Cat 2c E Insulated Conductor Systems U15 U25 U35

INSULATED
CONDUCTOR SYSTEMS
U 15 – U 25 – U 35
19 12
INSULATED CONDUCTORS U 15 – U 25 – U 35
Index U 15 U 25 U 35
Page Page Page
Basic description 4 4 4
Selection of conductors 5 5 5
Insulated conductors 5 23 34
Joint splices 6 23 34
Expansion sections 6 24 35
Feed terminals 6 24 35
Locating clamps 7 24 36
Insulated hangers 7 25 36
Rail holders 7 25 36
Insulators 7 25 36
Compact hangers, bracket profiles 7 26 –
Attachment hardware 8 26 –
Transfer guides 8, 9 26 37
Sectionalizing 9 25 34
End caps 9 25 34
Transfer funnels 10, 11 28 –
Collectors 11 – 14 27 38, 39
Connecting cables 15 – –
Collector brackets, Cable attachment clamp 16 28 38
Contact grease 15 28 36
Components for collectors, Spare parts 16 – 18 29 – 31 40, 41
Brush wear indicator 19 – –
Brackets, Snap-on brackets, Mounting brackets 20 33 –
Examples for ordering, Arrangement 21 32 42
Installation tools 22 – –
Earthing spider system – 43 43
Questionnaire 44, 45 44, 45 44, 45
Application photos 2, 5
Collector rings with insulated conductors see leaflet No. 102.
2
INSULATED CONDUCTORS U 15 – U 25 – U 35 19 12
GENERAL
SELECTION OF CONDUCTORS
ENGINEERING DATA
Pages 4 – 5
U 15
For light cranes and hoists/elevators, self-propelled monorail
carriers, automated storage and retrieval systems, assembly
and test tracks, motor powered gates and doors, for all kinds
of data and signal transmission, etc
Ampacity up to 100 A
Pages 5 – 22
U 25
For bridge- and portal crane electrification, stacker cranes,
heavy monorail systems, amusement & rapid transit rides,
construction- and maintenance lifts etc. – Ampacity up to
450 A
Pages 23 – 33
U 35
Applications as U 25;
however for heavy duty – Ampacity up to 1250 A
Pages 34 – 42
Questionnaire
Pages 44, 45
3
19 12
INSULATED CONDUCTORS U 15 – U 25 – U 35
General Joint splices
VAHLE insulated conductors U 15, U 25 and U 35 are designed Bolted joint splices are designed to rigidly join conductor bars
in accordance with today’s international safety requirements. and provide mechanical and electrical continuity. They include
They fully meet VDE 0100 and are finger safe to VDE 0470, part insulated protection covers.
1, protection code IP 23.
Expansion joint sections must be provided for high temperature
The adjacent picture demonstrates that the fluctuation and for system runs exceeding 100 m for U 15
VDE test finger cannot reach live conductors (150 m for U 25 / U 35) – see installation procedure.
– finger safety is guaranteed.
The shroud which envelopes the various Feed terminals
conductors is an excellent insulator. Therefo-
Feed terminal sets are preferably installed at conductor joints.
re our unipole insulated conductors guaran-
Adequate single core feed cables must be provided for
tee utmost safety in operation.
connection of the incoming power.
Any number of conductors can be installed
side by side at minimum space requirement.
End caps
Standard rail sections U 15, U 25 are 6 m
The open ends of unipole conductors are closed by end caps.
and U 35, 6.25 m long.
Shorter sections are available.
The ground conductor is identified by international colour Transfer funnels and Transfer guides
coding. Single pole and multi pole transfer guides are available for
spurlines, turntables and switches or other tranfer applications.
For obvious safety reasons phase and ground collectors are
not interchangeable.
Isolating sections
Approved and listed by Conductor isolating sections are available for sectionalizing
U 15: SEV and CSA, control circuits, maintenance bays etc.
U 25: UL
Consult factory label service.
Curves
Hangers Factory fabricated or field prepared radius bends can be used
Snap-on or bolt-on brackets can be used to install conductors for horizontal or vertical curves.
to the runway track. Spacing between rail supports:
U 15: see page 11, Collectors
U 25: see page 23,
U 35: see page 40. The current collectors are made of re-inforced polyamide/poly-
carbonate and stainless steel parts. These spring loaded units
provide positive contact with the conductor bars and have one
Insulators
or two pickup-shoes.
Insulators are recommended for difficult environmental conditi- The collector of the AE-Conductor which are working with only
ons (extreme humidity, chemicals etc.) > 10 m/min. travel speed or stand most of the time are only
permitted to work with 150 % of the continuous current.
Engineering data of shroud
standard high temp.
Resistance to chemicals:
shroud shroud
color green color gray Gasoline stable
Electrical properties: Mineral oil stable
Di-electric strength DIN 53481 30-40 45
kV/mm kV/mm Grease stable
Specific resistance DIN 53482 5 x 10 15 5 x 10 17 Caustic soda 25 % stable
Ohm/cm Ohm/cm Caustic soda 50 % stable
Surface resistance DIN 53482 1013 1015
Ohm Ohm Hydrochloric acid, concentrated stable
Leakage resistance Sulphuric acid up to 50 % stable
CTI 600-1.1 CTI 600-1.1
IEC 1112 / VDE 0303
Mechanical properties
75 N/mm2 95 N/mm2 Please consult factory for galvanizing plants, pickling
Flexible strength lines, other aggressive or deep freeze ambients, as well
± 10% ± 10%
as low voltage and data transmission applications, indi-
Tensile strength 50 N/mm2 50 N/mm2 cating special environmental conditions.
± 10% ± 10%
To speed up quotations and order processing, we would
Ambient –30° C to –30° C to appreciate receiving your drawings or sketches for
temperature +55° C +85° C systems with curves, dead sections, turntables, swit-
Flame test proof per class B1 ches, etc.
DIN 4102 no flaming particles, Please use our questionnaire, pages 44 and 45.
part 1 self-extinguishing
4
INSULATED CONDUCTORS U 15 19 12
Conductor code: Conductor spacing: Support spacing:

U = unipole insulated conductor on compact hangers 18 mm for straight runs & lateral curves,
15 = shroud size on standard hangers also horizontal RH = 5 m(2)
25 = conductor cross sectional with insulators min. 50 mm with single collector 1 m
area (mm2) with double collector (KDST)
C = copper conductor Curves: 800 mm
E = stainless steel conductor factory prepared min. radius 400 mm
or in the field with curve tool BVU for horizontal curves RH = 5 m(2)
Length: 10/15 with single collector 500 mm
6 m is standard length, with double collector (KDST)
shorter lengths are available Heating system:
available, please consult factory. 400 mm
RH = Radius
Chemical and electrical properties
Horizontal
curve see page 4
U 15/25 C U 15/25 E
Weight kg/m 0.295 0.285
Standard shroud, color green
Cat-No. phase(1) 162 13 • 162 15 •
Cat-No. ground(1) 162 19 • 162 21 •
High temperature shroud, color gray
Cat-No. phase(1) 162 16 • 162 18 •
Cat-No. ground(1) 162 22 • 162 24 •
Engineering Data
Conductor Rail Cross sectional area Leakage distance max. Impedance Ohm/1000 m
continuous based on 50 Hz & conductor spacing
Type mm2 Resistance
of shroud voltage amp. capacity
Ohm/1000 m
Cu stainless steel mm V A 18 mm 25 mm 50 mm
U 15/25 C 25 30 660 100 0.692 0.698 0.701 0.709
U 15/25 E 25 30 660 10 29.077 29.077 29.077 29.077
Selection of conductors
in accordance to ampere load and environmental conditions
U 15/25 C copper conductor for power and control system applications
U 15/25 E stainless steel conductor for control and data-transmission in corrosive atmospheres
New material handling techniques (automated overhead monorails) require reliable electrification and use U 15 conductors.
(1) Add last number (1, 2, 3, 4, 5 or 6 m length suffix) in accordance to bars required.
(2) Recommendation
5
19 12
ACCESSORIES FOR U 15
Bolted joint splice
applicable as feed terminal, too.
28
10
80
21
21 17
Corresponding to UE 15 K 4
Type Weight kg Cat.-No.
UV 15 K 4 (1) 0.040 160 102
Expansion sections
factory assembled on 1 m long conductor section incl. one joint splice.
The 1 m expansion assembly is part of the system length.
(29)
36
(10)
17
96 30
16 dim. on parenthesis
refer to UDVN max. expansion = 30 mm
Standard shroud, color green High temperature shroud, color gray
Weight kg Cat.-No. Weight kg Cat.-No.

Type Type
phase ground phase ground
UDV (3) 15/25 C K 4 (1) 0.430 160 276 160 277 UDV(3) 15/25 C K 4 (1) 0.430 160 280 160 281
UDV (3) 15/25 E K 4 (1) 0.420 160 288 160 289 UDV(3) 15/25 E K 4 (1) 0.420 160 292 160 293
UDVN (2) 15/25 C K 4 (1) 0.430 160 294 160 295 UDVN(2) 15/25 C K 4 (1) 0.430 160 298 160 299
UDVN (2) 15/25 E K 4 (1) 0.420 160 306 160 307 UDVN(2) 15/25 E K 4 (1) 0.420 160 308 160 309
Feed terminals
16
10
17
M5
29
34
80 100
42
42
Corresponding to UV 15 K Cross-section connection

Feed cables: 2 of max. 6 mm2 (AWG 9) Feed cable: 1 of max 25 mm2 (to ø 8,2 mm) (AWG 3)
Type Weight kg Cat.-No. Type Weight kg Cat.-No.
UE 15 K 4(1) 0.040 160 107 UEG 15 K (1) 0.060 160 216

Cable lug and cable by others Cable by others. Staggered installation.
Special cable lug comes with feed terminal.
(1) with stainless steel hardware

6 (2) max. ampacity 70 A
(3) max. ampacity 100 A
ACCESSORIES FOR U 15 19 12
Insulated hangers(2) Locating clamp

M6
Photo shows hanger with two
max. 8
locating clamps for an
anchor point
25
10
17
34
16
16
16
18
UA 15 0.020 160 113 USK 15 K 4 (1) 0.030 160 106

UA 15 K 4 (1) 0.020 160 115
Insulators(2) Rail holders

to be used with insulator only
cantilever = 3000 N
creapage distance = 60 mm M 6 x 11 deep
GH 40-M 6 0.100 160 117 UAK 15 0.015 160 121

GH 40-M 6 K 4 (1) 0.100 160 119 UAK 15 K 4 (1) 0.015 160 123
Compact hangers 2- to 7pole

Any number of conductors can be assembled by cutting / combining the compact hangers
For max. 660 volts, conductor spacing 18 mm.
Hanger KA 15 is for direct bolting to the support structure.
A
18 KA 15/6 (KH 15/6) Hanger KH 15 to go with bracket profile 28/12.
18 B
M 5 X 7 deep
17
Type Dim. A Dim. B Cat.-No. Weight kg

,5
KH 15/2 36 – 161 559 0.012

17
KH 15/3 54 – 161 453 0.018

KH 15/4 72 – 161 452 0.023
137 KH 15/5 90 – 161 558 0.029
43,5 KH 15/6 108 – 160 139 0.035
43,5 50
M 5 x 7 deep
KA 15/2(2) 36 – 161 566 0.015
KA 15/3(2) 54 – 161 567 0.023
10
KA 15/4(2) 72 36 162 010 0.028

30
KA 15/5(2) 90 36 161 498 0.033

KA 15/7 KA 15/6(2) 108 72 160 138 0.040
KA 15/7(2) – – 160 140 0.050
28
Bracket profiles 28/12
incl. locking hardware
2
12
Length Weight
Type for poles Cat.-No.
mm kg
HU 15/200 200 6+ 7 0.130 161 434
HU 15/330 330 12 +14 0.300 161 435
M6
12 Longer brackets furnished on special order.

