 6.8.1 1) Standard towing arm, section 6.9.1 Graphite contact 20 A, section 6.8.1 1) Transfer towing arm, section 6.9.2

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

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1) The sliding contacts of the control lines (poles 5, 6, 7) optionally are also available as silver-graphite-sliding contact. Technical data and other notes cf. chapter 6. 9

General layout

400 EK AK

2000

2000 1600 A 400 3) min.250 GA B S

2000

2000 1600 4003) min.250 GA S

2000
1)

2000 1600 FA 400 3) min.250 GA S

2000

2000 1600 400 3) min.250 GA S

2000

400

4
GA

GA GA

GA

GA

EK

AK

65

4000

4000

4000

4000

4000

Clearance 250 7 or 8 1 2 6

Clearance 150 8

or 7

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.

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Section A - B Steel structure etc.

Item 1 2 3 4 5 6

Designation DCL straight section DCL curve section Joint connector Sliding suspension Fixed suspension Line power feed Connector end cap as end power feed Connector end cap as track end cap End cap Current collector trolley 2) GS BS S GA FA ES

Dimensions 4000 mm R $ 800 mm

4000 mm

(PE)

AK

EK

Profile rib (orientation rib)

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Towing arm 2) Towing arm for transfer sections 2) Entry / transfer funnel 2)

Please note In place of an AK connector end cap, a track extension, an entry section, or a transfer section may be fitted. DCL installations - with a line power feed are supplied with an end cap item (8) at both ends. A track cannot be extended when an end cap is fitted. An installation with an end cap is exactly 74 mm shorter than the rated length. On request also available with connector end cap as track end cap so that the track can be extended. - with an end power feed are supplied with a connector end cap (7) at both ends.
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An installation with a connector end cap is exactly 130 mm longer than the rated length. Allow for clearance to connect the end power feed (approx. 250 mm).
1) When large cable cross-sections (from size PG42) are used with a DCL section with a line power feed, a third additional sliding suspension must be fitted close to the power feed enclosure. 2) Not shown 3) The 400 mm dimension must not be exceeded.

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Suspension arrangements

5.1 DCL suspension with C-rail bracket

5.1.1 Sliding suspension/fixed suspension Attachment to upper flange I

25 or 40

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Flange clamp Clamping range 8 to 16 mm Clamping range 16 to 30 mm

Part no. 974 548 44 974 549 44

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Attachment to lower flange II

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C-rail 40 x 40 min. 90 max. 150

Adjusting range

C-rail 40 x 25 min. 100 max. 165

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Part no. for C-rail 40 x 25 L= 300 500 600 700 920 968 427 44 850 184 44 974 550 44 974 551 44 974 553 44 213 600 44

Part no for C-rail 40 x 40 L= L= L= L= 1000 1270 1500 1820 974 554 44 650 275 44 650 274 44 958 521 44 213 601 44

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25 or 40

L= L= L= L=

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L = 6000

L = 6000

Adjusting range

min. 120, max.180

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5.1.2 Mounting and operating dimensions

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min. max.

30 90

Adjusting range

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min. 10 max. 75 C-rail 40 x 40 min. 0 max. 60

Adjusting range

C-rail 40 x 25

12

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Mounting arrangement I C-rail clamp section Mounting bracket

Fixed point 1)

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Mounting arrangement II

Sliding supension

C-rail clamp section

Fixed point 1)

Mounting bracket

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Component set for sliding suspension with C-rail bracket 1 off C-rail clamp section 1 off mounting bracket 1 off sliding suspension

Bestell-Nr.

876 638 44

The following information is required for ordering C-rails and flange clamps to fit DCL to I-beams: C-rail type and length (see table on page 12). Flange clamps for -beams (see below).

Girder width 160 - 400 425 - 600

Clamping range 8 - 16 mm 16 - 30 mm

Part no. 974 548 44 974 549 44

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1) Only for fixed suspension. The fixed suspension is a sliding suspension which is fixed on the profile section by means of a self-tapping screw. Self-tapping screw 3,5 x 9,5 to DIN 7981.

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5.2 DCL suspension with M8 threaded pin

5.2.1 Mounting and operating dimensions, sliding suspension/fixed suspension

Mounting angle
Fixed point 1)

M8 lock nut

Adjusting range

Sliding suspension
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max. 43

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Component set for sliding suspension with M8 threaded pin 1 off threaded pin fitting 1 off countersunk screw M8 x 70

Part no.

