MKLD-MKLF-MKLS - VAHLE, Inc

19 12POWERAIL MKLD – MKLF – MKLSINDEXPagePowerail versions 3Basic description 3Technical data 3Powerail types, cat. nos. and weights 4Engineering data and configurations 5Standard sections, curves and sealing strip 6Jointing material, hangers 7Brackets 8End sections, end feeds 9Line feeds 10, 11Contact sections 12Turntables, switches 12Transfer funnels, transfer guides 13Anti-condensation sections 14Expansions joint sections 15Collectors 16Double collectors 16Tow arms 17Flexible tow arms 17Flexible tow arm configurations 17Flat copper 18Cable glands 18Assembling tools 19Copper cassettes 19Straightening tool 19Conductor threading tools 19Sectionalizing 20Heating system 20Example for ordering 21Spare parts 21Questionnaire 22, 23Production programm 24VAHLE-Powerail MKL…Powerail MKL… is a totally enclosed conductor system forindoor and outdoor use. The insulated housing can accommodatedifferent copper sectionsTyp MKLD from 6 to 10 copper conductorscontinuous copper strips 40 - 200 Acopper strips come as separate items as coils.Typ MKLF from 6 to 10 copper conductorswith factory-assembled plug-in joints 40 - 100 A.Typ MKLS from 6 to 10 copper conductorswith factory-assembled bolted joints 40 - 200 A.MKL… Powerails require the minimum of space, are easy toinstall and cannot corrode.They meet all national and international safety requirements.MKL… can be equipped with neoprene sealing strips and with aheating system.Standard configurations are listed on page 5. Other configurationsare possible.2

19 12STANDARD SECTIONS · SEALING STRIPMKLDMKLFMKLSStandard sectionsType MKLD for continuous copper strips.AleftAright*LLI = long lip inside* LLA = long lip outside **VO = vertical curve upwards** VU = vertical curve downwards long lipStandard section (view to short lip)A-A56Type MKLF with plug-in joints, factory assembled.AMKL …e.g. 6poleleftArightStandard section (view to short lip)Type MKLS with bolted joints, factory assembled.short lipside10,5AleftArightStandard section (view to short lip)Straight standard sections have no stiffener clamps. Stiffener clamps can be supplied loose or assembled each meter.Stiffener clamps (paire)Cat.-No.Stiffener clamps (piece)Cat.-No.loose, galvanized steel 234 017factory assembled, galvanized steel 234 587loose, stainless steel 234 018factory assembled, stainless steel 234 588CurvesMin. bending radius, horizontal = 1100 mmMax. length L = 3600 mmMax. 120 °MKL…e.g. 6poleSurcharge on request (piece)Cat.-No.Horizontal curve LLI and LLA * 234 547Vertical curve VO and VU ** 234 620Long lip side of Powerails should always be mounted facing themachinery track.R for LLA R for LLI93R for VU R for VOSealing strip with accessories56TypeCat.-No.Sealing strip, p. pair (max. length 50 m) 234 794Fastener (2 per end) 258 432Joint (2 per joint) 258 300MKL…e.g. 8pole93102Not available for 9- and 10-pole systems.6

158JOINT MATERIAL · HANGERS19 12Joint cap, self-lockingMKLD15020Ready installed92Type Weight kg Cat.-No.MVMD 0,16 234 678Joint cap, self-locking167MKLFMKLS23100Ready installedType Weight kg Cat.-No.MVMS 0,240 234 585Sliding hangerM 8Fixpoint hangerMKLDMKLFMKLSmax. 35M 875 7540max. 3540153Fixpoint hanger mounted toPowerail section71Sliding hanger mounted to Powerail section64Type Weight kg Cat.-No.MGA 0,220 234 013Type Weight kg Cat.-No.MFN 0,275 235 1427

19 12BRACKETSEHK standard versionView w/o I-beam32L25Attachmentbracketmax. 3730DØ 13M 8Claw suitablefor D = 6-15 mm45claw93137 +6–15185 +6–15XBRDR = 10 x DXView w/o I-beamclawL25max. 48DØ 13Attachmentbracket30M 832Claw suitablefor D = 15-25 mm45B93137 +6–5185 +6–5EHK small claw version, D = max. 10 mmAttention:Make sure that hoist wheels have enough clearance. Usesmall claw if necessary. Check -beam dimension D.rail of EHK is identical to type S 1, Cat. 8a.Cat.-No. Cat.-No.Type X L B max Weight for standard with smallmm mm mm kg version claw versionEHK 250 250 350 170 1.070 251 600 251 720EHK 300 300 400 170 1.150 251 610 251 730EHK 400 400 500 170 1.300 251 620 251 740EHK 500 500 600 170 1.450 251 630 251 750EHK 600 600 700 170 1.600 251 640 251 760EHK 700 700 800 170 1.750 251 650 251 770EHK 750 750 850 170 1.820 251 660 251 780EHK 800 800 900 170 1.900 251 670 251 790Select next larger size bracket when your -beam dimension Bis more than 170 mm.8