(2) Attachment
7
hardware (see page 8) to be ordered separately; two flat washers to be used in slotted holes.
19 12
Attachment hardware for compact hangers, insulated hangers and insulators
max. 12 mm
Bracket
D
d
d D S Cat.-
Type Weight kg Cat.-No. Type Thread Weight kg
mm mm mm No.
Hardware set BE 5 K 4(1) 0.001 161 441 Washer 5.3 K 4(1) M5 5.30 15 1.60 0.002 161 408
Transfer guides for monorail systems

with and without feed terminals
(also serving for anchor points in conjunction with BFU 15 B)
d.
con
w/o w/o feed US 15 TS
20
65
Conductor
24 surface /
track
c/w feed USE 15 T

(oblique) (straight) (cable terminal 6.3 mm x 0.8 mm)
US 15 TS
(USE 15 TS)
max. gap between opposite transfer guides:
L. H. switch
6 mm for straight transfers
10 mm for oblique transfers
max. vertical and horizontal offset: 2 mm
Type feed terminal Weight kg Cat.-No.
US 15 T w/o 0.016 160 840

US 15 TS w/o 0.016 160 841 US 15 TS
(USE 15 TS)
USE 15 T c/w 0.018 160 842 R. H. switch
USE 15 TS c/w 0.018 160 843
Anchor bars for monorail transfer guide

for bolting to the track, consisting of 1 aluminium
bar, 2 hex. screws M 5 x 14 with washers, 2 locking pins 2 x 20 M 5 x 14
60
25
16,5
80
A
Dim. A
Type poles Weight kg Cat.-No.
mm
BFU 15 B-6 1 to 6 116 0.095 160 851 (Distance between conductor sliding surface and track = 24 mm;
BFU 15 B-8 1 to 8 152 0.120 160 852 corresponds to compact hanger KA 15/6)

8
Transfer guides
(no anchor point function) max. gap between opposite transfer guides 6 mm
max. vertical and horizontal offset ± 2 mm
Type feed terminal Weight kg Cat.-No.

16
10
US 15 w/o 0.010 160 125
USE 15 c/w 0.050 160 126
separately available:
0.040 160 859
16
(feed plug 6,3 x 0,8 mm) SE 15 feed plug

26,5
15
Isolating sections
Length of
Type(1) Weight kg Cat.-No.
A isolating piece A
IT/U 15- 5 M 5 0.003 160 111

IT/U 15-15 M 15 0.004 160 240
IT/U 15-30 M 30 0.004 160 112
IT/U 15-90 M 90 0.007 160 241
IT/U 15- 5 L 5 0.003 160 226
IT/U 15-15 L 15 0.004 160 243
Typ M: factory assembled per system layout
IT/U 15-30 L 30 0.004 160 227
Typ L: loose
Use two hangers, max. 2 x 200 mm apart for stability. IT/U 15-90 L 90 0.007 160 242
Conductors and hangers are to be ordered separately.
Isolating assemblies
Type symbol comprising Weight kg Cat.-No.

133
LT / LT - U 15 2 x LT/ U 15 0.032 160 844
→
2 x LT/ U 15
LT / LTE - U 15 0.034 160 845
9 1 x flat plug
.
→
→
c ond 2 x LT/ U 15
w/o LTE / LTE - U 15 0.036 160 846
2 x flat plug
43
Isolating assembly LT/LTE-U15
For ordering feed cable FLA see page 15.

Conductors and hangers are to be ordered separately.
Use two extra hangers, max. 2 x 200 mm apart for stability.
The two transfer button elements are pressed
together to form a rigid, well aligned unit.
End caps c/w locking pin 3 x 12
Type (1) Weight kg Cat.-No.

27
UK 15 - M (factory assembled) 0.005 161 656
UK 15 - L (loose) 0.005 160 109
(1) Type M = factory assembled

Type L = loose
9
19 12
TRANSFER FUNNELS FOR U 15
Transfer funnels for KSTU 30/55
for max. speed v = 120 m/min.(1)
ca. 680
24 for KA15/6 = 84
17 for KA15/7 = 91
20
9,4°
82
20 (w/o cond.)
35
max. 800
665 w/o cond.
18 18 18 18 18
C
D
B
slotted hole 7 x 15
40
375 65
Type A mm B mm C mm D mm Weight kg Cat.-No.
EFT U 15-2 - KSTU 44 130 157 180 2.960 161 747

EFT U 15-3 - KSTU 62 148 175 198 3.140 161 748
EFT U 15-4 - KSTU 80 166 193 216 3.320 161 749
EFT U 15-5 - KSTU 98 184 211 234 3.500 161 750
EFT U 15-6 - KSTU 116 202 229 252 3.680 161 751
EFT U 15-7 - KSTU 134 220 247 270 3.860 161 752
EFT U 15-8 - KSTU 162 238 265 288 4.040 161 753
Tranfer funnels for KSTLU / KDSTLU

12,5
615
24 for KA15/6 = 84
17 for KA15/7 = 91
120
10,4°
max. 800
570 w/o cond.

18 18 18 18 18
C
D
B
65
slotted hole 7 x 15
40
250 100
Type A mm B mm C mm D mm Weight kg Cat.-No.
EFT U 15-2 - KDSTLU 36 122 148 172 2.860 161 668

EFT U 15-3 - KDSTLU 54 140 166 190 3.060 161 669
EFT U 15-4 - KDSTLU 72 158 184 208 3.260 161 670
EFT U 15-5 - KDSTLU 90 176 202 226 3.460 161 671
EFT U 15-6 - KDSTLU 108 194 220 244 3.650 161 672
EFT U 15-7 - KDSTLU 126 212 238 262 3.850 161 673
EFT U 15-8 - KDSTLU 144 230 256 280 4.050 161 674
(1) Higher speeds on request.

10
TRANSFER FUNNELS AND CURRENT COLLECTORS FOR U 15 19 12
10
335
Transfer funnels for KSFU 25
59
85
15°
24
max. 800
320 w/o cond.
64
Type A mm B mm C mm D mm Weight kg Cat.-No. 154
EFT U 15-2 - KSFU 44 102 90 144 1.280 161 629

EFT U 15-3 - KSFU 62 120 108 162 1.400 161 630
18 1818 1818
EFT U 15-4 - KSFU 80 138 126 180 1.520 161 631
C
A
B
D
EFT U 15-5 - KSFU 98 156 144 198 1.640 161 632
EFT U 15-6 - KSFU 116 174 162 216 1.760 161 633
EFT U 15-7 - KSFU 134 192 180 234 1.880 161 634
EFT U 15-8 - KSFU 152 210 198 252 2.000 161 635
35
Collectors
c/w 2 m cable; contact pressure ca. 5 N
13,5 (17,8 KSTU) A
85 4,4
60
85 (95)
Picture 1
12
140 (190)
A < 300 mm conductor support spacing 0.8 m
A > 300 mm conductor support spacing 1.0 m
Connecting cable Lift & Weight Cat.-No.
Ampacity swivel kg
Type(2) A A/ D max/ phase- ground
mm2 mm A mm black yellow
KST 30 30 2.50 5 ± 20 0.240 152 085 152 086
KST 55 55 6.00 11 ± 20 0.368 154 438 154 439
KSTL 30 30 2.50 5 ± 30 0.240 152 089 152 091
KSTL 55 55 6.00 11 ± 30 0.368 154 443 154 444
KSTU 30 (3) 30 2.50 5 ± 20 0.240 152 087 152 088
KSTU 55 (3) 55 6.00 11 ± 20 0.368 154 441 154 442
Type Conductor support spacing for straight runs for curves

mm mm
All type single collectors 1000 500
U 15 with double collector 800 400
KDST, KDSTL, KDSTLU
Current collector Current collector

11
48 (not for transfer applications) 11
4.5
35 4.2
66
50
ZF 1
60
plug
terminal
70
6.3 x 0.8 plug ZF 1

for FLA 2.5 or terminal
WFLA 2.5 6.3 x 0.8
for FLA 2.5 or
M 5, phase WFLA 2.5
M 6, ground
ca. 70 M 5, phase
ca. 70 M 6, ground
Lift ±10 mm,swivel ±15 mm, contact pressure: ca. 3 N Lift ±10 mm, swivel ±10 mm, contact pressure: ca. 3.5 N
Connecting cable to be ordered separately. Connecting cable to be ordered separately.
Type(1) Ampacity Cat.-No. Type(1) Ampacity Cat.-No.
Weight kg Weight kg
A phase - black ground - yellow A phase - black ground - yellow
KST 20 20 0.050 155 071 155 072 KST 25 25 0.060 155 013 155 014
(1) Higher speeds on request. 11

(2) Suffix types e. g. KST 30 KST 30 PH, Cat.-No. 152 085; KST 30 KST 30 PE, Cat.-No. 152 086
(3) Collectors for transfer funnels EFT U 15 … KSTU
19 12
COLLECTORS FOR U 15
ca. 14 11
Double current collector 102
85 3.8
max. ampacity: 1 flat plug 25 A, 2 flat plugs 2 x 20 A 35
plug
terminal
6.3 x 0.8
Lift ±10 mm, swivel ±10 mm, for WFLA 2.5
80
contact pressure: ca. 3.5 N per brush plug ZF 2
terminal
Connecting cable to be ordered seperately. 6.3 x 0.8
for FLA 2.5
Cat.-No. or WFLA 2.5
Type (1) Weight kg
phase - black ground - yellow
M 5, phase
KST 2/40 0.080 168 137 168 138 ca. 70 M 6, ground
max. 138
Compact current collectors(2) 8
7
6
max. ampacity: 1 flat plug 25 A 18
5
4
3
2
1 RF 3
For conductor spacing of 18 mm;
8
Lift & swivel ± 15 mm
.1
ax
Contact pressure:
m
ca. 3.5 N per brush
Ground at No. 4, 3-pole at No. 3 DF 2
other position on request. c
88
For safety reasons during a
plug b
maintenance ground collector is terminal 15 15
6.3 x 0.8 42
always first and last contact. for FLA 2.5
7 71
or WFLA 2.5
(Connecting cable WFLA 2.5 to be ordered separately)
Cat.-No.
Type (1) a b c Weight
Base plate
Poles for power incl. 1 x ground for control
mm mm mm kg
HS ST
KSF 25-2 2 18 43 – 0.168 2pole – 155 038