876 637 44 2 off lock nut M8 1 off sliding suspension

5.3 Further fitting information

Straight sections feature plastic sliding suspensions for connection to C-rail or threaded pin fittings.. Line power feeds feature an additional sliding suspension. For C-rail fittings: - The mounting brackets are clipped into the sliding suspensions. - The C-rail clamp section is fitted according to mounting arrangement I or II (see section 5.1.2). For threaded pin fittings: - The threaded pin fitting with countersunk screw is clipped into the sliding suspensions. The max. distance between DCL sliding suspensions is 2000 mm for straight sections (see chapter 4). Sliding suspensions must be fitted every 500 mm (along the curve) for curved sections.
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The centre of every DCL installation must be secured by a fixed suspension. To do this, screw the enclosed 3,5 x 9,5 self-tapping screw into the sliding suspension. For DCL installations with entry/transfer sections, the funnels must be arrested.
1) Only for fixed suspension. The fixed suspension is a sliding suspension which is fixed on the profile section by means of a self-tapping screw. Self-tapping screw 3,5 x 9,5 to DIN 7981.

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Technical data

6.1 DCL straight section 4, 5, 6 und 7 poles

Suspension method Protective earth symbol (only for conductor line with PE) Attached to C-rail or suspended from threaded pin(must be ordered separately, see sections 5.1.1 and 5.2.1)

Profile sealing lip: fitted as required. May be added to order per meter.
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Profile rib (orientation rib)

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= Joint connectors are pre-assembled on the conductor enclosures.

GA = Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly. - Additional sliding suspensions may be fitted. - Specify suspension method and order separately. - Suspension diagram with dimensions see chapter 4. Please observe! Steel structure etc. Unless the installation is designed otherwise, it must be ensured that all DCL straight and curve sections are fitted in such a way that the protective earth conductor (PE) and the profile rib of the enclosure face towards the track support resp. the steelwork. Version without protective conductor (PE) Systems and current collecting trolleys without protective conductor connection (PE) will be supplied as follows. (PE) Systems Profile rib (orientation rib) The green-yellow marking of the protective conductor is not applicable. The conductor / pole is equipped resp. processed and can be used for the power- or for the control signal transmission. The cross section then corresponds to the conductor cross section of the power transmission (valid for sizes starting at 140). Current collecting trolley In this version the green-yellow core is replaced by a black core. The protective marking (PE) is not applied. The sliding contacts are equipped in accordance with the conductor- / poles-quantity. When all DCL straight and curve sections have been fitted, one sliding suspension must be fixed with a DCL straight section in the middle of the track (fixed point) to prevent the DCL installation moving to the side. Fixed point or fixed suspension: 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.
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Use only the enclosed 3,5 x 9,5 self-tapping screws to DIN7981 as there is a risk of accidental contact with live parts if longer screws are used.
1) Standard length 4000 mm. Indicate reduced length in order text for part no. Minimum reduced length 500 mm. For complete conductor line installations, the entire conductor line length including the power feed(s) must be specified in the order text.

15

Part number table (conductor material copper)

Size 35 Number of poles 64 78 100 L1 - L3 conductor cross-section mm 10 4 Phase L1 - L3 PE conductor Control cable 5 Phase L1 - L3 PE conductor Control cable 6 Phase L1 - L3 PE conductor Control cable 7 Phase L1 - L3 PE conductor Control cable 876 640 44 3 x 10 mm 1 x 10 mm 876 641 44 3 x 10 mm 1 x 10 mm 1 x 10 mm 876 642 44 3 x 10 mm 1 x 10 mm 2 x 10 mm 876 643 44 3 x 10 mm 1 x 10 mm 3 x 10 mm 15 876 606 44 3 x 15 mm 1 x 15 mm 876 610 44 3 x 15 mm 1 x 15 mm 1 x 10 mm 876 614 44 3 x 15 mm 1 x 15 mm 2 x 10 mm 876 618 44 3 x 15 mm 1 x 15 mm 3 x 10 mm 25 876 607 44 3 x 25 mm 1 x 25 mm 876 611 44 3 x 25 mm 1 x 25 mm 1 x 10 mm 876 615 44 3 x 25 mm 1 x 25 mm 2 x 10 mm 876 619 44 3 x 25 mm 1 x 25 mm 3 x 10 mm 38 876 608 44 3 x 38 mm 1 x 25 mm 876 612 44 3 x 38 mm 1 x 25 mm 1 x 10 mm 876 616 44 3 x 38 mm 1 x 25 mm 2 x 10 mm 876 623 44 3 x 38 mm 1 x 25 mm 3 x 10 mm 56 876 609 44 3 x 56 mm 1 x 38 mm 876 613 44 3 x 56 mm 1 x 38 mm 1 x 10 mm 876 617 44 3 x 56 mm 1 x 38 mm 2 x 10 mm 876 624 44 3 x 56 mm 1 x 38 mm 3 x 10 mm 140 160 60 100 140 200