END SECTIONSEND FEEDS19 12End sections0,3 m longEnd feedsMKLD16710040196Housing empty300156End feeds come loose w/o Powerail.They can be mounted at either end.Termination by others, using cable lugs and M 5 studs.Type Execution Weight kg Cat.-No.MSED/L left 0,550 235 144MSED/R right 0,550 235 145Type Cable gland Weight kg Cat.-No.dimensions see p. 18MKED 6-8/ 40-60 HS 0,580 235 152M 25 & M 40MKED 9-10/ 40-60 HS 1,040 235 155MKED 6-8/ 40 SS 0,520 235 157M 25MKED 9-10/ 40 SS 0,980 235 160End capEnd feedsMKLFMKLS11023110231006 - 8 pole 9 - 10 pole16723167110100100End feeds come loose w/o Powerail.They can be mounted at either end.Termination by others, using cable lugs and M 5 studs.Type Execution Weight kg Cat.-No.MSES left & right 0,286 235 141Type Cable gland Weight kg Cat.-No.dimensions see p. 18MKES 6-8/ 40-60 HS M 25 and M 40 0,580 235 230MKES 6-8/ 40 SS M 25 0,520 235 2339

19 12LINE FEEDSwith terminal box; incl. 1 m PowerailMKLDTypeCable gland(dim. see p. 18)Weight kgCat.-No.1503001000Termination by others using cable lugs and M 8 studs.83MNGD 6/ 40-100 HS 2,740 235 055MNGD 7/ 40-100 HS M 50 2,817 235 056MNGD 8/ 40-100 HS and 2,894 235 057MNGD 9/ 40-100 HS M25 2,954 235 058MNGD 10/ 40-100 HS 2,994 235 059MNGD 6/140-200 HS 2,744 235 060MNGD 7/140-200 HS M50 2,821 235 061MNGD 8/140-200 HS and 2,898 235 062MNGD 9/140-200 HS M25 2,958 235 063MNGD 10/140-200 HS 2,998 235 064MNGD 6/ 40 SS 2,667 235 050MNGD 7/ 40 SS 2,744 235 051MNGD 8/ 40 SS M 25 2,826 235 052MNGD 9/ 40 SS 2,886 235 053MNGD 10/ 40 SS 2,926 235 054MKLF1503001000Termination by others using cable lugs and M 8 studs.83TypeCable gland(dim. see p. 18)Weight kgCat.-No.MNGF 6/ 40 HS 3,367 235 089MNGF 7/ 40 HS 3,566 235 090MNGF 8/ 40 HS 3,763 235 091MNGF 6/ 60 HS M50 3,598 235 092MNGF 7/ 60 HS and 3,797 235 093MNGF 8/ 60 HS M 25 3,994 235 094MNGF 6/100 HS 3,841 235 095MNGF 7/100 HS 4,040 235 096MNGF 8/100 HS 4,237 235 097MNGF 6/ 40 SS 3,299 235 086MNGF 7/ 40 SS M 25 3,498 235 087MNGF 8/ 40 SS 3,695 235 088MKLSTypeCable gland(dim. see p. 18)Weight kgCat.-No.1503001000Termination by others using cable lugs and M 8 studs.83MNGS 6/ 40 HS 3,451 235 068MNGS 7/ 40 HS 3,662 235 069MNGS 8/ 40 HS 3,873 235 070MNGS 6/ 60 HS M 50 3,682 235 071MNGS 7/ 60 HS and 3,893 235 072MNGS 8/ 60 HS M 25 4,104 235 073MNGS 6/100 HS 3,925 235 074MNGS 7/100 HS 4,136 235 075MNGS 8/100 HS 4,347 235 076MNGS 6/140 HS 4,103 235 077MNGS 7/140 HS 4,314 235 078MNGS 8/140 HS 4,525 235 079MNGS 6/160 HS M50 3,427 235 080MNGS 7/160 HS and 4,638 235 081MNGS 8/160 HS M25 4,849 235 082MNGS 6/200 HS 4,670 235 083MNGS 7/200 HS 4,881 235 084MNGS 8/200 HS 5,092 235 085MNGS 6/ 40 SS 3,383 235 065MNGS 7/ 40 SS M 25 3,394 235 066MNGS 8/ 40 SS 3,805 235 06710