KSF 25-3 3 54 79 – 0.274 4pole (No. 4 = blank) 155 028 155 039
KSF 25-4 4 54 79 – 0.324 4pole 155 029 155 040
KSF 25-5 5 80 115 53 0.425 6pole (No. 6 = blank) 155 030 155 041
KSF 25-6 6 80 115 53 0.475 6pole 155 031 155 042
KSF 25-7 7 120 151 80 0.581 8pole (No. 8 = blank) 155 032 155 043
KSF 25-8 8 120 151 80 0.631 8pole 155 033 155 044
Separately available: phase ground
Collector KSF 25 0.050 155 023 155 024
max. 127
Compact current collectors 8
7
6
5
max. ampacity: 1 flat plug 32 A - FLA 2,5 4
3
40 A - FLA 4,0 14
2
1
55 A - FLA 6,0
RF 3
For conductor spacing of 18 mm;
Lift & swivel ± 15 mm
Contact pressure: . 18
max
ca. 3.5 N per brush
DF 2
Ground at No. 4, 3-pole at No. 3
53
plug
*
a
88
other position on request.

**
b
terminal
For safety reasons during 6.3 x 0.8 15
15
for FLA
maintenance ground collector is 7 42
71
always first and last contact.
Cat-No.
(1) Poles a b c Weight
Type Base plate for power incl. 1 x ground for control
mm mm mm kg
HS ST
KESR 32-55-1-18 1 54 79 - 0.194 4pole (No. 2 - 4 = blank) 155 201 –
KESR 32-55-2-18 2 54 79 - 0.264 4pole (No. 3 + 4 = blank) 155 202 155 209
KESR 32-55-3-18 3 54 79 - 0.334 4pole (No. 4 = blank) 155 203 155 210
KESR 32-55-4-18 4 54 79 - 0.404 4pole 155 204 155 211
KESR 32-55-5-18 5 80 115 53 0.525 6pole ( No. 6 = blank) 155 205 155 212
KESR 32-55-6-18 6 80 115 53 0.595 6pole 155 206 155 213
KESR 32-55-7-18 7 120 151 80 0.721 8pole (No. 8 = blank) 155 207 155 214
KESR 32-55-8-18 8 120 151 80 0.791 8pole 155 208 155 215
Separately available: phase black ground yellow
Collector KESR 32-55, 1pole 0.070 w/o 168 304 168 305
12 (1) Suffix types e.g.: KST 25 KST 25 PH, Cat.-No. 155 013 KSF 25-3 KSF 25-3 HS, Cat.-No. 155 028
(2) Install collectors in dragging position when equipment moves over transfer guides.
COMPACT CURRENT COLLECTORS FOR U 15 19 12
Compact current collectors(1) max. 138

max. ampacity: 1 plug terminal 25 A.
8 7
For conductor spacing of 6 5 4
3 2
18 mm. Lift & swivel ± 15 mm 18 1
Contact pressure: RF 3
ca. 3.5 N per brush
Ground at No. 4, 3-pole at No. 3
8
.1
other position on request.
ax
m
For safety reasons during
maintenance ground collector is
always first and last contact.
88
c DF 2
plug b a
terminal
6.3 x 0.8 15
15
for WFLA 2.5 7 42
71
Poles a b c Weight Cat.-No.

(1) Base plate for power incl. 1 x ground for control
Typ e mm mm mm kg
HS ST
KSFU 25-2 2 18 43 - 0.182 2pole 155 050 155 059
KSFU 25-3 3 54 79 - 0.295 4pole (No. 4 = blank) 155 051 155 060
KSFU 25-4 4 54 79 - 0.352 4pole 155 052 155 061
KSFU 25-5 5 80 115 53 0.460 6pole (No. 6 = blank) 155 053 155 062
KSFU 25-6 6 80 115 53 0.517 6pole 155 054 155 063
KSFU 25-7 7 120 151 80 0.625 8pole (No. 8 = blank) 155 055 155 064
KSFU 25-8 8 120 151 80 0.682 8pole 155 056 155 065
Separately available: phase ground
Collector KSFU 25 0.057 w/o 155 025 155 026
Compact double current collectors (1)

max. ampacity: 1 plug terminal 25 A, 2 plug terminals 2 x 20 A max. 148
8
7 RF 3
6
For conductor spacing of 5
4
18 mm. Lift & swivel ± 15 mm 3 plug
2
18 1 terminal
Contact pressure:
6.3 x 0.8
ca. 3.5 N per brush plug
Ground at No. 4, 3-pole at No. 3 terminal quick connect plug
other position on request. 6.3 x 0.8 and
for WFLA 2.5 flexible cable WFLA
For safety reasons during 2.5 mm2
maintenance ground collector is L = 0.5 m incl.
always first and last contact. GF 1 max. 18
DF 1
53
98
14
a
b
15
42
7
71
Cat.-No.
(1) Poles a b c Weight
Type Base plate for power incl. 1 x ground for control
mm mm mm kg
HS ST
KDS 2/40-1-18 1 54 79 - 0.194 4pole (No. 2 - 4 = blank) 155 077 155 089
KDS 2/40-2-18 2 54 79 - 0.264 4pole (No. 3 + 4 = blank) 155 078 155 090
KDS 2/40-3-18 3 54 79 - 0.334 4pole (No. 4 = blank) 155 079 155 091
KDS 2/40-4-18 4 54 79 - 0.404 4pole 155 080 155 092
KDS 2/40-5-18 5 80 115 53 0.525 6pole ( No. 6 = blank) 155 081 155 093
KDS 2/40-6-18 6 80 115 53 0.595 6pole 155 082 155 094
KDS 2/40-7-18 7 120 151 80 0.721 8pole (No. 8 = blank) 155 083 155 095
KDS 2/40-8-18 8 120 151 80 0.791 8pole 155 084 155 096
Separately available: phase-black ground-yellow
Collector KDS 2/40, 1pole 0.070 w/o 168 073 168 074
(1) Suffix types e.g. KSFU 25-2 KSFU 25 - 2 HS, Cat.-No. 155 050 · KDS 2/40 -1 -18 KDS 2/40 -1 -18 HS, Cat.-No. 155 077
13
19 12
COLLECTORS FOR U 15
Current collectors Double current collectors
17
100 4
100 200
75 100
75
65
65
12
12
c/w 2 m cable · lift & swivel ± 20 mm c/w 2 x 2 m cable · lift & swivel ± 20 mm
contact pressure: 9 N contact pressure: 9 N per brush
Am- Connecting cable Cat.-No. Am- Connecting cable Bestell-Nr.
Typ e(1) pacity Ø max/ Weight phase - ground - Typ e(1) pacity Ø max/ Weight phase - ground -
A mm2 mm kg black yellow A mm2 mm kg black yellow
KST 15 15 2.50 8.00 0.256 150 891 150 892 KDST 30 30 2.50 8.00 0.471 150 897 150 898
KST 40 40 6.00 11.00 0.428 152 840 152 850 KDST 80 80 6.00 11.00 0.821 152 960 152 970
KST 60 60 10.00 12.50 0.588 153 675 153 676 KDST 120 120 10.00 12.50 1.114 153 679 153 680

152 304
17 150
100 100
75 4 75
85
85
12 12
c/w 2 m cable · lift & swivel ± 40 mm c/w 2 x 2 m cable · lift & swivel ± 40 mm
Am- Connecting cable Cat.-No. Am- Connecting cable Cat.-No.
KSTL 15 15 2.50 8.00 0.272 150 893 150 894 KDSTL 30 30 2.50 8.00 0.492 150 899 150 901
KSTL 40 40 6.00 11.00 0.453 152 860 152 870 KDSTL 80 80 6.00 11.00 0.822 152 980 152 990
KSTL 60 60 10.00 12.50 0.591 153 677 153 678 KDSTL 120 120 10.00 12.50 1.188 153 681 153 682
Current collectors for transfer funnel EFT(2) Double current collectors for transfer funnel EFT(2)
304
152
spring released height
152 100
100 17 75
75 4
env. 135
ca. 135
85
85
env.50
12
env. 50
12
c/w 2 m cable c/w 2 x 2 m cable

lift ± 20 mm, swivel ± 40 mm contact pressure: 9 N lift ± 20 mm, swivel ± 40 mm contact pressure: 9 N per brush
KSTLU 15 15 2.50 8.00 0.313 150 895 150 896 KDSTLU 30 30 2.50 8.00 0.541 150 902 150 903
KSTLU 40 40 6.00 11.00 0.499 153 791 153 792 KDSTLU 80 80 6.00 11.00 0.895 153 786 153 787
KSTLU 60 60 10.00 12.50 0.652 153 793 153 794 KDSTLU 120 120 10.00 12.50 1.231 153 795 153 796
14 (1) Suffix types e.g. KST 15 KST 15 PH Cat.-No. 150 891.

(2) Released collector maintains center phase position for easy retracking.
COLLECTOR COMPONENTS FOR U 15 19 12
Connecting cable, high-flexible for collectors

(see current collectors on pages 12 and 13.)
FH
Cat.-No.
Type Cross section Outer Ø Weight
phase - ground -
mm2 mm kg
black yellow
FLA 4 0.080 165 049 165 050
FLA 2.5 2.50
FLA 4 4.00 6 0.100 165 051 165 052
WFH 4 0.080 168 107 168 108
WFLA 2.5 2.50
Flat plugs, only

WFLA Type for cross section mm2 Cat.-No.
FH 2.5 2.50 165 120

FH 4 4.00 165 121
1 m long with flat plug 6.3 x 0.8. WFH 2.5 2.50 168 109
Longer cables available.
Collector bracket Cable attachment clamp

for KST 15 thru KDSTLU 120 collector series for KSTLU 15 thru KDSTLU 120 collector series
Prepared for
ground collector
12
18
600
46
Longer brackets furnished on special order.