Permissible current (A) at 100 % CDF up to 35 C 2)

The combinations of conductor quantity / number of poles and size indicated in the order table can be purchased as components. As a standard material for the conductor copper is used. Alternatively, the conductor cross section 10 mm2 can be ordered in stainless steel plated version. The above mentioned part numbers are only valid for the conductor material copper. A version with stainless steel plated copper bar (10 mm2) has to be especially mentioned in the order. For straight sections not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with no PE. Suspensions DCL with C-rail installation or threaded bolts M8 have to be ordered separately. Component sets for sliding suspensions with C-rail installation or threaded bolts M8 have to be selected with the corresponding quantity (cf. chapter 7.1). Sliding suspensions are pre-mounted for the suspension distance 2000 mm. The following information is required for ordering a straight section (see model code order text): Conductor line type, component DCL-GS Number of poles (4, 5, 6, or 7 conductors) Size (35, 60, 100, 140, 200) protective earth conductor PE (with or without) Section and installation length in mm 1)
1) Standard length 4000 mm. Indicate reduced length in order text for part no. Minimum reduced length 500 mm. For complete conductor line installations, the entire conductor line length including the power feed(s) must be specified in the order text. 2) The permissible current for the conductors must be checked. Calculation or tables see chapter 3. 3) 10 mm2 (L1-L3, PE and / or control line) available upon request as stainless steel plated copper bar.

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

Suspension method Attached to C-rail or suspended from threaded pin (must be ordered separately, see sections 5.1.1 and 5.2.1)

This diagram shows an inside curve

a str

igh

str

aig

ht

Profile rib (orientation rib)

Profile sealing lip: fitted as required. May be added to order per meter.

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S Steel structure etc.

= Joint connectors are pre-assembled on the conductor enclosures.

GA = Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly. - Suspensions spaced at a distance of 500 mm along the curve. - Specify suspensions and order separately. - Suspension diagram with dimensions see chapter 4. Please observe! (PE) Unless the installation is designed otherwise, it must be ensured that all DCL straight and curve sections are fitted in such a way that the protective earth conductor (PE) and the profile rib of the enclosure face towards the track support resp. the steelwork.

Profile rib (orientation rib)

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For designing of systems with straight and curve sections the following has to be observed: The straight ends of the curve sections with 178 mm are fixed values and if necessary have to be deducted from the total length of the connecting straight section. 17

For curved sections not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with no PE.

The following information is required for ordering a curved section (see model code order text): Conductor line type, component DCL-BS Number of poles (4, 5, 6, or 7 conductors) Size (35, 60, 100, 140, 200) Radius (mm) Angle (degrees) Curve I or curve A 2) 1) protective earth conductor PE (with or without)

1) The permissible current for the conductors must be checked. Calculation or tables see chapter 3. 2) Definition of curve type I and curve type A: On curve I the protective earth conductor and the profile rib are on the inside of the curved section. On curve A the protective earth conductor and the profile rib are on the outside of the curved section. On curved sections which do not feature a protective earth conductor, the profile rib is only for orientation. The view refers to the centre of the radius.

Model code

Order text, e.g.: DCL-BS 5-100- PE- R = 1500, = 45, curve A 3)

18

3) Profile sealing lip may be added to order per meter. Please specify in the order.