LINE FEEDSfor single core cable connection, incl. 1 m Powerail section19 12TypeCable gland(dim. see p. 18)Weight kgCat.-No.MKLDMNLD 6/ 40-100 HS 2,432 234 740MNLD 7/ 40-100 HS M 25 for PE, 2,509 234 745L1, L2, L3,MNLD 8/ 40-100 HSM 25 for 1-42,586 234 746MNLD 9/ 40-100 HS M 25 for 9/10 2,657 234 747MNLD 10/ 40-100 HS 2,697 234 748MNLD 6/140-200 HS 2,447 234 749MNLD 7/140-200 HS M 25 for PE, 2,524 234 750L1, L2, L3,MNLD 8/140-200 HS M 25 for 1-4 2,601 234 755MNLD 9/140-200 HS M 25 for 9/10 2,672 234 756MNLD 10/140-200 HS 2,712 234 757MNLD 6/ 40 SS 2,374 234 735MNLD 7/ 40 SS 1 x M 25 2,451 234 736MNLD 8/ 40 SS 2,533 234 737MNLD 9/ 40 SS 2,612 234 7382 x M 25MNLD 10/ 40 SS 2,652 234 7391503001000Termination by others using cable lugs and M 8 studs.50TypeCable gland(dim. see p. 18)Weight kgCat.-No.MKLFMNLF 6/ 40 HS 3,059 235 131MNLF 7/ 40 HS 3,258 235 132MNLF 8/ 40 HS 3,455 235 133MNLF 6/ 60 HS M 25 for PE, 3,290 235 134MNLF 7/ 60 HS L1, L2, L3, 3,489 235 105MNLF 8/ 60 HSM 25 for 1-43,686 235 106MNLF 6/100 HS 3,533 235 107MNLF 7/100 HS 3,732 235 108MNLF 8/100 HS 3,929 235 109MNLF 6/ 40 SS 3,006 235 098MNLF 7/ 40 SS M25 3,205 235 099MNLF 8/ 40 SS 3,402 235 1001503001000Termination by others using cable lugs and M 8 studs.50TypeCable gland(dim. see p. 18)Weight kgCat.-No.MKLSMNLS 6/ 40 HS 3,143 235 113MNLS 7/ 40 HS 3,345 235 114MNLS 8/ 40 HS 3,565 235 115MNLS 6/ 60 HS M 25 for PE, 3,374 235 116MNLS 7/ 60 HS L1, L2, L3, 3,585 235 117MNLS 8/ 60 HSM 25 for 1-43,796 235 118MNLS 6/100 HS 3,617 235 119MNLS 7/100 HS 3,828 235 120MNLS 8/100 HS 4,039 235 121MNLS 6/140 HS 3,806 235 122MNLS 7/140 HS 4,017 235 123MNLS 8/140 HS 4,228 235 124MNLS 6/160 HS M 25 for PE, 4,119 235 125MNLS 7/160 HS L1, L2, L3, 4,341 235 126MNLS 8/160 HSM 25 for 1-44,552 235 127MNLS 6/200 HS 4,373 235 128MNLS 7/200 HS 4,584 235 129MNLS 8/200 HS 4,795 235 130MNLS 6/ 40 SS 3,090 235 110MNLS 7/ 40 SS M 25 3,301 235 111MNLS 8/ 40 SS 3,512 235 1121503001000Termination by others using cable lugs and M 8 studs.5011

19 12CONTACT SECTIONS, TURNTABLES AND SWITCHESContact section*TurntableSliding switchKSGPlease submit drawings of transfer applications. Specify dimensions a, b, c, R and angle . ( max. 50°).12*Contact sections must not be activated before collectors are fully engaged.Flexible support type tow arms MFM (see page 17) for collectors are essential with contact sections.