Additional support should then be provided to avoid bending of
twisting of the collector bracket.
Type Length mm Weight kg Cat.-No. Type Weight kg Cat.-No.
UM 12 600 0.710 153 506 KBK (1) 0.030 153 519
Collector bracket
for KST 15 thru KDSTLU 120 collectors, for KST 30 thru KSTLU 55 collectors, for control collectors only
see page 14 see page 11
30
40 mm wide
30 x 11
slotted hole
170
90
18
12
30
15
65
Type Weight kg Cat.-No. Type Weight kg Cat-No. Type Weight kg Cat.-No.
UMAS 12 HS -A 0.600 152 233 UMAS 12 HS -B 0.600 152 232 UMAS 12 ST 0.600 152 234
Contact Grease
for joints and feeds
20 g for approx. 40 joints Cat.-No. 120 016

15
19 12
COLLECTOR COMPONENTS FOR U 15
Copper-graphite brushes 48
75 75 35
60 60
10
10
10
19
RH
RH
RH
ground-identification
KMK 30-55 phase KMK 30-55 ground KMK 20
102
66 66 85
50 35
50
10
10
10
23
23
23
RH
RH
RH
KMK 25 KMKU 25/18 (2) KMK 2/40
102
100 100
85
GF 1 35 GF 1 75 75
10
10
10
23
RH
RH
RH
DSW 2/40 DS 2/40 KMK 60 KMK 60 U
Dim. RH = allowed rest of hight
RH Weight
Type for collectors width of carbon brushes mm Cat.-No.
mm kg
KMK 30-55 PH KST 30 to KSTL 55 4.40 1.50 0.031 154 440

KMK 30-55 PE KST 30 to KSTL 55 4.40 1.50 0.034 154 453
KMK 20 KST 20 4.50 5.50 0.020 155 068
KMK 25 KST 25, KSF 25 4.20 1.50 0.030 155 000
KMKU 25/18 KSFU 25 4.20 1.50 0.035 155 002
KMK 2/40 KST 2/40 3.80 1.00 0.050 168 135
DSW 2/40(1) KDS 2/40 3.80 1.00 0.050 168 151
DS 2/40 KDS 2/40 3.80 1.00 0.050 168 065
KMK 60 KST 15 to KDSTL 120 4.00 3.00 0.110 153 512
KMK 60 U KSTLU 15 to KDSTLU 120 4.00 3.00 0.120 153 513
S S
Springs
D
D
L L
Pressure spring DF
Guiding spring GF Tension spring ZF/RF
S D L
Type for collectors Cat.-No.
mm mm mm
ZF 1 KST 20, KST 25 0.63 5.40 22.00 153 514
ZF 2 KST 2/40 0.85 6.45 24.00 153 515
ZF 3 KST 15 to KDST 120 1.10 10.80 28.50 153 516
ZF 4 KSTL 15 to KDSTL 120 & KSTLU 15 to KDSTLU 120 1.30 11.00 29.00 153 517
DF 1 KSFR 2/40 1.00 7.00 38.00 153 847
DF 2 KSF 25 0.90 7.70 43.00 153 848
DF 3 KDS 2/40 0.55 9.55 24.00 152 011
RF 3 KSF 25, KSFR 2/40 0.40 4.40 31.00 153 849
GF 1 KSFR 2/40 0.35 2.00 22.00 153 850
(1) Also spare part for collector KSFR 2/40 (old type)
16 (2) 18 mm wide
For KST 15 thru KDSTLU 120
Part-No. Description Weight kg Cat.-No.
1 Collector base for KST 15 thru KST 60 phase PH 0,080 153 736
2 Collector base for KST 15 thru KST 60 ground PE 153 737
3 Collector base for KDST 30 thru KDST 120 (double arm) phase PH 0,100 153 738
4 Collector base for KDST 30 thru KDST 120 (double arm) ground PE 153 739
5 Collector base for KSTL 15 thru KSTL 60 phase PH 0,090 153 740
6 Collector base for KSTL 15 thru KSTL 60 ground PE 153 741
7 Collector base for KDSTL 30 thru KDSTL 120 (double arm) phase PH 0,130 153 742
8 Collector base for KDSTL 30 thru KDSTL 120 (double arm) ground PE 153 743
9 Collector base for KSTLU 15 thru KSTLU 60 phase PH 0,090 153 804
10 Collector base for KSTLU 15 thru KSTLU 60 ground PE 153 805
11 Collector base for KDSTLU 30 thru KDSTLU 120 (double arm) phase PH 0,130 153 806
12 Collector base for KDSTLU 30 thru KDSTLU 120 (double arm) ground PE 153 807
13 Connecting cable AEA 2,5 PH, 2 m long Phase PH 0,072 151 374
Connecting cable AEA 2,5 PE, 2 m long ground PE 151 375
13 Connecting cable AEA 6 PH, 2 m long Phase PH 0,260 153 744
Connecting cable AEA 6 PE, 2 m long ground PE 153 745
13 Connecting cable AEA 10 PH, 2 m long Phase PH 0,400 153 746
Connecting cable AEA 10 PE, 2 m long ground PE 153 747
14 Gummifeder(1) für KSTLU 15, KSTLU 40, KSTLU 60, KDSTLU 30 0,008 153 748
KDSTLU 80, KDSTLU 120
a
c
e
d
b
f
g
h
i
k
m
j l
n
(1) Rubber spring will be included when ordering KMK 60 U brush.
17
19 12
For KST 30-55 thru KSTLU 30-55
Weight
Part.-No. Description Cat.-No.
kg
1 Brush phase PH 0.031 154 440

2 Brush ground PE 0.031 154 453
Collector base & arm KST, complete phase PH 152 275
3 0.083
Collector base & arm KSTL, complete phase PH 152 279
Collector base & arm KST, complete ground PE 152 276
4 0.083
Collector base & arm KSTL, complete ground PE 152 281
5 Terminal cap (black) phase PH 0.002 152 291
6 Terminal cap (green) ground PE 0.002 152 292
7 Spacer for KSTU 30-55 only 0.003 152 293
8 Connecting cable RKA 2.5 PH, 2 m long phase PH 154 447
0.130
Connecting cable RKA 2.5 PE, 2 m long ground PE 154 448
8 Connecting cable RKA 6 PH, 2 m long phase PH 154 449
0.250
Connecting cable RKA 6 PE, 2 m long ground PE 154 450
9 Terminal bolt 0.002 152 658
➆ ➁
➄ ➂
➈
➃
➅
18
BRUSH WEAR INDICATOR FOR U 15 19 12
Brush wear indicator KVT 15 N The brush wear indicator automatically checks the wear of
carbon brushes. The indicator is infinitely variable to the wearing
height of carbon brushes. A worn down carbon brush actuates
an impulse. It is recommended to place the indicator near a
maintenance area in order to open automatically a switch leading
the monorail hoist to the repair zone.
Size of web cut of monorail track: 120 x 50 mm (L x H)
Pay attention to the installation instructions. PE always at No 4.

Other positioning on request.
Brush wear indicator for U 15 with micro-switch

Dim. a Weight
Type Poles Cat.-No.
mm kg
KVT 15 N-4 4 76 0.860 161 720
KVT 15 N-5 5 94 1.020 161 721
KVT 15 N-6 6 112 1.165 161 722
KVT 15 N-7 7 130 1.310 161 723
Brush wear indicators for uneven number of conductors keep

KVT 15 N – 7 for a 7poles installation the lowest pole free.
19
19 12
BRACKETS · SNAP-ON BRACKETS FOR U 15
Snap-on brackets facilitate installation of Powerails on flat flange beams PE, PB, PBI and PBv.
They are adjustable to suit beam flange dimensions (tg) of up to 43 mm.
Compact hanger KA 15/6
Drawings show snap-on brackets with compact hangers

and hardware. Hangers and hardware must be ordered
separately see page 7 and 8.
Type AKL
vertical configuration
(side entry) Flange Dim. tg/mm 8 – 43
Type AKL with U 15 Cat.-No. 151 925
Weight kg 0.184
Hangers for insulated conductors to be ordered separately.
Compact hanger KA 15/7
Type Length L Cat.-No.

Support bracket HKO… mm
HKO 400 400 161 605

L HKO 500 500 161 606
50 track S1 B HKO 600 600 161 607
A 30
HKO 700 700 161 608
30
HKO 800 800 161 609

HKO 900 900 161 610
14.5
HKU 400 400 161 799

3, 4, 5 x 18 39 HKU 500 500 161 800
1 2
HKU 600 600 161 801
Compact hanger
KH 15/2 to 6 pol. HKU 700 700 161 802
HKU 800 800 161 803
HKU 900 900 161 804
18
3, 4 C
ø 5.5
Type Dim. A Dim. B Dim. C
mm mm mm
30
KH 15/2 36 96 –
24
50 Compact hanger
KH 15/3 74 114 –
KA 15/2 to 6 pol. KH 15/4 72 132 36
x 18
A
KH 15/5 90 150 36
Support bracket HKU…
KH 15/6 108 168 72
20
EXAMPLES FOR ORDERING U 15 19 12
Compact Configuration, 124 m, 5-pole + ground electrification system for 100 Amps.
Qty. Description Type Cat.-No.
100 VAHLE unipole insulated conductors, 6 m long phase U 15/25 C-6 162 136
20 VAHLE unipole insulated conductors, 6 m long ground U 15/25 C-6 162 196
1 VAHLE unipole insulated conductor, 2 m long ground U 15/25 C-2 162 192
10 expansion sections each 1 m long phase UDV 15/25 C K 4 160 276
2 expansion sections each 1 m long ground UDV 15/25 C K 4 160 277
120 joint splices UV 15 K 4 160 102
6 feed terminals UEG 15 K 4 160 216
36 locating clamps USK 15 K 4 160 106
12 end caps UK 15-L 160 109
125 compact hangers KH 15/6 160 139
125 bracket profiles, 200 mm long HU 15/200 161 434
5 current collectors phase KST 25 155 013
1 current collector ground KST 25 155 014
Standard configuration, 40 m, 3-pole + ground electrification system for 10 Amps.
18 VAHLE unipole insulated conductors, 6 m long phase U 15/25 E-6 162 156
3 VAHLE unipole insulated conductors, 4 m long phase U 15/25 E-4 162 154
6 VAHLE unipole insulated conductors, 6 m long ground U 15/25 E-6 162 216
1 VAHLE unipole insulated conductor, 4 m long ground U 15/25 E-4 162 214
24 joint splices UV 15 K 4 160 102
4 feed terminals UE 15 K 4 160 107
8 locating clamps USK 15 K 4 160 106
8 end caps UK 15-L 160 109
164 insulated hangers UA 15 160 113
3 current collectors phase KST 25 155 013
1 current collector ground KST 25 155 014
21
19 12
INSTALLATION TOOLS FOR U 15
Curve tool
Details for vertical and horizontal curves see bending procedure
(installation procedure U 15).
Motor powered tool furnished on special order.
Filler rod is to be ordered separately.
BVU 10/15 10.000 160 147