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

M6 slot-head screws Prepared opening 1)

Connecting bar only for 100 A, 140 A and 200 A DCL conductor

Connecting terminal
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2)

Profile sealing lip: fitted as required. May be added to order per meter.
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Profile rib (orientation rib)

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= 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. 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.
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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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Part number table (conductor material copper)

Size 35 Number of poles 64 78 100 L1 - L3 conductor cross-section mm 10 4 L1 - L3 + PE Control cable 5 L1 - L3 + PE Control cable 6 L1 - L3 + PE Control cable 7 L1 - L3 + PE Control cable 876 646 44 4 x 1,5 - 16 mm 876 647 44 4 x 1,5 - 16 mm 1 x 1,5 - 16 mm 876 648 44 4 x 1,5 - 16 mm 2 x 1,5 - 16 mm 876 649 44 7 x 1,5 - 16 mm 3 x 1,5 - 16 mm 15 876 650 44 4 x 1,5 - 16 mm 876 654 44 4 x 1,5 - 16 mm 1 x 1,5 - 16 mm 876 658 44 4 x 1,5 - 16 mm 2 x 1,5 - 16 mm 876 662 44 7 x 1,5 - 16 mm 3 x 1,5 - 16 mm 25 876 651 44 4 x 25 - 70 mm 876 655 44 4 x 25 - 70 mm 1 x 1,5 - 16 mm 876 659 44 4 x 25 - 70 mm 2 x 1,5 - 16 mm 876 663 44 4 x 25 - 70 mm 3 x 1,5 - 16 mm 38 876 652 44 4 x 25 - 70 mm 876 656 44 4 x 25 - 70 mm 1 x 1,5 - 16 mm 876 660 44 4 x 25 - 70 mm 2 x 1,5 - 16 mm 876 664 44 4 x 25 - 70 mm 3 x 1,5 - 16 mm 56 876 653 44 4 x 25 - 70 mm 876 657 44 4 x 25 - 70 mm 1 x 1,5 - 16 mm 876 661 44 4 x 25 - 70 mm 2 x 1,5 - 16 mm 876 665 44 4 x 25 - 70 mm 3 x 1,5 - 16 mm 140 160 60 100 140 200

Permissble current (A) at 100 % CDF up to 35 C 1)

The combinations of conductor quantity / number of poles and size indicated in the order table can be purchased as components. As a standard material for the conductor copper is used. Alternatively, the conductor cross section 10 mm2 can be ordered in stainless steel plated version. The above mentioned part numbers are only valid for the conductor material copper. A version with stainless steel plated copper bar (10 mm2) has to be especially mentioned in the order. For line power feeds not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with no PE. Suspensions DCL with C-rail installation or threaded bolts M8 have to be ordered separately. Component sets for sliding suspensions with C-rail installation or threaded bolts M8 have to be selected with the corresponding quantity (cf. chapter 7.1). Sliding suspensions are pre-mounted for the suspension distance 2000 mm.

The following information is required for ordering a line power feed (see model code order text): Conductor line type, component DCL-ES Power feed, number of poles (4, 5, 6, or 7 conductors) Size (35, 60, 100, 140, 200) protective earth conductor PE (with or without)

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.

Model code

Order text, e.g.: Line power feed or DCL-ES-4-140-PE DCL-ES-7-60 (no PE)

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6.4 DCL connector end cap as end power feed

Prepared openings Open as required and fit rubber sleeve(s). Straight /curved section

Rubber sleeves for cable dia. up to 24 mm 1)

Clip

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 and bolts.
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Clearance

AK S GA

= = =

Connector end cap clipped together with the joint connector. Joint connectors are pre-assembled on the conductor enclosures. Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly.
42210644.eps

The following information is required for ordering or selecting a connector end cap as a power feed (see model code order text): Conductor line type, DCL AK connector end cap Connection cross-section 16 mm (IN 60 A)

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.

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Model code

Order text, e.g.: DCL connector end cap as end power feed DCL-AK-16 Rubber sleeve PG 21 21

6.5 DCL connector end cap as track end cap

(for DCL conductor line with end power feed or with extended track)

Connector end cap

Straight /curved section

42052444.eps

Clearance

AK S GA

= = =

Connector end cap clipped together with the joint connector. Joint connectors are pre-assembled on the conductor enclosures. Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly.

