Overview

This document provides comprehensive technical specifications, selection criteria, installation guidelines, and accessory details for insulated unipolar conductor rails (U20, U30, U40 series) used in industrial electrification systems such as cranes, monorails, and amusement parks.

1. General Specifications

• Manufactured per VDE 0100, UL, SEV standards; compliant with EN 60529 (IP23) for suspended installations.
• Safety ensured by insulating profiles and protective conductor identification; additional measures required for voltages above 25 VAC or 60 VDC when collectors leave rails.
• Standard rail length: 6 meters; rails can be combined for multi-pole systems with minimal spacing.
• Supports allow thermal expansion sliding; locking clamps used at mid-length or expansion joints.
• Special isolators recommended for harsh environments (chemical, galvanic, humid).

2. Product Components and Accessories

• Joint connections secured by screws with plastic covers; expansion joints recommended for lengths >100 m or large temperature variations.
• Connection terminals installed at rail joints; unipolar cables used for feeding.
• End caps seal rail ends; collectors made of impact-resistant plastic and stainless steel with carbon brushes, available in single or double versions.
• Transfer pieces and entry sections facilitate electrified track sections, turntables, and switches.
• Rails can be bent on-site or factory-formed for horizontal and vertical curves.

3. Electrical and Mechanical Characteristics

• Electrical insulation meets DIN and IEC standards; dielectric strength 30-40 kV/mm; high surface resistance.
• Mechanical strength: flexural resistance ~75-95 N/mm²; tensile strength ~50 N/mm².
• Operating temperature: standard -30°C to +55°C; heat-resistant versions up to +80°C or +100°C on request.
• Flame retardant classification B1 (hardly flammable, self-extinguishing).
• Chemical resistance includes gasoline, mineral oil, grease, caustic soda (25-50%), hydrochloric and sulfuric acids up to 50% concentration.

4. Selection Procedure for Conductor Rails

1. Calculate nominal and starting currents of motors and loads.
2. Select conductor rail type based on maximum permissible current (Iadm) from tables.
3. Verify voltage drop under starting current conditions; maintain below 3% nominal voltage.
4. Select appropriate current collectors.

• Use motor data tables or formulas; apply reduction factors for duty cycle (ƒED) and simultaneous crane operation.
• Adjust current capacity for ambient temperatures above 35°C using correction factors.
• Optimize feeding points location and number to reduce voltage drop and balance current distribution.

5. Electrical Parameters and Temperature Corrections

• Resistance and impedance values provided at 20°C; correction factors (ƒ1, ƒ2) adjust calculations for higher temperatures.
• Voltage drop formulas for three-phase and DC systems incorporate resistance/impedance, feeding length, starting current, and temperature corrections.

6. Installation and Safety Recommendations

• Rails must slide in supports to accommodate thermal expansion; expansion joints mandatory for systems >100 m.
• Use insulated bolts or isolators for outdoor installations.
• Ensure proper grounding and short-circuit devices per VDE 0105/9.7 standards.
• Consult manufacturer for installations in aggressive environments (chemical plants, galvanizing baths).
• Detailed plans required for curved sections, switches, or turntables; use provided questionnaires.

7. Product Series and Accessories

U20 Series

• Includes various insulated conductor rails and accessories such as locking clamps, end caps, insulated suspension bolts, and compact supports compatible with KST series sockets.
• Mechanical properties: flexural resistance up to 3000 N; standard fixing screws M6 x 10 or M6 x 12.
• Sockets available in single/double versions with current ratings 15 A to 120 A; mechanical tolerances ±20 to ±40 mm; contact pressure ~9 N per brush.
• Drag arms and replacement parts detailed with weights and reference numbers.

U30 Series

• Unipolar insulated rails with conductor cross-sections 75-200 mm²; max voltage 1000 V; current ratings 90-330 A.
• Standard length 6 m; max support distances 1500 mm (straight/large curves), 750 mm (small curves).
• Optional heating cable for de-icing on specific types.
• Accessories include expansion joints (1.5 m sections), joint unions, connection terminals, locking clips, end caps, transfer and sectionalizing pieces, suspensions, and compact supports.
• Current collectors available in single/double versions rated 100-200 A; allow ±60 mm horizontal and +45/-40 mm vertical displacement; contact pressure ~29-30 N.

U40 Series

• Larger insulated rails with conductor cross-sections 200-500 mm²; weights 2.55-5.24 kg/m; standard and heat-resistant versions.
• Expansion joints (2 m sections) with max expandable lengths specified; stainless steel joint unions available.
• Connection terminals support multiple cables up to 150 mm²; locking clips and end caps for secure assembly.
• Transfer pieces allow subdivision with ±6 mm vertical/lateral offsets and max 12 mm air gap; isolated sectioning devices prevent electrical bridging during maintenance.
• Suspension components include insulated bolts, high-voltage insulators, and rail supports; stainless steel versions offered.
• Current collectors (UST and UDST series) rated 200-400 A with lateral installation options; contact pressure 50-70 N; support arms >600 mm require additional support.

8. Installation and Assembly Guidelines

• Use washers per DIN 9021 for slotted holes; offset mounting of expansion joints, union joints, and connection terminals to accommodate thermal expansion.
• Maintain maximum support distances and minimum bending radii (e.g., 25 mm for horizontal curves).
• Apply contact grease on joints and terminals for optimal conductivity and protection.
• Ensure proper grounding and short-circuit devices compliant with VDE standards.
• Use isolated sectioning devices for safe maintenance operations.
• Follow displacement and pressure tolerances for socket brushes to maintain reliable electrical contact.

9. Selection and Calculation Examples

• Voltage drop should not exceed 3% of nominal voltage; if exceeded, increase conductor size or add feeding points.
• Starting current (IAA) calculated by summing largest motor starting currents multiplied by motor-type factors and applying reduction factors.
• Nominal current (IN) derived from motor power and voltage; permanent current (ID) adjusted by duty cycle factor (ƒED).
• Socket outlet current ratings reduced for ambient temperatures above 35°C using correction factor (ƒT).
• Example provided for two overhead cranes sharing a 180 m conductor rail at 400 V with 3 feeding points, demonstrating current calculations and voltage drop verification.

10. Ordering and System Design

• Detailed questionnaires collect system data including number of lines, current collectors, crane types, voltages, line lengths, environmental conditions, feeding and sectioning points, and maximum allowable voltage drop.
• Example orders illustrate quantities, types, weights, and reference numbers for complete systems including rails, joints, clamps, end caps, supports, sockets, and drag arms.
• Spare parts lists with reference numbers ensure compatibility and ease of maintenance.

Critical Information Summary

• Maintain voltage drop below 3% nominal voltage; use temperature correction factors for ambient temperatures above 20°C.
• Select conductor rails and current collectors based on calculated nominal and starting currents, applying reduction and correction factors.
• Use expansion joints for systems longer than 100 m to accommodate thermal expansion.
• Ensure mechanical installation respects maximum support distances and bending radii.
• Use insulated bolts, isolators, and stainless steel components in harsh or corrosive environments.
• Apply contact grease on joints and terminals for optimal electrical performance.
• Follow VDE standards for grounding and short-circuit devices; use isolated sectioning devices for maintenance safety.
• Provide detailed system data for accurate design and ordering; verify compatibility of supports and sockets.