KBH Busbar
KBH Busbar
KBH Busbar
SYSTEMS IN MOTION
4b/en 2016
2
Enclosed conductor system KBH
Inhalt
Enclosed conductor system KBH...................................... 3 Removing section.......................................................... 20
Technical description....................................................... 4 Maintenance Sections.................................................... 21
Technical data................................................................. 6 Anti-Condensation section............................................. 22
Jointing material, Hangers & End caps.............................. 8 Expansion section......................................................... 23
Brackets.......................................................................... 9 Single Current collector.................................................. 24
End feeds, Line feeds..................................................... 10 Double collector & Tow arms.......................................... 25
Line feeds.......................................................................11 Flexible tow arm............................................................ 26
Terminal Box.................................................................. 12 Examples for ordering.................................................... 27
Heating.......................................................................... 14 Spare part list................................................................ 29
Contact sections, turntables & switches......................... 16 APOS Positioning system............................................... 30
Transfer funnels............................................................. 17 VAHLE Powercom®......................................................... 31
Transfer guides.............................................................. 18 Questionnaire................................................................ 32
Transfer guides & Conductor dead section...................... 19 Pictures of plants........................................................... 33
System photo
End cap KE
conductor section
Joint cap KVM
3
Technical description
Applications Double isolating sections are recommended to guarantee safely
For mobile power consumers like cranes, monorails, electric separated conductor sections as per EN 60204.
hoists, machine tools, automated storage and retrieval systems,
lighting systems. Collectors
The current collectors are made of re-inforced polyester fiberglass,
Approvals for high strength and light weight. Spring loaded carbon brushes
UL-approved maintain uniform contact. Connecting cables and hinged or flexible
towing arms included.
Housing
Color grey, plastic housing for 4 or 5 conductors. The length of the connecting cable may not exceed 3 m if the
Standard section 4 m. Other sections are available. added overload protection device is not designed for the load
The ground conductor is identified by international color code. capacity of this cable. Refer also to regulation VDE 0100, part 430
Phase reversing prevented by design of the collector and housing. and EN 60204-32. (Note: this occurs often with several collectors
Higher number of conductors possible by combination of several per system).
conductor systems.
Continuity of ground conductor
Couplings The continuity of the ground conductor has to be guaranteed as
Through plastic joint caps. per regulation EN60204-32 for conductor rails. Runways of lifting
devices may not be used as ground conductor, only an additional
Feed Sets connection is permissible. Therefore a continuous ground conduc-
Through line feeds or end feeds. tor is required.
When selecting the „overload“ protection devices, selection has to
be made according to DIN VDE 0100 part 530. With following system requirements double collectors have to
be used:
End caps • as proper measure to fulfil the continuity of the ground conductor
The open ends of the conductor system are closed by end caps for system via carbon brushes. Refer to regulation EN 60204-1-2007-
KBHF and KBHS. 06 and EN 60204-32-2009-03.
• Transfers with switches and turntables
Hangers • Operational voltage below 50 V
Support bracket at the crane track (see page 9). • low voltages, frequency controlled drives
Max. support distance of the conductor at following ambient • Transmission of data- and/or emergency stop signals
temperatures: • high electrical loads
• Indoor systems and
roofed outdoor systems: ≤ 35° C = 2,00 m Removing section for collectors
• Indoor and outdoor systems Assembly and disassembly of the collector is possible at the end
with and without heating: 35° C = 1,33 m of the track as well as at the removing section. By opening and
• Cold storage: ≤ 0° C = 1,33 m closing the sliders at the bottom of the conducor housing the coll-
ector can be mounted and demounted easily. Before opening the
Expansion during temperature fluctuation removing section the conductor system has to be without voltage.
The Expansion sections are required to compensate the different
expansions between copper conductors and steel- or concrete Safety advice
structures, in varying temperatures without interrupting electrical It must be ensured that the arrangement of the conductor system
power. The different expansions between the plastic housing and provides minimum distances (0,5 m) between fixed and mobile
the copper conductors will be compensated in every joint. plant parts (i.e. between conductor rails, collector trolleys and
towing arms) so as to avoid the risk of pinching.