TRANSFER FUNNELS · TRANSFER GUIDESincl. sections19 12Transfer funnelsEnergize Powerail only after current collector brushes havefull contact with copper conductors. Do not use transferfunnel like a switch.B140 ± 10MKLDMKLFMKLSWeightCat.-No.Type*kg L.H. version R.H. versionMTN 6/ 40-200 … HS 2,201 235 162 235 172MTN 7/ 40-200 … HS 2,265 235 163 235 173MTN 8/ 40-200 … HS 2,528 235 164 235 174MTN 9/ 40-200 … HS 2,581 235 165 235 175MTN 10/ 40-200 … HS 2,634 235 166 235 176MTN 6/ 40 … SS 2,201 235 167 235 177MTN 7/ 40 … SS 2,265 235 168 235 178MTN 8/ 40 … SS 2,528 235 169 235 179MTN 9/ 40 … SS 2,581 235 170 235 180MTN 10/ 40 … SS 2,634 235 171 235 181horizontal offset ± 15 mmvertical offset + 10 mmshort lip245500 for MKLF & MKLS525 for MKLDBL.H. versionw/o cond.Bshort lipR.H. version110Transfer guides, straight165BWeightCat.-No.Type*kg L.H. version R.H. versionMUN 6/ 40-200 … HS 2,155 235 182 235 192MUN 7/ 40-200 … HS 2,219 235 183 235 193MUN 8/ 40-200 … HS 2,482 235 184 235 194MUN 9/ 40-200 … HS 2,535 235 185 235 195MUN 10/ 40-200 … HS 2,588 235 186 235 196MUN 6/ 40 … SS 2,155 235 187 235 197MUN 7/ 40 … SS 2,219 235 188 235 198MUN 8/ 40 … SS 2,482 235 189 235 199MUN 9/ 40 … SS 2,535 235 190 235 200MUN 10/ 40 … SS 2,588 235 191 235 201horizontal offset ± 8 mmvertical offset ± 3 mmshort lipBL.H. version70w/o cond.350 for MKLF & MKLS375 for MKLDBshort lipR.H. version75Transfer guides, oblique205BWeightCat.-No.Type*kg L.H. version R.H. versionMUNS 6/ 40-200 … HS 2,185 235 202 235 212MUNS 7/ 40-200 … HS 2,249 235 203 235 213MUNS 8/ 40-200 … HS 2,512 235 204 235 214MUNS 9/ 40-200 … HS 2,565 235 205 235 215MUNS 10/ 40-200 … HS 2,618 235 206 235 216MUNS 6/ 40 … SS 2,185 235 207 235 217MUNS 7/ 40 … SS 2,249 235 208 235 218MUNS 8/ 40 … SS 2,512 235 209 235 219MUNS 9/ 40 … SS 2,565 235 210 235 220MUNS 10/ 40 … SS 2,618 235 211 235 221horizontal offset ± 8 mmvertical offset ± 3 mmshort lipDetails of oblique cutper system layout.BL.H. version350 for MKLF & MKLS375 for MKLDBR.H. version110w/o cond.short lip75*Complete types e.g. MUN 6/40-200… HSL.H.-version: MUN 6/40-200 L HS Cat.-No. 235 18213

19 12ANTI-CONDENSATION SECTIONSincl. 1 m sectionMKLDTypeWeightkgCat.-No.MBD- HS 2,520 235 223MBD- SS 2,520 235 2221000»X«»X«MKLFX: See page 2 for different versionsof Powerail endsThe anti-condensation section consists of 1 m Powerail with aircirculation holes, covered by a protection hood.The anti-condensation section is to be used where Powerailsare passing from indoor to outdoor, preventing condensation ofhot air, escaping from the indoor section, in the cooler outdoorsection.TypeWeightkgCat.-No.MBF- 6/ 40 HS 3,034 235 236MBF- 7/ 40 HS 3,156 235 237MBF- 8/ 40 HS 3,276 235 238MBF- 6/ 60 HS 3,266 235 239MBF- 7/ 60 HS 3,388 235 240MBF- 8/ 60 HS 3,508 235 241MBF- 6/100 HS 3,509 235 242MBF- 7/100 HS 3,631 235 243MBF- 8/100 HS 3,750 235 244MBF- 6/ 40 SS 3,034 235 245MBF- 7/ 40 SS 3,156 235 246MBF- 8/ 40 SS 3,276 235 247MKLSFeedingNo extra feeds required as the Powerail is not interrupted.CollectorsNo extra collectors required.InstallationThe anti-condensation section is to be placed outdoors, close tothe transfer point.TypeWeightkgCat.-No.MBS- 6/ 40 HS 3,118 235 260MBS- 7/ 40 HS 3,252 235 261MBS- 8/ 40 HS 3,386 235 262MBS- 6/ 60 HS 3,350 235 263MBS- 7/ 60 HS 3,484 235 264MBS- 8/ 60 HS 3,618 235 265MBS- 6/100 HS 3,593 235 266MBS- 7/100 HS 3,727 235 267MBS- 8/100 HS 3,861 235 268MBS- 6/140 HS 3,767 235 269MBS- 7/140 HS 3,901 235 270MBS- 8/140 HS 4,035 235 271MBS- 6/160 HS 4,091 235 272MBS- 7/160 HS 4,225 235 273MBS- 8/160 HS 4,358 235 274MBS- 6/200 HS 4,334 235 275MBS- 7/200 HS 4,468 235 276MBS- 8/200 HS 4,601 235 277MBS- 6/ 40 SS 3,118 235 278MBS- 7/ 40 SS 3,252 235 279MBS- 8/ 40 SS 3,868 235 28014*For longer runs use expansion joint section (see page 15)