42210744.eps

The following information is required for ordering or selecting a connector end cap as track end cap (see model code order text): Conductor line type, DCL AK connector end cap

Model code

Order text, e.g.: DCL connector end cap as track end cap DCL-AK

22

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6.6 End cap

(for DCL installations with line power feed or sections subsequently cut to length on site)

Straight /curved section

Oval flat head screw 3,5 x 10 DIN7981

42109544.eps

Clearance

EK GA

= =

End cap screwed together with the conductor enclosure. Sliding suspensions: are fitted to the conductor enclosures and have to be positioned during assembly.
42210844.eps

Use only the enclosed 3,5 x 10 oval flat head screws to DIN7981 as there is a risk of accidental contact with live parts if longer screws are used.

The following information is required for ordering or selecting an end cap (see model code order text): Conductor line type, DCL EK end cap

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Model code

Order text, e.g.: End cap DCL-EK

23

6.7 Entry/transfer section

Suspension method Attached to C-rail or suspended from threaded pin(must be ordered separately, see sections 5.1.1 and 5.2.1)

View X

View X

Orientation rib Funnel left-hand

Orientation rib Funnel right-hand

42279444.eps

Dead funnel area

Conductor line Dimension mm

Profile rib (orientation rib)

1 2 3 4 5 6 352 243 134

41761944.eps

243
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Profile sealing lip: fitted as required. May be added to order per meter. 24
42212444.eps

7 PE

For transfers left-hand and right-hand funnels are required. Entry/transfer speed 100 m/min. Min. distance between transfer funnels 10 mm. Max. lateral misalignment between the funnels 10 mm. Max. vertical misalignment between the funnels 8 mm. S = Joint connectors are pre-assembled on the conductor enclosures. F = Fixed suspension slides on funnel enclosure to be positioned and secured with self-tapping screw during assembly.

Use only the enclosed 3,5 x 9,5 self-tapping screws to DIN7981 as there is a risk of accidental contact with live parts if longer screws are used.

Part number table

Number of poles

Type right-hand

Conductor line assignment 1-3,7 (PE)

Part no. 876 695 44 876 700 44 876 696 44

4 left-hand right-hand 5 left-hand right-hand 6 left-hand right-hand 7 left-hand

1-3,7 (PE) 5 876 701 44 876 697 44 1-3,7 (PE) 4,6 876 702 44 876 698 44 1-3,7 (PE) 4-6 876 703 44

The combinations of conductor quantity / number of poles and size indicated in the order table can be purchased as components. As a standard material for the conductor copper is used. Alternatively, the conductor cross section 10 mm2 can be ordered in stainless steel plated version. The above mentioned part numbers are only valid for the conductor material copper. A version with stainless steel plated copper bar (10 mm2) has to be especially mentioned in the order. For transfer sections not fitted with a protective earth conductor (PE), this must be indicated in the order section and specified as a part no. with no PE. Note The current collector trolley must be prepared for DCL with entry/transfer setions or profile sealing lip. Open the terminal box on the current collector trolley and separate the upper terminal box enclosure half on the prepared openings (prepared openings see figure in section 6.8). The following information is required for ordering or selecting transfer sections (see model code order text): Conductor line type, DCL 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)

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Model code

Order text, e.g.: Transfer section (funnel right-hand) or (funnel left-hand) DCL-TR-4-PE DCL-TL-7 (no PE) 25

6.8 DCL current collector trolley 4, 5, 6 and 7 poles

Guide wheel

5 Travel wheel 4 2 3 6

7 Guide roller

The current collector trolley must be prepared for DCL with entry/ transfer setions or profile sealing lip. Open the terminal box on the current collector trolley and separate the upper terminal box enclosure half on both terminal box halves along the prepared opening.

Prepared opening (separate on both sides)

41762044.eps

42210944.eps

DCL-SAW-6-20 2) DCL-SAW-6-40-M 3) DCL-SAW-7-40 1) DCL-SAW-7-20 2) DCL-SAW-7-40-M 3)

876 586 44 876 778 44 876 587 44 876 588 44 876 779 44

6 6 7 7 7

4 4 4 4 4

2 2 3 3 3

20 A / GR 40 A / BR 40 A / BR 20 A / GR 40 A / BR

20 A / GR 20 A / SIGR 40 A / BR 20 A / GR 20 A / SIGR

(4 x 4 + 2 x 2,5) mm (4 x 6 + 2 x 2,5) mm (4 x 6 + 3 x 2,5) mm (4 x 4 + 3 x 2,5) mm (4 x 6 + 3 x 2,5) mm

26

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1) Bronze sliding contact material, connecting conductor cross-sections L1 - L3 + PE max. 6,0 mm. Control conductor connecting cable crosssection 1,5 mm. Other cross-sections on request. 2) Graphite sliding contact material, connecting conductor cross-sections L1 - L3 + PE max. 4,0 mm. Control conductor connecting cable crosssection 2,5 mm. Other cross-sections on request. 3) Sliding contact materials bronze and silvergraphite, connecting conductors L1 L3 + PE (bronze) max. 6.0 mm2. Connecting conductors of the control conductors (silver-graphite) 2.5 mm2. Other cross section on request.