Anti-condensation sections
These sections are used for transfer of the Powerail to outdoor Please note: For use in galvanizing and pickling plants, under
areas to avoid condensation. The conductor system is not separa- agressive conditions and low voltage applications we would
ted electrically. appreciate receiving detailled information,especially of the
environmental conditions.
Contact sections, turntables and switches For quotations and order processing including conductor
Conductor sections for working areas and transfer applications see systems with curves, dead sections, turntables, switches etc.
page 17 and 19. we require your drawings or sketches. Please use our question-
naire, page 28.
Sectionalizing
Conductor dead sections are electrical interrupts of the conductor.
Under normal operating conditions a cross over with collectors to
switch the voltage off or on is only allowed with low power ratings
(control current).
The conductors can be seperated through air gaps (5 mm) or
insulating pieces (35 mm). With the air gap the collector carbon
bridges the gap, e.g. for mains.
The insulating piece is longer than the carbon and each conductor
section can be separated electrically, e.g. for control.
4
Technical data
Electrical values:
Type max. Nominal Dielectric Spec. resistance Surface Leakage
continuous voltage (UL) strength resistivity resistance
current
KBH 200 A 690 V (600 V) IEC IEC 60093 IEC 60093 1013 Ω EN 60112
(at 100% DC) 60243–1–3 5 x 1015 Ω/cm CTI 400–2,7
30–40 kV/mm
Mechanical properties:
Type Flexible Tensile Temperature Combustibility: Resistance to
strength strength range chemicals: (at 45 °C)
(ambient):
KBH 75 N/mm2 ± 10% 40 N/mm2 ± 10% -30 °C up to +60 flame retardant Gasoline, Mineral Oil, Grease, acid
°C DIN 4102 part 1 class sulfur up to 50%, caustic soda up
B1; self extinguishing to 50% and hydrochloric acid up
to 25%, concentrated
Correction factor ƒT
Ambient temperature °C 35 °C 40 °C 45 °C 50 °C 55 °C 60 °C
5
Technical Data
rechte Seite A
A
A
A
Type(1) No.of Max.continuous current A at 35°C(6) Copper cross section mm2 Nominal
conductors L1 L2 L3 voltage V(4)
HS with PE
SS without PE 60 % DC 80 % DC 100 % DC L1 L2 L3 N / 5(2) control
line
KBHF
KBHF4/63-....HSC 4 81 70 63 3 x 10 10 - - 690
KBHF4/63-....SSD (5)
4 81 70 63 - - - 4 x 10 690
KBHF4/80-....HSC 4 103 89 80 3 x 17 17 - - 690
KBHF4/100-....HSC 4 129 112 100 3 x 26 26 - - 690
KBHF5/63-....HSC 5 81 70 63 3 x 10 10 10 - 690
KBHF5/63-....SSD (5)
5 81 70 63 - - - 5 x 10 690
KBHF5/80-....HSC 5 103 89 80 3 x 17 17 17 - 690
KBHF5/100-....HSC 5 129 112 100 3 x 26 26 26(3) - 690
KBHS
KBHS4/63-....HSC 4 81 70 63 3 x 10 10 - - 690
KBHS4/63-....SSD (5)
4 81 70 63 - - - 4 x 10 690
KBHS4/80-....HSC 4 103 89 80 3 x 17 17 - - 690
KBHS4/100-....HSC 4 129 112 100 3 x 26 26 - - 690
KBHS4/125-....HSC 4 161 140 125 3 x 33 26 - - 690
KBHS4/160-....HSC 4 207 179 160 3 x 51 26 - - 690
KBHS4/200-....HSC 4 258 224 200 3 x 70 42 - - 690
KBHS5/63-....HSC 5 81 70 63 3 x 10 10 10 - 690
KBHS5/63-....SSD (5)
5 81 70 63 - - - 5 x 10 690
KBHS5/80-....HSC 5 103 89 80 3 x 17 17 17 - 690
KBHS5/100-....HSC 5 129 112 100 3 x 26 26 26(3) - 690
KBHS5/125-....HSC 5 161 140 125 3 x 33 26 26(3) - 690
KBHS5/160-....HSC 5 207 179 160 3 x 51 26 26 (3)
- 690
KBHS4/200-....HSC 5 258 224 200 3 x 70 42 26 (3)
- 690
(1) ... Suffi x types e.g. 2 m KBHF4/63-2000HSC, Best–Nr. 600 972, shorter legths are made up from the next larger standard length.