FU 15 Filler-rod (4 m) 0.340 160 735
C
Drill jig B
20
The drill guide should be used when conductor ends have to be A
A
prepared for end caps or transfer guides on site.
Drill B and D for end caps.
20
Drill B for transfer guide US 15 and USE 15.
81
BS 15 0.100 160 148

Please see installation instructions for U 15.
Punch tool
To prepare square holes in the shroud
for types US 15 T thru USE 15 TS transfer guides
and LT/LT-U 15 thru LTE/LTE-U 15 isolating assemblies.
HST 15 4.300 160 332
22
INSULATED CONDUCTORS U 25 19 12
23
Conductor code: Support spacing:
19
U = unipole insulated conductor - for straight runs &
25 = shroud size for inside & outside curves: 1500 mm
U 25 C
12
50-125 = conductor cross sectional - horizontal curves:

area (mm2) up to RH = 10 m(2): 750 mm
C = copper conductor
27
- horizontal curves:
AE = Aluminium conductor contact
above RH = 10 m(2): 1500 mm
15
surface stainless steel.
7
8
Length: Curves:
6 m is standard length, factory prepared from R = 800 mm
RH Radius
Horizontal curve shorter lengths are available or in the field
23 horizontal curves: from R = 7000 mm
19 inside & outside curves: from R = 2500 mm
Conductor spacing: AE-conductor on request.
U 25 AE on standard hangers 50 – 80 mm
12
on compact hangers 50 mm
Heating system available on request.
Chemical and electrical properties
27
and temperature resistance see page 4.

15
Type U 25/50 C U 25/75 C U 25/100 C U 25/125 C U 25/90 AE U 25/125 AE

Weight kg/m 0,550 0,740 1,000 1,260 0,450 0,540
Cat.-No. phase(2) 171 02 • 171 03 • 171 04 • 171 20 • 171 24 • 171 28 •
Cat.-No. PE(2) 171 12 • 171 13 • 171 14 • 171 21 • 171 25 • 171 29 •
High temperature shroud, color grey
Cat.-No. phase(2) 171 07 • 171 08 • 171 09 • 171 22 • 171 26 • 171 30 •
Cat.-No. PE(2) 171 17 • 171 18 • 171 19 • 171 23 • 171 27 • 171 31 •
Engineering data
Leakage max. max. Impedance(3) Ohm/1000 m
Conductor Rail Cross sectional area Resistance
distance of covers voltage Amp. capacity based on 50 HZ & conductor spacing
Typ2 mm2 Ohm/1000 m
mm V A at 35 °C 50 mm 80 mm
U 25/ 50 C 50 53 1000 200 0,351 0,378 0,388

U 25/ 75 C 75 53 1000 300 0,239 0,269 0,283
U 25/100 C 100 53 1000 400 0,180 0,219 0,236
U 25/125 C 125 53 1000 450 0,140 0,188 0,208
U 25/ 90 AE(4) 90 53 1000 230 0,347 0,369 0,380
U 25/125 AE(4) 125 53 1000 320 0,240 0,271 0,285
Selection of conductors
in accordance to ampere load and environmental conditions.
U 25 / … C copper conductors for power and control system application.
U 25 / … AE Aluminium conductor and stainless steel conductor surface for power and control system
27 Bolted joint splices

Typ UV 25, UV 25 K 4, UV 25 AE and UV 25 AE K 4 applicable
50
as feed terminal, too.
M6
21
160 Type connectin cable Weight kg Cat.-No.

max. mm2
UV 25 2 x 16 0,190 170 595
UV 25 K 4(5) 2 x 16 0,190 170 596
UV 25 AE 2 x 16 0,150 170 960
45 UV 25 AE K 4(5) 2 x 16 0,150 170 961
45
Are adequate fo feed terminal UE
(1) Add last number (1, 2, 3, 4, 5 or 6 m length suffix) in accordance to bars required.
(1) recommendation
23
19 12
Expansion sections Fixpoint Expansion section
factory assembled on 1.5 m long conductor section incl. one X X
rigid joint and will be installed from 150 m of system length on. max. 75 m L max. 75 m
Expansion sections (distance between fix points)

For UDV 25 C
to t max. L to t max L
20 °C 147 m 40 °C 73,5 m
393
30 °C 97,5 m 50 °C 58,5 m
31
For UDV 25 AE
280
to t max. L to t max L
20 °C 108 m 40 °C 54 m
156
30 °C 72 m 50 °C 42 m
°C expansion capacity max. 30 mm
i 20
0 bteo
33
+ 320
280 500 –
1
Investigation of expansion sections

n = L1
L
393 n = Number of UDV (rounded)
L1 = Length of assembly minus 150 m
L = Expansion capacity max. of UDV
(see table)

UDV 25 C K 4 (1) 2,550 171 057 171 058 UDV 25 C K 4 (1) 2,550 171 067 171 068
UDV 25 AE K 4 (1) 1,900 171 059 171 060 UDV 25 AE K 4 (1) 1,900 171 069 171 070
30 Locating clamp
27
Photo shows hanger

with two locating
20 clamps for an anchor Type Weight kg Cat.-No.
point. (1)
USK 25 K 4 0.024 170 010
Feed terminals
Types UE 25, UE 25 K 4(1), UE 25 AE and UE 25 AE K 4(1)
are adequate to bolted joint splice
ide
27 w Connecting cable Weight kg Cat.-No.
160 Type
max. mm2
UE 25 2 x 16 0,190 170 599
UEG 25 2 x 95 0,560 170 597
21
UEG 25-M 2 x 95 0,560 170 396

M6
45 UE 25 K 4(1) 2 x 16 0,190 170 600
45 UEG 25 K 4(1) 2 x 95 0,560 170 598
UEG 25 K 4(1)-M 2 x 95 0,560 170 397
e
190 53 wid UE 25 AE 2 x 16 0,150 171 158
UE 25
UEG 25 AE 2 x 95 0,456 170 962
UEG 25 AE-M 2 x 95 0,456 170 964
UE 25 AE K 4(1) 2 x 16 0,150 171 159
61
UEG 25 AE K 4(1) 2 x 95 0,456 170 963

M12 UEG 25 AE-K 4(1)-M 2 x 95 0,456 170 965
45
45 UEG 25 Cables & lugs by others.
UEG requires staggered arrangement with conductor spacing
of less than 80 mm. Type M = factory assembled.
24 (1) with stainless steel hardware

Contact Grease 20 g for approx. 40 joints Cat.-No. 120016

for joints and feeds 421 g for approx. 1000 joints Cat.-No. 120 017
Isolating sections
30 A 30
max. 200
max. 200 min. 200 max. 200 max. 200
Feed
Typ M = Factory assembled according to system layout 30 stromlos

w/o cond.
Typ L = Loose c/w two locking pins 3 x 20.
Consider one extra hanger. Distance from center of Type Weight kg Cat.-No.
isolating section 200 m.
IT/U 25/30 M 0.015 170 070
Conductors, hangers and feeds are to be ordered separately.
IT/U 25/30 L 0.015 170 071
In order to avoid voltage bridging and for clearing of maintenance, control and live areas use two isolating sections.
Distance A depends on collector type and length of brake path of machinery.
End caps Insulated hangers (1)

c/w locking pin 3 x 20
max. 10
M8
26,5
21
27
30
Type M = factory assembled
Type L = Loose Width: 40 mm
UK 25-M 0.005 170 793 UA 25 0.040 170 761

UK 25-L 0.005 170 013 UA 25 K 4 (2) 0.040 170 762
Insulators (1) Rail holders

to be used with insulator
M8
8
14,5
27
30
cantilever = 3000 N Width: 40 mm

creapage distance = 60 mm
GH 40-M 8 0.100 170 146 UAK 25 0.023 170 868

(2) (2)
GH 40-M 8 K 4 0.100 170 148 UAK 25 K 4 0.023 170 869
(1) Use flat washers (see page 32) on both sides of brackets with slotted holes.
25
19 12
KA 25/4
200
Compact hangers, 2 - 4-pole
max. 10
M8
Any number of conductors can be assembled by cutting/
combining the compact hangers.
20
24 Conductor spacing 50 mm.

.5 Hanger KA 25 is for direct bolting to the supporting structure
21
Hanger KH to be used with bracket profile 38/17.

26.5
Hanger KA 25/4-SKU to be used with mounting bracket SKU.

50 25
50 50
25
KA 25/4 SKU 200 Type (2) Weight kg Cat.-No.

M8
ma x. 17
KA 25/2 0,084 170 838

29 ,5
KA 25/3 0,102 170 839

24 KA 25/4 0,120 170 840
,5
21
KA 25/2 K 4(2) 0,084 170 853

26 .5
KA 25/3 K 4(2) 0,102 170 854

50 25
50 50 KA 25/4 K 4(2) 0,120 170 855
25
KA 25/4-SKU 0,151 170 878
KH 25/4 200 KH 25/2 0,034 170 848
24
.5 KH 25/3 0,050 170 849
14.5
KH 25/4 0,070 170 850

41
50 25
50 50
25
Bracket profiles 38/17

Length
Type Poles Weight kg Cat.-No.
mm
HU 25/400 400 4–5 0.830 170 667
HU 25/600 600 10 1.160 170 668
cyl. M 8 Longer brackets furnished on special order.(3)
Attachment hardware for Compact hanger KH/25…
25 x 30
M8
max. 3
D
d
Ø 28
Type Weight kg Cat.-No. Type Thread d D S Weight

mm Cat.-No.
mm mm kg
SE 8 0.055 170 677 Washer 8,4 M8 8.40 25 1.60 0.007 170 624
SE 8 K 4 (2) 0.055 170 955 Washer 8,4 K 4 (2) M8 8.40 25 1.60 0.007 170 625
Transfer guide
This guide serve for transfer
or power interrrupting applications.
US 25 K 4 (2) 0.060 170 329
d. Max. horizontal and vertical offset using collectors

con
w/o KSTL 15-60 - KDSTL 120 ± 3 mm, air gap 2-5 mm
25 69 KST 100/25 - KDSTU 350/25 ± 3 mm, air gap 5-8 mm
Transfer guide US 25 is fastened to conductor ends by means of
a stainless screw.
26 (1) Attachment hardware to be ordered separately; two flat washers to be used in slotted holes.
(3) Delivery incl. 2 Attachment hardware SE 8.
COLLECTORS FOR U 25(1) 19 12