EXPANSION JOINT SECTIONSincl. 1 m section19 12TypeWeightkgCat.-No.MDD- 6-8 HS 1,890 235 224MDD- 9 HS 1,883 235 225MDD- 10 HS 1,877 235 226MDD- 6-8 SS 1,890 235 227MDD- 9 SS 1,883 235 228MDD- 10 SS 1,877 235 229500Dim. »a« max. 70 mma1000 + a500Expansion section Typ MDD is required to compensate differencein expansion between insulated housing and copper conductors.The expansion joints are used if the Powerail length betweenfeeds, curves, transfer guides and other fix points is exceeding10 m.Max. length to temperature differences∆ t 20° C = 70 m ∆ t 40° C = 35 m ∆ t 80° C = 17 m∆ t 30° C = 45 m ∆ t 60° C = 23 mLonger runs or higher differences in temperature require severalexpansion joints.MKLDAdditional feed points and collectors are not necessary as theconductor rail is not electrically separated.TypeWeightkgCat.-No.MDS- 6/ 40-100 HS 5,400 235 395MDS- 7/ 40-100 HS 5,520 235 396MDS- 8/ 40-100 HS 5,640 235 397MDS- 6/140-200 HS 5,900 235 398MDS- 7/140-200 HS 6,020 235 399MDS- 8/140-200 HS 6,140 235 400MDS- 6/ 40 SS 5,400 235 401MDS- 7/ 40 SS 5,520 235 402MDS- 8/ 40 SS 5,620 235 403»X«500Dim. »a« max. 100 mm»X« see page 2 for finish of endsa1000 + aExpansion joint section Type MDS is required to compensatedifference in expansion between insulated housing and supportingstructure:The expansion joints are used if the powerail length betweenfeeds, curves, transfer guides and other fix points is exceeding20 m.Max. length to temperature differences:∆ t 90° C (–30° C to + 60° C) one expansion joint section per100 m, and so on each 100 m.500»X«MKLFMKLSAdditional feed points and collectors are not necessary as theconductor rail is not electrically separated.15

15215019 12COLLECTORS · DOUBLE COLLECTORSMKLDMKLFMKLSCollectors223Connecting cables:for power line: cable 1 4 x 6 mm 2cable 2 … x 1,5 mm 2for control line: cable 1 … x 2,5 mm 2(two cables for 8-pole and more)cable 2 cable 1TypeAmpacityat 60% EDANo.ofpolesø of connectingcables mmcable 1 cable 2Travelling speednormal Transferm/min. m/min.WeightkgCat.-No.MSW 6/50-1 HS 50 6 ≈17,0 ≈ 7,0 180 100 1,150 234 118MSW 7/50-1 HS 50 7 ≈17,0 ≈ 7,5 180 100 1,185 235 146MSW 8/50-1 HS 50 8 ≈17,0 ≈ 8,0 180 100 1,220 234 120MSW 9/50-1 HS 50 9 ≈17,0 ≈ 9,0 180 100 1,259 235 147MSW 10/50-1 HS 50 10 ≈17,0 ≈10,0 180 100 1,298 235 148MSW 6/25-1 ST 25 6 ≈13,5 – 180 100 0,850 234 121MSW 7/25-1 ST 25 7 ≈13,5 – 180 100 0,880 235 149MSW 8/25-1 ST 25 8 ≈11,0 ≈11,0 180 100 0,910 234 123MSW 9/25-1 ST 25 9 ≈12,0 ≈11,0 180 100 0,949 235 150MSW 10/25-1 ST 25 10 ≈13,0 ≈11,0 180 100 0,988 235 151Collectors for higher speeds on request.For curves use single collectors only.Connecting cable 1 m, longer cable available.Example of ordering collector with 2 m cableCat.-No. 234 118-2for collector MSW 6/50-2 HSDouble collectors533Connecting cables:for power line: cable 1 4 x 6 mm 2cable 2 … x 1,5 mm 2for control line: cable 1 … x 2,5 mm 2(two cables for 8-pole and more)310cable 2 cable 1TypeAmpacityat 60% EDANo.ofpolesø of connectingcables mmcable 1 cable 2Travelling speednormal Transferm/min. m/min.DMSW 6/100 S-1 HS 100 6 ≈17,0 ≈ 7,0 180 100 2,440 234 160DMSW 7/100 S-1 HS 100 7 ≈17,0 ≈ 7,5 180 100 2,510 234 758DMSW 8/100 S-1 HS 100 8 ≈17,0 ≈ 8,0 180 100 2,580 234 162DMSW 9/100 S-1 HS 100 9 ≈17,0 ≈ 9,0 180 100 2,658 234 759DMSW 10/100 S-1 HS 100 10 ≈17,0 ≈10,0 180 100 2,736 234 760DMSW 6/50 S-1 ST 50 6 ≈13,5 – 180 100 1,830 234 163DMSW 7/50 S-1 ST 50 7 ≈13,5 – 180 100 1,990 234 765DMSW 8/50 S-1 ST 50 8 ≈11,0 ≈11,0 180 100 2,160 234 165DMSW 9/50 S-1 ST 50 9 ≈12,0 ≈11,0 180 100 2,238 234 766DMSW 10/50 S-1 ST 50 10 ≈13,0 ≈11,0 180 100 2,316 234 767Connecting cable 1 m, longer cables available. Example of ordering double collectors with 2 m cableCat.-No. 234 160-2for collector DMSW 6/100-2 HSWeightkgCat.-No.16