(2) In case of using a conductor as N see page 3.
(3) 5th. Conductor max. 80 A at 100% DC.
(4) Nominal voltage UL= 600 V
(5) control line
(6) Power consumption UL on request
6
Technical Data
A–A A–A
KBH 4 conductors KBH 5 conductors
54 54
N/5
L1 L3 L1 L3
(2) (4) (2) (4)
70
70
yellow yellow
(dark grey) (dark grey)
L2 L2
(1) (3) (1) (3)
green green
(dark grey) (dark grey)
9 9
• The last number of the order specifies the section length. Please suffix the order number with 1, 2, 3, 4.
Ground = PE
7
Jointing material, Hangers & End caps
130
17
89
90
Joint cap, self locking ready installed
M8
max. 35
142
58 35
Sliding hanger Sliding hanger at conductor section
130
17
89
90
End cap End cap ready installed
left and right version
Type Weight kg Order-No.
EK-KE 0,150 600 008
8
Brackets
view without - beam
Fixing claw suitable for D = 6-15 mm Fixing claw suitable for D = 15-25 mm
L 25 X
32 M8
A L 25
support bracket
M8
30
max.48
max. 37
A
D
D
30
45 fixing claw
-15
121 +6
32
-15
170+6
70
45 B A
-15
121+6
-15
170+6
70
Tow arm level
15
15
R=
B 10x
D
D
standard small
version fixing claw(1)
HK-EHK250-NS 250 350 170 1,080 251 600 -
HK-EHK250-KS... - 251 720-...
HK-EHK300-NS 300 400 170 1,128 251 610 -
HK-EHK300-KS... - 251 730-...
HK-EHK400-NS 400 500 170 1,266 251 620 -
HK-EHK400-KS... - 251 740-...
HK-EHK500-NS 500 600 170 1,394 251 630 -
HK-EHK500-KS... - 251 750-...
HK-EHK600-NS 600 700 170 1,561 251 640 -
HK-EHK600-KS... - 251 760-...
HK-EHK700-NS 700 800 170 1,761 251 650 -
HK-EHK700-KS... - 251 770-...
HK-EHK750-NS 750 850 170 1,782 251 660 -
HK-EHK750-KS... - 251 780-...
HK-EHK800-NS 800 900 170 1,936 251 670 -
HK-EHK800-KS... - 251 790-...
(1) e.g. HK-EHK250-KS12 → Order-No. 251720-12 for fixing claw with D=12mm
Select next larger size bracket when your -beam dimension B is more than 170 mm.
9
End feeds, Line feeds
17
130
89
End feed comes loose without conductor section.
It can be mounted at the left or right hand side.
Electrical connection with customer supplied cable shoes to M6 terminals. M 40 90
M 32 (below)
Max. connecting cross section 10 mm2.
Type Weight kg Cable gland (Dimensions see page 13) Order-No.
ES-KKE4/63-80HS 0,271 M 40 600 010
ES-KKE5/63-80HS 0,288 M 40 600 107
ES-KKE4/63SS 0,252 M 32 600 015
ES-KKE5/63SS 0,265 M 32 600 108
120
20
End feed (up to 100 A)
177
End feed comes loose without conductor section.
It can be mounted at the left or right hand side.
Electrical connection with customer supplied cable shoes to M6 terminals.
85
Max. connecting cross section 35 mm2.