152 304
17
100 100
75 4 75
approx. 135
85
85
12 12

lift & swivel ± 40 mm lift & swivel ± 40 mm 30
12 Ground
Am- Connectin cable Cat.-No. Am- Connecting cable Cat.-No.
Typ e Weight Typ e
pacity Ø max/ pacity Ø max/ Weight
kg phase ground phase ground
A mm2 mm A mm2 mm kg
KSTL 15 15 2.50 4.40 0.272 150 893 150 894 KDSTL 30 30 2.50 4.40 0.492 150 899 150 901
KSTL 40 40 6.00 11.00 0.453 152 860 152 870 KDSTL 80 80 6.00 11.00 0.822 152 980 152 990
KSTL 60 60 10.00 12.50 0.591 153 677 153 678 KDSTL 120 120 10.00 12.50 1.188 153 681 153 682
Current collector 42 Double current collector

495
247,5
5 200
200
120
120
approx. 210
150
150
24
24 Ground

lift: ± 45 mm, swivel: ± 60 mm lift: ± 45 mm, swivel: ± 60 mm
contact pressure: 30 N contact pressure: 30 N per brush 50 24

Typ e pacity A/ Ø max/ Weight Typ e pacity A/ Ø max/ Weight
A mm2 mm kg A mm2 mm kg
KST 100/25 100 16.00 14.50 1.707 170 319 170 320 KDST 200/25 200 16.00 14.50 3.077 170 321 170 322
KST 125/25 125 25.00 16.50 1.800 171 017 171 018 KDST 250/25 250 25.00 16.50 3.100 171 019 171 020
Current collectors* For transfer funnel use Double current collectors*For transfer funnel use
KSTU 140/25 or KSTU 175/25 (2) KDSTU 280/25 or KDSTU 350/25 (2)
42
247,5 495
6
140
140
approx. 220
ca. 220
150
150
24
Ground
c/w 2 m cable c/w 2 x 2 m cable 24

lift: ± 45 mm, swivel: ± 60 mm lift: ± 45 mm, swivel: ± 60 mm
contact pressure: 29 N contact pressure: 29 N per brush 50 24

Typ e pacity A/ Ø max/ Weight Typ e pacity A/ Ø max/ Weight
A mm2 mm kg A mm2 mm kg
KST 25.00 140/25 140 16.50 1.660 170 538 170 539 KDST 280/25 280 25.00 16.50 3.020 170 542 170 543
KST 35.00 175/25 175 18.50 1.700 171 037 171 038 KDST 350/25 350 35.00 18.50 3.100 171 047 171 048
KSTU 140/25 140 25.00 16.50 1.700 170 540 170 541 KDSTU 280/25 280 25.00 16.50 3.100 170 544 170 545
KSTU 175/25 175 35.00 18.50 1.800 171 039 171 040 KDSTU 350/25 350 35.00 18.50 3.200 171 049 171 050
(1) The collector of the AE-conductor which are working with only ≤ 10 m/min. travel speed or stand most of the time are only
27
(2) Special collectors for aggressive environments on request.
19 12
COMPONENTS & COLLECTOR BRACKETS FOR U 25
Transfer funnels, 2-pole up to 6-pole
assembled per system layout.
Transfer funnels are necessary for passing switches and turn-
tables.
Conductor spacing 50 mm.
The following collectors have to be used:
For pendant arrangement: KSTU 140/25, KSTU 175/25,
KDSTU 280/25 or KDSTU 350/25.
For lateral arrangement: KSTUR 140/25 on request.
Vmax = 100 m/min.
Connecting conductor bars with transfer guides US 25 K 4 UTI to be
ordered separately.
dim. A dim. B dim. C

Type Poles
mm mm mm
EMK 25/2 2 46 83 216
EMK 25/3 3 88 125 258
EMK 25/4 4 130 167 300
EMK 25/5 5 172 209 342
EMK 25/6 6 214 251 384
40 mm wide
Collector brackets for KSTL 15 thru KDSTL 120
5
25
15
18
Prepared for
ground collector
120
12
190
18
11 x 30 slotted hole
600
40
5
65
85
UM 12 0.710 153 506 UMA 12 0.640 170 334

Longer brackets furnished on special order. In this case an Suitable for conductor spacing 50 mm (3-poles + ground).
extra support is to be provided to avoid bending or twisting of
the collector bracket.
Collector brackets for KST 100/25 thru KDSTU 350/25 40
13,5 Ø
120
80
24
24
35
10
600
325
Prepared for
ground collector Prepared for ground collector
UM 24 2.600 175 076 UMF 24 2.850 170 272

Longer brackets furnished on special order. In this case an
extra support is to be provided to avoid bending or twisting of
the collector bracket.
28
Copper-graphite brush
100
75 120 140
10
17
RH
53
RH
RH
KMK 60 KMK 100/25 KMK 140/25
Dim. RH: allowed rest of hight

RH Weight
Type for current collector mm kg Cat.-No.
KSTL 15, KSTL 40, KSTL 60,

KMK 60 7.50 0.110 153 512
KDSTL 30, KDSTL 80, KDSTL 120
KMK 100/25 KST 100/25, KDST 200/25, KST 125/25, KDST 250/25 38.00 0.180 170 768
KST 140/25, KDST 280/25, KSTU 140/25, KDSTU 280/25
KMK 140/25 1.00 0.152 170 164
Tension spring (stainless steel)
Type for current collectors S D L Weight Cat.-No.

mm mm mm kg
KSTL 15, KSTL 40, KSTL 60,

ZF 4 1.30 11.00 29.00 0.004 153 517
KDSTL 30, KDSTL 80, KDSTL 120
KST 100/25, KDST 200/25, KST 125/25, KDST 250/25
ZF 6 KST 140/25, KDST 280/25, KSTU 140/25, KDSTU 280/25 2.25 17.30 56.50 0.023 170 167
29
19 12
Spares for collectors KSTL 15 thru KDSTL 120
Part.-No. Description Weight kg Cat.-No.
1 Brush (see page 35) – –

2 Collector base for KSTL 15 thru KSTL 60 phase PH 153 740
0.090
3 Collector base for KSTL 15 thru KSTL 60 ground PE 153 741
4 Collector base for KDSTL 30 thru KDSTL 120 phase PH 153 742
0.130
5 Collector base for KDSTL 30 thru KDSTL 120 ground PE 153 743
Connecting cable AEA 2.5 mm2, PH, 2 m long phase PH 151 374
6 0.072
Connecting cable AEA 2.5 mm2, PE, 2 m long ground PE 151 375
Connecting cable AEA 6 mm2, PH, 2 m long phase PH 153 744
6 0.260
Connecting cable AEA 6 mm2, PE, 2 m long ground PE 153 745
Connecting cable AEA 10 mm2, PH, 2 m long phase PH 153 746
6 0.400
Connecting cable AEA 10 mm2, PE, 2 m long ground PE 153 747
7 Tension spring (see page 29)
e
➆
30
Spares for Collectors KST 100/25 thru KDSTU 350/25
1 Brush KMK 100/25 (see page 29) – –

2 Brush holder for KST 100/25, KST 125/25, KDST 200/25, KDST 250/25 0,195 170 338
3 Brush KMK 140/25 (see page 29) – –
4 Brush holder for KST 140/25, KDST 280/25, KST 175/25, KDST 350/25 0,375 170 169
4 Brush holder(1) for KSTU 140/25, KDSTU 280/25, KSTU 175/25, KDSTU 350/25 0,375 170 406
5 Collector base for KST 100, KST 125, KST 140 and KST 175 phase PH 170 340
0,578
6 Collector base for KST 100, KST 125, KST 140 and KST 175 ground PE 170 341
5 Collector base for KSTU 140, KSTU 175 phase PH 170 555
0,555
6 Collector base for KSTU 140, KSTU 175 ground PE 170 556
7 Collector base for KDST 200, KDST 250,KDST 280, and KDST 350 phase PH 170 342
0,795
8 Collector base for KDST 200, KDST 250,KDST 280, and KDST 350 ground PE 170 343
7 Collector base for KDSTU 280, KDSTU 350 phase PH 170 557
0,795
8 Collector base for KDSTU 280, KDSTU 350 ground PE 170 558
9 Connecting cable RKA 16/8 mm2, PH, 2 m long phase PH 0,614 170 344
Connecting cable RKA 16/8 mm2, PE, 2 m long ground PE 0,459 170 345
9 Connecting cable RKA 25/8 mm2, PE, 2 m long ground PE 0,600 170 174
Connecting cable RKA 35/8 mm2, PE, 2 m long ground PE 0,600 170 998
10 Rubber spring complete for KSTU 140/25, KDSTU 280/25, KSTU 175/25, KDSTU 350/25 0,035 170 412
11 Tension spring (see page 29) – –
12 Terminal bolt M 8 x 20 K 4 for KST 100, KST 125,KDST 200 and KDST 250 0,022 170 818
13 Terminal bolt M 8 x 12 K 4 for KST 140, KST 175, KSTU 140, KSTU 175, KDST 280, 0,010 170 871
KDST 350, KDSTU 280 und KDSTU 350
➄
➀ ➂
➁ ➃
➅
g
m 12
➈
h 10
11
(1) Rubber spring (No. 10) is part of the brush holder.

31
19 12
ARRANGEMENT AND EXAMPLE FOR ORDERING U 25
80 with UEG 25
50
M8 80 with UEG 25
UEG 25
50
M8
max. 10
39.5
max. 9
33.5
40
UEG 25
27
KST 100/25 - KDSTU 350/25 = 150
KSTL 15 - KDSTL 120 = 85
273 m power supply system, 3-pole + ground

132 VAHLE unipole insulated conductors, 6 m long Phase PH U 25/75 C-6 171 036
3 VAHLE unipole insulated conductors, 5 m long Phase PH U 25/75 C-5 171 035
cut to 4.5
44 VAHLE unipole insulated conductors, 6 m long Ground PE U 25/50 C-6 (1) 171 126
1 VAHLE unipole insulated conductor, 5 m long Ground PE U 25/50 C-5 (1) 171 125
cut to 4.5
9 Expansion sections, 1.5 m long Phase PH UDV 25 C K 4 170 057
3 Expansion sections, 1.5 m long Ground PE UDV 25 C K 4(1) 170 058
176 Bolted joint splices UV 25 170 595
8 Feed terminals UEG 25 170 597
32 Locating clamps USK 25 K 4 170 010
8 End caps UK 25-L 170 013
732 Insulated hangers UA 25 170 761
3 Double collectors Phase PH KDST 280/25 170 542
1 Collector Ground PE KST 140/25 170 539
1 Collector bracket UM 24 175 076
1 Contact greese – 120 017
32 (1) Capacity reduces per VDE 0100, part 540.