50 ±10TOW ARMS19 12Installation to tubefor single and double collectorstube Ø 34by othersMKLDMKLFMKLS10053190224 up to middle of tubeType Weight kg Cat.-No.MGR 0,560 234 015MGR/K 0,560 234 021Installation to plain surfacefor single and double collectors257Ø 91005360+ 0–10Type Weight kg Cat.-No.MGF 0,590 234 016MGF/K 0,590 234 022190For single collectors – flexible support typefor systems with transfer funnels MTN33090slotted hole 9 x 18138Type Weight kg Cat.-No.MFM 1,120 234 211max. horizontal offset ± 15 mm,max. vertical offset ± 10 mm.Flexible tow arm configurationmax. horizontal offset ±15 mmmax. vertical offset ±10 mmca. 82treadslotted hole 9 x 18ca. 619033013817

19 12FLAT COPPER AND STAINLESS STEEL STRIPSMKLDWeight Cu Weightt InoxMax. length ofkg/mkg/mfor shaft I11 mm wide strips*Cat.-No.Cat.-No..* With straightening tool (see page 19). 11 mm 2 max. length (m) 90 260 3000,10 234 198 0,09 234 38411 x 1 mm(40 A)Type of cassette A B CWeight Cu Weight InoxMax. length ofkgkgfor shaft II13 mm wide strips*Cat.-No.Cat.-No..10 mm 2 max. length (m) 115 300 –0,09 234 197 – –13 x 0,8 mm(40 A)Type of cassette A B C17 mm 2 max. length (m) 65 200 3000,15 234 199 0,13 234 38313 x 1,3 mmType of cassette A B C(60 A)26 mm 2 max. length (m) 45 130 2000,23 234 200 – –13 x 2 mm(100Type of cassette A B CA)*33 mm 2 max. length (m) 35 100 1600,29 234 201 – –13 x 2,5 mm(140 A)Type of cassette A B C*42 mm 2 max. length (m) 25 60(80) (120)0,37 234 202 – –13 x 3,2 mmType of cassette(160 A) *A B C51 mm 2 max. length (m) 22 50(65) (100) 0,45 234 203 – –13 x 3,9 mm(200 A) *Type of cassette A B C*Longer lengths to be connected with bolted joints.Use bolted joints and possibly expansion sections for bigger lengths than shown in the table. In thiscase installation by Vahle experts is recommended, especially for copper cross section of 42 mm 2 and51 mm 2 .Consult factory for proper layout.Shaft IShaft IIShaft IMKLDMKLFMKLSCable glands for feedsCable glands for cable-Ø capacity A pagein mmexecution: D/F/SM 25 and M 40 9 – 19 and 17 – 26 40 – 60 HS 9M 25 9 – 19 40 SS 9M 25 and M 50 9 – 19 and 23 – 34 40 – 100 HS 10M 25 and M 50 9 – 19 and 29 – 40 140 – 200 HS 10M 25 9 – 19 40 SS 10M 25 for PE and L1/L2/L3 6 – 15 40 – 200 HS 11M 25 for 1 – 4 and 9/10 9 – 19 40 – 200 HS 11M 25 6 – 10pole 9 – 19 40 SS 1118

ASSEMBLING TOOLS19 12Copper cassettesArrangement of laying mechanismMKLDExecution Type Dim. » X« Dim. » Y« Weight kg Cat.-No.of cassetteA EZK 1 single 462 500 3,500 234 219B EZK 2 single 662 700 4,450 234 220C EZK 3 single 862 900 5,400 234 250A DEZK 1 double 462 500 6,500 234 221B DEZK 2 double 662 700 8,200 234 222C DEZK 3 double 862 900 9,900 234 251Type of copper cassette depends on copper cross section and systemlength (see page 18).„X“„Y“Single copper casstte type EZKStraightening tool (required from strip sections 26 mm 2 upwards)Type Weight kg Cat.-No.RV 1,610 234 218Double copper cassette type DEZKConductor threading tools and installation carrierappr. 5 m longTyp EZR 6-8Type Weight kg Cat.-No.EZR 6-8for conductors inside housing, shafts I & II1.450 234 204EZR 9/10for conductors outside housing, shafts I 0.170 234 730(not shown)Installation carrier(for sealing strip; not shown)1.620 234 37619