Type Weight kg Cable gland (Dimensions see page 13) Order-No.
ES-KKE4/63-100HS 0,613 M 32 or M 50 (1)
600 422
ES-KKE5/63-100HS 0,646 M 32 or M 50(1) 600 423
250 140
50
250 140
158
10
Line feeds
250 140
b
Line feed (incl. 1 m section, 63–100 A)
With spring loaded connector.
Electrical connection with customer supplied cable shoes to M6 terminals.
Type Weight kg Dimension Cable gland Order-No.
a b (Dimensions see page 13)
250 140
a
11
Line feed & Terminal Box
250 140
50
Line feed
including 1m section (125 - 200 A) with 2m single cores
128
Electrical connection with customer supplied cable shoes
to M 6 terminals. See below.
400
120
“A” “B”
200
12
Curves, Sealing strip & Cable glands for feeds
Curves 54
safety web
160 A = 1000 mm
70
yellow
200 A = on request (dark grey)
L2
max. ) 120° (1) (3)
VRO
min. bending radius, vertical = 2000 mm green
(dark grey)
max. curved length = 3600 mm
VRU
9
HR for SA HR for SI
Horizontal curve for SI and SA Vertical curve for VRO and VRU
SI = Safety-web inside VRO = Vertical radius upwards
SA = Safety web outside VRU = Vertical radius downwards
2 sealing strips
(1) T he max. single length is 40 m long. For further distances are joint laces necessary.
For each meter system length have 2 m sealing strip to beordered. The delivery will be in pairs.
13
Heating
Heating cable
Type Resistance(1) Order-No.
HL-0,10-EYCEX-5203-PTFE-260-750 0,10 Ω/m 196 381
HL-0,15-EYCEX-5203-PTFE-260-750 0,15 Ω/m 196 382
HL-0,20-EYCEX-5203-PTFE-260-750 0,20 Ω/m 196 383
HL-0,32-EYCEX-5203-PTFE-260-750 0,32 Ω/m 196 384
HL-0,38-EYCEX-5203-PTFE-260-750 0,38 Ω/m 196 385
HL-0,48-EYCEX-5203-PTFE-260-750 0,48 Ω/m 196 386
HL-0,60-EYCEX-5203-PTFE-260-750 0,60 Ω/m 196 387
HL-0,81-EYCEX-5203-PTFE-260-750 0,81 Ω/m 196 389
HL-1,00-EYCEX-5203-PTFE-260-750 1,00 Ω/m 196 390
HL-1,44-EYCEX-5203-PTFE-260-750 1,44 Ω/m 196 391
HL-2,00-EYCEX-5203-PTFE-260-750 2,00 Ω/m 196 392
HL-3,00-EYCEX-5203-PTFE-260-750 3,00 Ω/m 196 393
HL-4,00-EYCEX-5203-PTFE-260-750 4,00 Ω/m 196 394
HL-4,40-EYCEX-5203-PTFE-260-750 4,40 Ω/m 196 395
HL-5,16-EYCEX-5203-PTFE-260-750 5,16 Ω/m 196 396
HL-5,60-EYCEX-5203-PTFE-260-750 5,60 Ω/m 196 397
(1) Tolerance ± 2,5 %
We recommend a heating system for outdoor installations and conduc-
tor systems in humid plants. The heating consists of two heating cables
which are arranged according to the illustration beside.
The type of heating cable has to be calculated: heat output per heating
cable between 20 - 25 W/m.
For longer heating distances the total length has to be devided into diffe-
rent heating sections.
For shorter heating distances to feed with lower secondary voltage via
(2) Arrangement of the heating cables on both sides transformer.
400V
28
26
25
24 H0 U2
N(W/m)
H1
H2
.4
H0
H1
H0
22 8 R ∧ L2
.44
.8
.0
.0
.6
0
20
U = Supply voltage (Volt)
18
R = Resistance of heating cable (Ohm/m)
30 40 50 60 70 80 90 100 110 120 130
L = Lenght of heating section (m)
l(m)
230V
28
26
25
24 H0
N(W/m)
H2.0
H0
.15
H0
H3.0
H1.