Poles Designation Part no. Total DCL-SAW-4-40 1) DCL-SAW-4-20 2) DCL-SAW-5-40 1) DCL-SAW-5-20 2) DCL-SAW-5-40-M 3) DCL-SAW-6-40 1) 876 581 44 876 582 44 876 583 44 876 584 44 876 777 44 876 585 44 4 4 5 5 5 6 L1-L2-PE 4 4 4 4 4 4 Control conductor 0 0 1 1 1 2 IN, 80 % ED / Sliding contact material 40 A / BR 20 A / BR 40 A / BR 20 A / GR 40 A / BR 40 A / BR 40 A / BR 20 A / GR 20 A / SIGR 40 A / BR

Metric cable union / corrugated tube

Connecting cable conductors 4 x 6 mm 4 x 4 mm (4 x 6 + 1 x 2,5) mm (4 x 4 + 1 x 2,5) mm (4 x 6 + 1 x 2,5) mm

M 25 / NW 17

(4 x 6 + 2 x 2,5) mm

6.8.1 Current collector technical data

Sliding contact material Application range Permissible Volatage with 80 % CDF Continuous current 2) with 60 % CDF with 40 % CDF Connecting cable 3) L1 - L3 + PE Control Cable Straight section Travel speed Curve section

Bronze Energy supply

Graphite1) Energy supply Data transmission 24 to 690 V .

Silver - Graphite 1) Data transmission

40 A 45 A 50 A 6 mm x 2000 mm

20 A 20 A 25 A

20 A 20 A 25 A

4 mm x 2000 mm

2.5 mm, max. 25 A, 80% ED max. 200 m/min max. 100 m/min

Transfers Curve-negotiating for R $ 800 mm

For the transmission of control signals and at low voltages (24 48 V, IN # 1 A) the use of silver-graphite-sliding contacts in connection with stainless steel plated copper bars is recommended. If necessary, the use of at least 2 current collecting trolleys can be reasonable. The following information is required for ordering a current collector trolley (see model code order text): Conductor line type, DCL Current collector trolley Number of poles ( 4,5, 6, or 7 sliding contacts) Permissible current (20 or 40 A) Protective earth conductor PE (with or without) Connecting cable length (mm) For current collecting trolleys not fitted with protective earth conductor (marking PE is not applied) this must be indicated in the order section and specified as a part no. with no PE. In this version the green-yellow core is replaced by a black core. The marking (PE) is not applied.

1) Current collector trolleys with graphite sliding contacts must be used in DCL installations operated close to the sea, outdoors and in chemical environments. Use a higher number of current collector trolleys to ensure contact reliability. 2) If 2 current collector trolleys are connected in parallel, twice the rated current can be expected to occur. If 3 current collector trolleys are connected in parallel, the rated current will be increased by a factor of 3 - 10%. 3) Single conductors in the corrugated tube. Maximum cable length 2000 mm Other lengths on request. Minimum length: 500 mm / maximum length: 10000 mm.

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Model code

Order text, e.g.: DCL-SAW-4-40-PE or DCL-SAW-7-20-3500 (no PE, 3500 mm connecting cable) 27

6.9 Towing arm for DCL current collector trolley

6.9.1 Standard towing arm (not for transfer sections)

Detail X

42225844.eps

42206144.eps

Model code

Order text, e.g.: Towing arm DCL-MIT

28

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6.9.2 Towing arm for free transfer sections

42225944.eps

42226344.eps

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Model code

Order text, e.g.: Towing arm for transfer section DCL-MIT

29

6.10 Profile sealing lip

42212444.eps

6.10.1 Assembly tool for fitting the profile sealing lip

Disconnect the DCL installation from the power supply before fitting the profile sealing lip.