19 12SECTIONALIZING · HEATING SYSTEMMKLDMKLFMKLSSectionalizingIllustration shows insulated section30 mm insulated sectionPlease indicate which conductors are to be interrupted(see page 4). Factory assembled.5 mm air gap 30 mm insulated sectionType Cat.-No. Type Cat.-No.MSTL 1 235 302 MSTI 1 235 312MSTL 2 235 303 MSTI 2 235 313MSTL 3 235 304 MSTI 3 235 314MSTL 4 235 305 MSTI 4 235 315MSTL 5 235 306 MSTI 5 235 316MSTL 6 235 307 MSTI 6 235 317MSTL 7 235 308 MSTI 7 235 318MSTL 8 235 309 MSTI 8 235 319MSTL 9 235 310 MSTI 9 235 320MSTL 10 235 311 MSTI 10 235 321Heating system* ** Arrangement ofheating cablesHeating systems are recommended for outdoor Powerail installationswith icing conditions and for extremely humid environments.The heating is accomplished by heating conductorsbeing arranged inside the Powerail housing as shown in theadjacent drawing.Attention! Heating system to be used only when temperatureis + 5° C or lower.Selection of heating cablesN (W/m)N (W/m)400 V3432302826242220Composition ofheating cable:20 30 40 50 60 70 80 90 100 110 120 130230 V3432302826242220H 3,00H 2,00H 1,44H 3,00H 2,00H 1,44Conductor: material resistor CrNi, strandedInsulation: PTFE-(Teflon)tinned copper braidSheath: PTFE-insulationOD: 3,7 mm - 4,3 mmLayout of one heating section with feeder boxes at both endsTemperature control units on request.H 1,00H 0,81H 0,60H 0,48H 1,00L (m)H 0,38H 0,81H 0,60H 0,4820 30 40 50 60 70 80 90 100 110 120 130L (m)H 0,32H 0,20H 0,15Determine a heating cable between 24 and 30 watt/m capacity.For longer runs, not covered by the adjacent diagrams, dividethe length of the system into two or more heating sections.Supply lower voltage via a transformer in case of shorter heatingsections.Heating capacity [Watt/m]: N’ =U = supply voltage [Volt]R = resistance of heating cable [Ohm/m]L = length of heating section [m]Wire resistance data:heating cable: H 0,15 → 0,15 Ohm/mheating cable: H 0,20 → 0,20 Ohm/mheating cable: H 0,32 → 0,32 Ohm/mheating cable: H 0,38 → 0,38 Ohm/mheating cable: H 0,48 → 0,48 Ohm/mheating cable: H 0,60 → 0,60 Ohm/mheating cable: H 0,81 → 0,81 Ohm/mheating cable: H 1,00 → 1,00 Ohm/mheating cable: H 1,44 → 1,44 Ohm/mheating cable: H 2,00 → 2,00 Ohm/mheating cable: H 3,00 → 3,00 Ohm/mtolerance ± 2,5 %Example for ordering heating system for 60 m Powerail1) 122 m heating cable type H 1,44(incl. safety lengths)Supply voltage 400 V, 2 heating sectionsHeating capacity per above diagram approx. 2 x 31 W/mwith 60 m 2 x 31 W/m approx. 3720 W = 3,72 kW.2) Two terminal boxes for heating system3) Four sets of connecting material4) Threading tool for heating cableAll switches, fuses, cable etc. by others!U 2R · L 220

EXAMPLE FOR ORDERING · SPARE PARTS19 12System length 64 mMKLDMKLFMKLSX = 300 mm end section = expansion section for copper conductorfor MKLD (w/o cond.). Not for MKLF and MKLS.Example for orderingSystem length 64 m MKL…8/100-HS (see page 5)Qty.DescriptionMKLD MKLF MKLSType Cat.-No. Type Cat.-No. Type Cat.-No.15 Flat copper strip 4 m MKLD-4 HS 235 104 – – – –1 Flat copper strip 3 m MKLD-3 HS 235 103 – – – –15 Powerail 4 m – – MKLF 8/100-4 HS 234 944 MKLS 8/100-4 HS 234 8241 Powerail 3 m – – MKLF 8/100-3 HS 234 943 MKLS 8/100-4 HS 234 8231 Line feed MNGD 8/40-100 HS 235 057 MNGF 8/100-HS 235 097 MNGS 8/100-HS 235 0761 End section, right MSED/R 235 145 – – – –1 End section, left MSED/L 235 144 – – – –2 End caps – – MSES 235 141 MSES 235 14118 Joint caps MVMD 234 678 – – – –16 Joint caps – – MVMS 234 585 MVMS 234 5851 Fixpoint hanger MFN 235 142 MFN 235 142 MFN 235 14230 Sliding hangers MGA 234 013 MGA 234 013 MGA 234 013195 m Flat copper strip, 3 coils à 65 m 26 mm 2 234 200 – – – –65 m Flat copper strip, 1 coil à 65 m 17 mm 2 234 199 – – – –130 m Flat copper strip, 2 coils à 65 m 10 mm 2 234 197 – – – –130 m Flat copper strip, 2 coils à 65 m 11 mm 2 234 198 – – – –1 Collector MSW 8/50-1 HS 234 120 MSW 8/50-1 HS 234 120 MSW 8/50-1 HS 234 1201 Tow arm MGR 234 015 MGR 234 015 MGR 234 0151 Copper cassette EZK 2 234 220 – – – –1 Laying mechanism RV 234 218 – – – –1 Conductor threading tool EZR 6-8 234 204 – – – –Spare partsfor PowerailCat.-No.Plug in joint for MKLF (11 mm Cu; 40 A) 234 688Plug in joint for MKLF (13 mm Cu; 40–100 A) 234 687Bolted joint for MKLS (11 mm Cu; 40 A) 234 686Bolted joint for MKLS (13 mm Cu; 40–200 A) 234 685Joint Cap for transfer guide and transfer funnel, pair (MKLD, MKLF and MKLS) 234 779Sealing strip 235 794Spare partsfor collectorsCat.-No.Carbon brush phase, incl. brush holder (lateral) 230 199Carbon brush PE, incl. brush holder (lateral) 230 200Carbon brush 7th and 8th pole (above) 234 158Carbon brush 9th and 10th pole (below) 234 370Carbon pressure spring, standard for phase and PE 258 757Carbon pressure spring, reinforced for phase and PE 238 760Throat part 234 154Trolley wheel 234 155Connecting bar for double collector 234 51521