H0
H1.4
H0
H0
H0
22
.32
.48
.81
.2
.38
.6
0
4
20
18
30 40 50 60 70 80 90 100 110 120 130
(1) Arrangement of heating cable
(2) Deflection ± 2,5%
l(m)
14
Heating
Layout examples (depending on system situation)
a) 2 heating circuits
heating circuit 1 heating circuit 2
c) 2 heating circuits
Attention: max. 25 W/m per heating cable grid 230 or 400 VAC
Terminal
box
For each end feed box 2 sets of material for connecting ends are required.
For line feed you need 4 sets of material for connection ends.
Switch gear assembly and temperature control unit as per customers inquiry.
Fuses, cables etc. have to be provided by the customer.
15
Contact sections, turntables & switches
Contact section(1)
Transfer funnel
Track
b
a
max. 20 mm
Line feed Powerail
Switch
Transfer guide
a
Line feed
Transfer guide
a
max. 20 mm
(1) Contact sections must not be activated before collectors are fully engaged.
16
Transfer funnels
17
Transfer guides
50±10
18
Transfer guides & Conductor dead section
Hints for dimensioning the left-and right hand version refer to page 6 and 7.
35 mm isolating piece
Please advise us which conductors should be disconnected (see Page 6 and 7).
The dead section comes factory assembled. Picture shows a isolating piece.
19
Removing section
A-A A-A
close open
83
By opening and closing the sliders at the bottom of the removing
section housing the collector can be mounted and demounted easily. 9
74 110
Before opening disconnect mains.
20
Maintenance Sections
For maintenance work with KBH systems, collector removal and
conductor bar replacement can be easily and quickly achieved with
(1)
a maintenance section. Maintenance sections conveniently drop 40 0 0
out or reinstall at existing runway installations. To obtain best
possible accessibility at longer runways we recommend installing
several maintenance repair sections at convenient intervals or
locations.
(1) Standardlänge = 4000 mm; jede andere Länge und auch Revisionssteilstücke im Bogen (Rmin = 1000 mm / Lmin = 1000 mm) auf Anfrage.
21
Anti-Condensation section
Anti-condensation section
with special bolted joints for KBHF and KBHS at both ends. 1000
22
Expansion section
Expansion section
The Expansion sections are required to compensate the different 1000 + a
500
expansions between copper conductors and steel- or concrete a
structures, in varying temperatures without interrupting electrical 500
power.
install one expansion joint per 100 m. End cap Expansion section Conductor system
Arrangement of fixpoints according to sketches. crane runway max. 100 m max. 125 m
X
temperature of -10 °C to +35 °C during installation.
X X
23
Single Current collector
170
Collector KSW
max. speed 150 m/min.
For conductor systems with sealing strip up to 100 m/min.
Connecting cable:
119
for 25 A with 2,5 mm2/core
for 40 A with 4,0 mm2/core
for 60 A with 6,0 mm2/core
1 m long, longer cables on request.
272
Collector KSWS
max. speed 250 m/min.
For conductor systems with sealing strip up to 100 m/ min.
Connecting cable:
119
(1) at 40% DC
24
Double collector & Tow arms
Double collector DKSW (max. speed 150 m/min.)
480
Also for conductor systems with sealing strip up to 100 m/min.
The double collectors are supplied as an assembly kit consisting of 310
2 collectors (KSW) and a connecting bar with mounting material.
For the collector KSWS there are no double collectors available 2 single
collectors must be used instead.
Connecting cable:
121
for 50 A with (2x) 2,5 mm2/core
for 80 A with (2x) 4,0 mm2/core
for 120 A with (2x) 6,0 mm2/core
1 m long, longer cables on request.