MOUNTING BRACKETS FOR U 25 19 12
For flange thickness D from 10 to 32 mm
L
min. 50
200 30
SKO
34
17
M 10
X 50
B
M 10
SKU
200 30
51
34
min. 50
X 50
L
for KH 25/4 and KA 25/4
I-Beam flange
Distance X for brackets
width B mm SKO SKU
L = 500 L = 600 L = 700 L = 800 L = 900 L = 500 L = 600 L = 700 L = 800 L = 900
up to 80 170-195 170-295 170-395 170-495 – 120-225 120-325 120-425 120-525 –
over 80 to 120 – 190-275 190-375 190-475 190-575 140-205 140-305 140-405 140-505 140-605
over 120 to 160 – 210-255 210-355 210-455 210-555 160-185 160-285 160-385 160-485 160-585
over 160 to 200 – 230-235 230-335 230-435 230-535 – 180-265 180-365 180-465 180-565
over 200 to 260 – – 260-305 260-405 260-505 – 210-235 210-335 210-435 210-535
Compact hangers, rail holders and insulators are to be ordered separately
SKO SKU
Type Cat.-No. Type Cat.-No. L Weight

mm ca. kg
SKO 500 170 094 SKU 500 170 104 500 0.690
SKO 600 170 095 SKU 600 170 105 600 0.780
SKO 700 170 096 SKU 700 170 106 700 0.870
SKO 800 170 097 SKU 800 170 107 800 0.960
SKO 900 170 098 SKU 900 170 108 900 1.050
33
19 12
INSULATED CONDUCTORS U 35
Conductor code:
U = unipole insulated conductor
35 = shroud size
200, 230, 300, 400, 450, 500 = conductor cross
U 35 C sectional area (mm2)
C = copper conductor
AE = Aluminium conductor
contact surface stainless steel
Length:
6.25 m is standard length;
other lengths are available
RH = Radius Horizontal curve Support spacing:
– for straight runs and vertical
inside and outside curves: 2500 mm
– for horizontal curves up to RH = 15 m(1): 1250 mm
41
– for horizontal curves over RH = 15 m: 2500 mm
33
Conductor spacing:
U 35 AE – 90 mm for collectors UST 200/35,
UDST 400/35 and feed UE
23, 5
– 130 mm for collectors UST 300/35,

UDST 600/35 and feed UEG
47
Curves:
23,5
factory prepared
Heating system:
available
9 See page 4 for shroud properties.
(1) Recommendation
Type U 35/200 C U 35/300 C U 35/400 C U 35/500 C U 35/230 AE U 35/450 AE

Weight (kg/m) 2.400 3.400 4.300 6.100 1.070 1.650
Cat.-No. phase(2) 175 20 • 175 21 • 175 22 • 175 33 • 175 41• 175 45•
Cat.-No. ground (2) 175 26 • 175 27 • 175 28 • 175 34 • 175 42• 175 46•
High temperature shroud, color gray
Cat.-No. phase (2) 175 23 • 175 24 • 175 25 • 175 35 • 175 43• 175 47•
Cat.-No. ground (2) 175 29 • 175 30 • 175 31 • 175 36 • 175 44• 175 48•
Engineering Data
Cross Leakage Distance of max Continuous Resistance Impedance (3) Ohm/1000 m
Type sectional area covers voltage Amp. capacity on 50 Hz, conductor spacing
copper mm2 mm V A/35 °C Ohm/1000 m
90 mm 130 mm
U 35/200 C 200 85 1000 600 0.094 0.156 0.174
U 35/300 C 300 85 1000 720 0.060 0.138 0.159
U 35/400 C 400 85 1000 860 0.046 0.132 0.154
U 35/500 C 500 85 1000 1250 0.034 0.131 0.152
U 35/230 AE(4) 230 85 1000 500 0.134 0.183 0.199
U 35/450 AE(4) 450 85 1000 800 0.069 0.143 0.163
Bolted joint splices

60
UV 35/200-300 0.882 175 012

UV 35/400 1.021 175 126
77
124
UV 35/500 1.273 175 369

UV 35/200-300 K 4(5) 0.882 175 013
260 M 10
UV 35/400 K 4(5) 1.021 175 127
UV 35/500 K 4 (5) 1.273 175 370
UV 35/230 AE 0.674 175 491
UV 35/450 AE 0.776 175 492
UV 35/230 AE K 4(5) 0.674 175 495
88
88 UV 35/450 AE K 4(5) 0.776 175 496
(2) Add last number (1, 2, 3, 4, 5 or 6 m length suffix) in accordance to bars required, whereby last number 6 relates to the standard 6.25 m sections.
34 (3) Based on 50 Hz.
(4) The collector of the AE-conductor which are working with only ≤ 10 m/min. travel speed or stand most of the time are only

(5) Stainless steel hardware
Expansion sections Fixpoint

Festpunkt Expansion section
Dehnverbinder
Factory assembled on 2.5 m conductor section incl. one rigid joint. X X

The 2.5 m expansion assembly is part of the system length and will max. 75 m L max. 75 m
be installed from 150 m of system length on.
60
77
Determination of expansion sections
n = L1
L 55 6 3 1 ,5
n = Number of UDV (rounded up)
L1 = system length minus 150 m
L = max. expansion capacity of UDV
12 3 7
43
(see table)
0 °C
+40 a btei 2
0
2500 -5
Expansion capacity max. = 90 mm
6 3 1 ,5
Expansion capacity Expansion capacity

for UDV 35/200-500 C for UDV 35/230-450 AE
to t max. L to t max L to t max. L to t max L
30 °C 176 m 50 °C 105.5 m 30 °C 130.0 m 50 °C 78.0 m

40 °C 132 m 60 °C 88.0 m 40 °C 97.5 m 60 °C 65.0 m
Cat.-No. Cat.-No.
Type Weight kg phase ground Type Weight kg phase ground
UDV 35/200-400 C K 4(1) 16.00 175 527 175 528 UDV 35/200-400 C K 4(1) 16.000 175 529 175 530
UDV 35/500 C K 4(1) 17.50 175 540 175 541 UDV 35/500 C K 4(1) 17.500 175 542 175 543
UDV 35 /230-450 AE K 4(1) 7.00 175 517 175 518 UDV 35/230-450 AE K 4(1) 7.000 175 519 175 520
Feed terminals
Connecting Weight
260 e Type cable Cat.-No.
60 wid kg
max. mm2
UE 35/200-400 2 x 150 1,264 175 040
UE 35/500 2 x 150 1,204 175 397
77
UEG 35/200-400 4 x 185 1,930 175 105

UEG 35/200-400 -M 4 x 185 1,930 175 147
M 12
UEG 35/500 4 x 185 1,998 175 371
88 UEG 35/500-M 4 x 185 1,998 175 394
88
UE 35 UE 35/200-400 K 4(1) 2 x 150 1,264 175 043
UE 35/500 K 4(1) 2 x 150 1,204 175 398
UEG 35/200-400 K 4(1) 4 x 185 1,930 175 106
UEG 35/200-400 K4(1)-M 4 x 185 1,930 175 324
260
60 wid
e UEG 35/500 K 4(1) 4 x 185 1,998 175 372
UEG 35/500 K4(1)-M 4 x 185 1,998 175 417
UE 35 AE 2 x 150 0,872 175 489
UEG 35 AE 4 x 185 1,278 175 487
127
UEG 35 AE-M 4 x 185 1,278 175 521

UE 35 AE K 4(1) 2 x 150 0,872 175 490
UEG 35 AE K 4(1) 4 x 185 1,278 175 488
M 12
88
UEG 35 AE K 4(1)-M 4 x 185 1,278 175 522
88 UEG 35
UEG 35
Cable lugs and cables by others. UEG requires staggered arrangement
with conductor spacing of less than 130 mm. M = factory assembled.

35
19 12
Contact grease for joints & feeds 20 g for approx. 40 joints Cat.-No. 120 016
Insulated hangers
UA 35 0.120 175 137

Width: 50 mm UA 35 K 4 (1) 0.120 175 138
Allowed change power 1050 N
Rail holders Locating clamp

to be used with insulator
50
16
40
Photo shows hanger with two

locating clamps for an anchor
Width: 50 mm point.
Allowed change power 1050 N

(1)
UAK 35 0.060 175 139 USK 35 K 4 0.074 175 039
UAK 35 K 4 (1) 0.060 175 140
Insulators
deep
Cantilever = 1200 N Cantilever = 3600 N

Creapage distance = 69 mm Creapage distance = 111 mm
GHH 30-M 12 0.210 175 052 GHH 75-M 12 0.560 175 056
(1) (1)
GHH 30-M 12 K 4 0.210 175 054 GHH 75-M 12 K 4 0.560 175 058
(1)
36 with stainless steel hardware
End caps
with locking pin 3 x 32
120
Typ M = factory assembled per layout

Typ L = loose
UK 35-M 0.064 175 171

UK 35-L 0.064 175 060
Transfer guides
Transfer guides are used for transfer or power-interrupting
applications.
Max. vertical and horizontal offset ± 6 mm . 130
ma x
max. air gap: 20 mm
UTI 35/200 0.060 175 061
UTI 35/300 0.060 175 123
UTI 35/400 0.060 175 124
UTI 35/500 0.060 175 367
UTI 35/230 0.060 175 501
UTI 35/450 0.060 175 502
Photo shows transfer guide with
UTI 35 are transfer buttons (bellmouth shaped conductor ends) conductor section and insulated
50 ds. hanger.
with integrated isolating piece. They are factory assembled to onlo
ocm
UT I 35 w/sot r
layout plans.
In the area of the transfer guide one hanger and the locating
clamps have to be provided
Conductor rails, hangers and locating clamps to be ordered
separately.
Isolating sections
Typ M = factory assembled per layout
Typ L = loose
Consider two extra hangers, max 2 x 400 mm apart
for stabilizing 200 IT/U 35 M
w/o cond.
Conductor rail, hangers and feeds are to be ordered separately
200 A 200
max. 400 max. 400 min. 270 max. 400 max. 400
feed
In order to avoid voltage bridging and for clearing of maintenance, control and live areas use two isolating sections.
Distance A depends on collector type and length of brake path of machinery.