DCL assembly tool

Cable slider

Roller pair

Handle

42262144.eps

The profile sealing lip is supplied on rolls in lengths measuring 40 m. Profile sealing lip sections have to be bonded together using cyanoacrylate glue (super glue)2) for longer DCL tracks. Ensure the bonding surfaces are clean and fit together.

Profile sealing lip length = 2 x DCL installation length The profile sealing lips are individually pushed into both sides of the DCL conductor enclosure (see also assembly instructions 214 399 44, section 3.11.1). If profile sealing lips are used with the DCL, the teminal box enclosure halves on the current collector trolley must be prepared. (see note in section 6.8).

Model code

Order text, e.g.: DCL profile sealing lip DCL assembly tool for profile sealing lip Cyacrylat glue (super glue), 20 gr.

876 508 44 1) 876 509 44 000 383 44 2)

30

1) Profile sealing lip may be added to order per meter. Please specify in the order. 2) Order, if required.

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6.11 Isolating section

For control purposes, the DCL conductor line can be interrupted by means of isolating sections on straigth sections or line feeds. The isolating sections can only be combined with 100 A copper conductors. The isolating section can be fitted in the factory or on site. If the isolating sections are fitted in the factory, the following detailed information is required: - postition of the isolating section/sections in the installation - conductor no. - length of each isolating section

ctor ondu Cu c A 100

5,5

5, 5

205
ctor ondu Cu c A 100 5,5 Isola ting sect ion U nS sectio ting la o off, is

ctor ondu Cu c A 100

5, 5

5,5 98 5,5
ion S sect ting Isola

ctor ondu Cu c A 100

5, 5

5, 5

42145244.eps

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Model code

Order text, e.g.: Isolating section U Isolating section S 876 676 44 876 678 44 31

Component parts

7.1 Straight sections and accessories

7.1.1 Component set for sliding suspension with C-rail bracket
Designation Sliding suspension Mounting bracket C-rail clamping section 876 638 44 Part no.

7.1.2 Component set for sliding suspension with M8 threaded pin

Designation Sliding suspension Threaded pin fitting

Part no.

876 637 44 Lock nutM8 (2 off) Countersunk screw M8 x 70

7.1.3 Component set for conductor connector

Designation Conductor connector U section Conductor connector lug Round head screw M6 x 20 Lock nut M6 Clamp section 1) Round head screw M6 x 22

Quantity 1 2 2

Part no.

876 693 44 2 2 2

7.1.4 Isolating sections

Designation Isolating section U 2) Isolating section S 2)

Part no. 876 676 44 876 678 44

32

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).

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7.2 DCL Spare part-sets

7.2.1 Current collector and current collector trolley

The parts listed below are subject to a greater or lesser amount of wear while a current collector trolley is in operation. Wear depends on various factors and is not determined by the current collector trolley operating period alone. Preventive maintenance is therefore required. Worn current collector trolleys or other components must be replaced immediately.

Sliding contact set Bronze or Graphite

Sliding contact sets DCL - SAW - 4 + 5 / 6 + 7 - 40 A, bronze1 ) Designation Sliding contact set 5-pole 40 A (for 4 + 5-pole SAW) Sliding contact set 7-pole 40 A (for 6 + 7-pole SAW) Part no. 876 715 33 876 716 33

Sliding contact sets DCL - SAW - 4 + 5 / 6 + 7 - 20 A, graphite2 ) Designation Sliding contact set 5-pole 20 A (for 4 + 5-pole SAW) Sliding contact set 7-pole 20 A (for 6 + 7-pole SAW) Part no. 876 717 33 876 718 33

Sliding contact set Bronze / Silver-Graphite

Sliding contact sets DCL - SAW - 5 / 6 + 7 40 A, bronze / 20 A, silver-graphite3 ) Designation Sliding contact set 5-pole 40 A / 20 A (for 5-pole SAW) Sliding contact set 7-pole 40 A / 20 A (for 6 + 7-pole SAW) Part no. 876 726 33 876 727 33

Line power feed set

Designation Connection side 70 DCL (enclosure front parts) Center part (enclosure side parts) Entry spout PG 21 Entry spout PG 42 Hex. nut M6 Cyl. screw M6 x 12 Qty. 2 2 1 1 2 2 876 532 33 Part no.