A–A A–A
by customer
Version with square hollow profile Version with tube(2)
(without adapter plate)
A A
0
10 53
190
Tow arm 234
to ce
nter
Installation options of 30 mm square-, hollow of tu
be
profile or tube with 30–34 mm M8
252
85 slotted hole 9 x 30
0
10 53
60
51 ± 10
190
Tow arm
Installation option for plane surface
Type Weight kg Order-No.
MN-MGF 0,524 600 335
MN-MGF/K(3) 0,442 600 337
(1) At 40% DC
(2) For assembly use enclosed adapter plate
(3) Stainless steel
25
Flexible tow arm
70
L1
L2
6,3
ca. 60 (¹)
A A
Ø 10
30
6 18
fixing side
9 6
90 68
330
305
26
Examples for ordering
Installation length of 64 m KBH... (configuration see page 6 and 7)
1 Fixpoint hanger AH-KFA 600 007 AH-KFA 600 007 AH-KFA 600 007
32 Sliding hanger AH-KGA 600 000 AH-KGA 600 000 AH-KGA 600 000
1 Current collector SA-KSW4/40- 600 096 SA-KSW5/40- 600 099 SA-KSW5/40- 600 099
1HS28-60 1HS28-60 1HS28-60
1 Tow arm MN-MGU 600 334 MN-MGU 600 334 MN-MGU 600 334
27
Examples for ordering
End feed
R
=
45°
21
00
Expansion section
X
conductor system
42
42
X X
L=
00
crane runway 35
Fixpoint hanger(1)
R = 2700
1075
29075
2610
End cap
(1)
Rest of conductor system
to be installed with sliding hangers
28
Spare part list
29
APOS Positioning system
were developed for automated handling systems in material flow technology.
The control system can constantly query the absolute position of the mobile consumer.
The APOS Positioning System can be used in connection with the VAHLE Powercom® Data Transmission System.
Reading head
next Position
Features
30
VAHLE Powercom®
VAHLE Powercom®-Data transmission systems in conjunction with VAHLE conductor bars or sliprings were developed for automated
handling systems in material flow technology. They enable the uninterrupted and cost effective data transfer between the central control
system and the accompanying automation devices on the conveying vehicles. The VAHLE Powercom® data transmission system can be used
in connection with the VAHLE Powercom® Data Transmission System.
19,2 187,5
kbps kbps
Example of use
1 VAHLE-Powercom®
2 VAHLE-Powercom® 3
Double filter
3 VAHLE-Powercom®
Terminal resistance
1
1
1
2
31
Questionnaire
Company:____________________________________________________ Date:_______________________________________________________
Fon:_________________________________________________________ Fax:________________________________________________________
eMail:_______________________________________________________ Internet:____________________________________________________
3. O
perating voltage: __________ Volt Frequency: __________ Hz
6. M
ounted position of conductor system:
Conductor system pendant, collector cable facing to the bottom Conductor system pendant, lateral payout of conductor cable(1)
8. Indoor: Outdoor:
11. Hall expansion joints: __________ pieces expansion min.: __________ expansion max.: __________
13. Position and number of isolating sections (e.g. for maintenance)(1): ________________________________________________________
16. Travel speed: __________ m/min. in curves: __________ m/min. at transfers: ___________ m/min.
17. Max. voltage drop from the conductor system feed point to the consumer considering starting current.
18. P
ower consumption of the individual consumer loads: ___________________________________________________________________
Crane 1 Crane 2
Motor data Power Nominal current Starting current Type of Power Nominal current Starting current Type of
Motors Motors
kW A cos ФN % DC A cos ФA (2) kW A cos ФN % DC A cos ФA (2)
Hoist motors
Auxiliary hoist
Long travel
Cross travel
_____________________________________________________________________________________________________________________________
For curved tracks, powerail with isolating sections etc., we require sketches to enable us to prepare
(1)
a quotation
Signature__________________________________
(2)
Use: K for squirrel cage motor, S for slipring motor, F for frequency controlled motor
We reserve all rights to make alterations in the interests of further development
Please copy and fill in the questionnaire
32
Pictures of plants
33
Notes
34
Notes
35
Scope of delivery and services Catalog no.