19 12QUESTIONNAIRECUSTOMERATTENTION OFADDRESSTELEPHONEE-MAILTELEFAXINTERNET1. Type of crane/machine to be electrified2. Voltage Volts~/=: Phases, c/s3. Length of conductor system4. Number of power conductors: control lines: ground: neutral:5. Indoor Outdoor6. Special site conditions (humidity, dust, chemical influences etc.)7. Temperature conditions °C min. °C max.8. Number of cranes/machines supplied by the one system9. Ampere load of each crane/machine(use table on page 30)10. Permissible voltage drop11. Number and position of feed points*12. Number and position of isolating sections*13. Installation position envisaged*14. Brackets required (see page 8) yes no c/c distance beam/Powerail:15. Max. travelling speed of machinery16. Other important data:22* Please submit prints or sketches, also for curved tracks.

QUESTIONNAIRE19 12To the nearest local VAHLE agency:Date:MotordataPowerkWCrane 1Nominal current Starting currentA cos ϕ N% ED A cos ϕ AType ofmotor**PowerkWCrane 2Nominal current Starting currentA cos ϕ N% ED A cos ϕ AType ofmotor**Hoist motorAuxiliary hoistLong travelCross travelMotordataPowerkWCrane 3Nominal current Starting currentA cos ϕ N% ED A cos ϕ AType ofmotor**PowerkWCrane 4Nominal current Starting currentA cos ϕ N% ED A cos ϕ AType ofmotor**Hoist motorAuxiliary hoistLong travelCross travelMark motors* which can operate simultaneously.Mark motors ∆ which can start simultaneously.**Use K for squirrel cage motorS for slipring motorF for frequency controlled motorFurther remarks:Signature:In accordance with our company’s policy of continued improvement, we reserve the right to amend specifications and details at any time.23

Catalog No. 4c/E 2005MANAGEMENTSYSTEMDQS certified in accordance with DIN EN ISO 9001:2000OHSAS 18001 (Reg. no. 003140 QM OH)Catalog No.Copperhead Conductor Systems1 aBattery Charging Systems1 bInsulated Conductor Systems U 102 aInsulated Conductor Systems U 20 – U 30 – U 402 bInsulated Conductor Systems U 15 – U 25 – U 352 cAluminium Enclosed Conductor Systems LSV – LSVG3 aPowerail Enclosed Conductor Systems KBSL – KSL – KSLT 4 aPowerail Enclosed Conductor Systems VKS – VKL4 bPowerail Enclosed Conductor System MKLD – MKLF – MKLS 4 cPowerail Enclosed Conductor System KS–104 dPowerail Enclosed Conductor System KBH4 eHeavy Enclosed Conductor Systems 5Trolley Wire and Accessories 6Cable Tenders 7Cable Carriers for -tracks 8 aCable Carriers for Flatform Cable on -beams8 bFCable Carriers for Round Cable on -beams8 bRCable Carriers for -tracks 8 cConductor Cables and Fittings8 LSpring Operated Cable Reels9 aVAHLE POWERCOM ® – Data Transmission Systems9 cCPS ® – Contactless Power Supply9 dSMG – Slotted Microwave Guide9 eWCS – Position Encoding System9 fMotor Powered Cable Reels 100503 • Printed in Germany • 2005-0504 • DS • 1600 • 03/05PAUL VAHLE GMBH & CO. KG • WESTICKER STRASSE 52 • D 59174 KAMEN/GERMANY • TEL. (+49) 23 07/70 40Internet: www.vahle.de • e-mail: postmaster@vahle.de • FAX (+49) 23 07/70 44 44