End power feed set

Designation End cap Connection cap DCL-AK-16 Entry spout PG 21 Self-tapping screw ST 3.5x9.5 Qty. 2 2 876 534 33 4 6 Part no.

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1) Sliding contacts power + control conductor: bronze 2) Sliding contacts power + control conductor: graphite 3) Sliding contacts power: bronze Sliding contacts control conductor: silver-graphite

33

Resistance to acids, chemicals and fuels

8.1 Acids

Medium Acid
Chromic acid Chromic-sulfuric acid Nitric acid Sulfuric acid Ethanoic acid Carbonic acid Oleic acid D-tartaric acid Formic acid Arsenic acid Boric acid Hydrofluoric acid Lactic acid Phosphoric acid Oxalic acid Hydrochloric acid Citric acid

Remark Conc.
40 % 20 % 10 % 10% 5% 10 % + + + + + 10 % 20 % 20 % 10 % + + + + + 10 % 50 % 10 % 20 % 10 % + + + + Max. temperature + 30C from +30C to +60C Increased wear of current collectors Increased wear of sliding contacts Avoid direct contact.

8.2 Fuels, oil, grease etc.

Medium
Petroleum spirit Regular petrol Supergrade petrol Kerosine White petroleum spirit Diesel oil Benzole Oil, grease (free from aromatics) Drilling oil ATE brake oil Foodstuffs Seawater distance < 5km distance > 5km + + + +

Remark

Avoid direct contact

Avoid direct contact

Use double current collectors

8.3 Chemicals

Medium
Alkaline solutions Ammonia water Alcohol Hydrocarbons alipphatic aromatic <1% >1% + / + -

Remark
Minimum distance 5 m

Applies to all chemicals: Conductors (Cu) subject to increased oxidation (corrosion) Resistance information only valid for room temperature (20 C).

Chloric solvents Ester Ketone Trichlorethylene Alcaline solvents Ethyl acetate Butanol Butyl acetate

Cannot be answered in a general way. -

resitant to a limited extent - not resistant

Tuluol Xylene Carbon tetrachloride Acetone

34

Bleaching lye

20338744.p65/070606

+ resistant

Methanol

1 page(s) Page 1

Enquiry
Demag Compact Line

Project no.

Demag-Compact-Line Selected/dimensioned by

O O

DCL - _____ - _____ PE - PVC 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 Complete DCL track

O O O

Yes Yes No

No

_____ number of DCL tracks O Spare parts see remark curved according to enclosed drawing

Track layout

straight

Electrical power feed point

O O

Line power feed End power feed

_____ number of _____ number of

Current collector trolley

_____ number of O O O Bronze sliding contacts Graphite sliding contacts

_____ mm cable length

Including standard towing arm (not for transfer sections)

Suspension method Accessories

O O

C-rail Yes, the following:

O O

M 8 threaded pin No

Remarks:

20338744.p65/070606

Address and reference of the customer

_______________________________________________________________________ 35

1 page(s) Page 1

Order
Demag Compact Line

Project no.

Demag-Compact-Line

DCL - _____ - _____ PE - PVC

Selected/dimensioned by

Customer

Demag Wetter / Deutschland

Type

_____ Number of poles

_____ A (rated current)

Length Rated voltage/frequency

_____ m _____ V _____ Hz

Control voltage

_____ V

Protective earth conductor PE

Yes

No

Complete DCL track

O O

Yes No

_____ number of DCL tracks O Spare parts see remark O curved according to enclosed drawing

Track layout

straight

Electrical power feed point

O O

Centre power feed section End power feed

_____ number of _____ number of

Current collector trolley

_____ number of O O O Bronze sliding contacts Graphite sliding contacts

_____ mm cable length

Including standard towing arm (not for transfer sections)

Suspension method

C-rail

M 8 threaded pin

Accessories

Yes, the following:

No

Remarks:

Address and reference of the customer

_______________________________________________________________________ 36
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.

Printed in Germany DZS/1200/2T/PDF 080704 20338744.p65/070606

20338744.p65/070606

Notes

37

38

Notes

20338744.p65/070606

20338744.p65/070606

Notes

39

Demag Cranes & Components GmbH Antriebstechnik

20338744.p65/070606

Postfach 67 D-58286 Wetter Telefon (0 23 35) 92-0 Telefax (0 23 35) 92 72 98 E-Mail drives@demagcranes.com www.demagcranes.de 40