IT/U 35/200 M 0.200 175 062 IT/U 35/200 L 0.200 175 101
IT/U 35/300 M 0.200 175 063 IT/U 35/300 L 0.200 175 102
IT/U 35/400 M 0.200 175 064 IT/U 35/400 L 0.200 175 103
IT/U 35/500 M 0.200 175 399 IT/U 35/500 L 0.200 175 400
IT/U 35/230 M 0.200 175 499 IT/U 35/230 L 0.200 175 497
IT/U 35/450 M 0.200 175 500 IT/U 35/450 L 0.200 175 498
37
19 12
COLLECTORS AND COMPONENTS FOR U 35
Current Collectors Double current collectors
Use current collectors USTR in case of lateral opened Use current collectors UDSTR in case of lateral opened
conductor system conductor system
247 494
72
250 6 250
170
170
78
78
24
24
c/w 2.7 m cable c/w 2 x 2.7 m cable

(pendent 2,3 m) (pendent 2.3 m) 24 Ground
lift & swivel ± 50 mm lift & swivel ± 50 mm
contact pressure ca. 30 N contact pressure: ca. 30 N per brush
Type pacity Ø max/ Weight phase - ground - Type pacity Ø max/ Weight phase - ground -
UST 200/35 200 50 21 2.000 175 068 175 069 UDST 400/35 400 50 21 3.700 175 072 175 073
USTR 200/35 200 50 21 2.000 175 169 175 170 UDSTR 400/35 400 50 21 3.700 175 185 175 186
The collector of the AE-conductor which are working with only ≤ 10 m/min. travel speed or stand most of the time are only
Collector brackets
40 wide
53
40
22
slotted holes 11 x 30
Prepared for
ground collector
226
24
376
35
600
75
100
120
UM 24 2.600 175 076 UMA 24 2.800 175 125
Longer brackets furnished on special order. For 3-pole & ground systems c/w 90 mm cond. spacing.
In this case an extra support is to be provided to avoid bending

or twisting of the collector bracket.
38
COLLECTORS FOR U 35 (1) 19 12
Current collectors
Use current collectors USTR in case of lateral opened conductor system.
374
72
250
6
325
40
M 16
max. 20
70 for phase 50
120 for ground
47 67
w/o 2.7 m cable 190

(pendent 2,3 m)
lift ± 70 mm, swivel ± 80 mm
contact pressure: 50-70 N
Am- Connecting cable Cat.-No.
Typ e * pacity Ø max/ Weight phase - ground -
A mm2 mm kg black yellow
UST 300/35 300 95 26 10.900 175 087 175 088
USTR 300/35 300 95 26 10.900 175 320 175 321
Double current collectors

Use current collectors UDSTR in case of lateral opened conductor system.
748 72
6
250
325
40
M 16
max. 20
70 for phase 50
120 for ground
47 67
190
w/o 2 x 2.7 m cable

(pendent 2,3 m)
lift ± 70 mm, swivel ± 80 mm
contact pressure: 50-70 N per brush
Am- Connection cable Cat.-No.
Typ e * pacity Ø max/ Weight phase - ground -
A mm2 mm kg black yellow
UDST 600/35 600 95 26 18.300 175 089 175 090
UDSTR 600/35 600 95 26 18.300 175 174 175 175
(1) The
collector of the AE-conductor which are working with only ≤ 10 m/min. travel speed or stand most of the time are only 39
19 12
Spares for collectors UST 200/35, UST 300/35, UDST 400/35, UDST 600/35, USTR 200/35,
UDSTR 400/35, USTR 300/35 and UDSTR 600/35
Part-No. Description Weight kg Cat.-No.
1 Brush KMU 300/35 with connecting screw 0.400 175 077

2 Brush holder 0.500 175 078
3 Collector base for UST 200/35 phase 175 080
0.550
4 Collector base for UST 200/35 ground 175 081
5 Collector base for UDST 400/35 phase 175 082
0.795
6 Collector base for UDST 400/35 ground 175 083
7 Collector base for USTR 200/35 phase 175 550
0.780
8 Collector base for USTR 200/35 ground 175 551
9 Collector base for UDSTR 400/35 phase 175 552
0.940
10 Collector base for UDSTR 400/35 ground 175 553
11 Collector base for USTR 300/35 phase 175 554
6.380
12 Collector base for USTR 300/35 ground 175 555
13 Collector base for UDSTR 600/35 phase 175 556
8.050
14 Collector base for UDSTR 600/35 ground 175 557
a RH= 51 mm (allowed rest of hight)
c g
d
b h
f k l
m n
j
40
Spares for collectors UST 200/35, UST 300/35, UDST 400/35, UDST 600/35, USTR 200/35
USTR 300/35, UDSTR 400/35 and UDSTR 600/35
15 Connecting cable RKA 50 mm , 2,7 m long for UST 200/35, UDST 400/35,
2 phase 2.220 175 084
USTR 200/35 and UDSTR 400/35
16 Connecting cable RKA 50 mm2, 2,7 m long for UST 200/35, UDST 400/35, ground 175 085
17 Connecting cable RKA 95 mm2, 3 m long for UST 300/35, UDST 600/35, phase 3.750 175 149
18 Connecting cable RKA 95 mm2, 3 m long for UST 300/35, UDST 600/35, ground 175 150
19 Tension spring ZF 7 for UST 200/35, UDST 400/35, USTR 200/35 and UDSTR 400/35 0.030 160 719
20 Lateral tension spring ZF 6 for USTR 200/35 and UDSTR 400/35 0.023 170 167
21 Tension spring for USTR 300/35 and UDSTR 600/35 0.030 175 558
22 Cable attachment clamp 0.150 175 107
23 Lever compl. for UST 300/35, UDST 600/35, USTR 300/35 and UDSTR 600/35 0.750 175 093
24 Spring box compl. for UST 300/35 and UDST 600/35 2.250 175 094
25 Base plate compl. for UST 300/35 phase 3.470 175 095
26 Base plate compl. for UST 300/35 ground 175 096
27 Base plate compl. for UDST 600/35 phase 3.490 175 097
28 Base plate compl. for UDST 600/35 ground 175 098
29 Terminal bolt M 12 x 25 K4 0.054 175 401
s u
u
21
22
o t
p
q u
23
u
r
24
u
29
u
25 u
27
u
26 u
28
41
19 12
ARRANGEMENT AND EXAMPLE FOR ORDERING U 35
130 with UEG
Arrangement with UDST 400/35 Arrangement with UST 300/35
250 m power supply system 720 A, 3-pole + ground
Qty Description Type Cat.-No.
117 VAHLE unipole insulated conductors, 6.25 m long phase U 35/300 C-6 175 216
cut to 3.75 m
39 VAHLE unipole insulated conductors, 6.25 m long ground U 35/200 C-6 (1) 175 266
(1)
1 VAHLE unipole insulated conductor, 4 m long ground U 35/200 C-2 175 264
cut to 3.75 m
3 Expansion sections, 2.5 m long phase UDV 35/200-400 C K4 175 527
1 Expansion sections, 2.5 m long ground UDV 35/200-400 C K4 175 528
156 Bolted joint splices UV 35/200-300 175 012
8 Feed terminals UE 35/200-400 175 040
16 Locating clamps USK 35 K 4 175 039
8 End caps UK 35 L 175 060
404 Insulated hangers UA 35 175 137
6 Double collectors phase UDST 400/35 175 072
1 Double collector ground UDST 400/35 175 073
2 Collector brackets UM 24 175 076
1 Contact grease 120 017
42 (1) Capacity reduces per VDE 0100, part 540

EARTHING SPIDER SYSTEM 19 12
Earthing spider system, 4-pole for insulated conductors – VDE 0105 Part 100 (EN 50110-1)
Serves for earthing and short-circuiting the phase conductors with the ground conductor in the case of maintenance work.
The system consists of terminal clamps for the conductors and copper wire ropes.
Earthing spider system cannot be used together with compact conductor arragement.
L1 L2 L3 PE
77 PE clamp with blue mark

24
170
311
Length 500 mm Length 600 mm

50 mm2 50 mm2
Type for conductor type Copper section of wire rope Cat.-No.
EUK U 25 and U 35 50 mm 2 130 035
43
19 12
QESTIONNAIRE FOR INSULATED CONDUCTOR SYSTEMS
Fa. Date:
Tel: Fax:
Internet: e-mail:
1. No. of conductor systems:
2. Type of crane/machinery to be electrified:
3. Voltage: Volts, ~/= Phases: c/s:

(Three phase current)
4. Length of conductor systems:
5. Number of conductors: (power lines: control lines: neutral (ground): )
6. Arrangement of conductors:
Conductor rails suspending / Collectors standing
Conductor rails resp. current collectors lateral
Others:
7. Number of cranes or machines electrified from the one system:
8. Indoor: Outdoor:
9. Special site conditions (humidity, dust, chemical effects etc.):
10. Temperature conditions: °C min. °C max.
11. Expansion gaps of building: pieces in max distance: mm
12. Number and position of feeder points:
13. Number and position of isolating sections (e.g. for maintenance areas):
14. Mounting position envisaged:

(prints and sketches should be submitted whenever obtainable)
15. Travelling speed of machinery:
16. Ampere load of each crane/machine:

(Use table on page 50).
17. Max. voltage drop from feeder point to current collectors 3% or % of voltage rating
Other important data:
Please submit prints or sketches for curved tracks, discontinuous.
44
QUESTIONNAIRE FOR INSULATED CONDUCTOR SYSTEMS 19 12
To our nearest local agency: Date:
Paul Vahle GmbH & Co. KG

D 59172 Kamen
Telefax 0 23 07 / 7 47 04
e-mail: [email protected]
Internet: www.vahle.de
Crane 1 Crane 2
Motordata Power
Nominal current Starting current
Power
kW A cosϕN % ED A cosϕA kW A cosϕN % ED A cosϕA
Hoist motor
Auxiliary hoist
Long travel
Cross travel
Crane 3 Crane 4
Motordata Power
Power
kW A cosϕN % ED A cosϕA kW A cosϕN % ED A cosϕA
Hoist motor
Auxiliary hoist
Long travel
Cross travel
Mark motors * which can operate simultaneously.

Mark motors ∆ which can start simultaneously.
Further remarks: e.g.
Signature:
45
19 12
Notices
46 In accordance with our company’s policy of continued improvement, we reserve the right to amend specifications and details at any time.
19 12
Notices
47
Catalog No. 2 c/E 2006
MANAGEMENTSYSTEM
DQS certified in accordance with DIN EN ISO 9001:2000

OHSAS 18001 (Reg. no. 003140 QM OH)
Catalog No.
Copperhead Conductor Systems 1a
Battery Charging Systems 1b
Insulated Conductor Systems U 10 2a
Insulated Conductor Systems U 20 – U 30 – U 40 2b
Insulated Conductor Systems U 15 – U 25 – U 35 2c
Aluminium Enclosed Conductor Systems LSV – LSVG 3a
Powerail Enclosed Conductor Systems KBSL – KSL – KSLT 4a
Powerail Enclosed Conductor Systems VKS – VKL 4b
Powerail Enclosed Conductor Systems MKLD – MKLF – MKLS 4c
Powerail Enclosed Conductor System VKS 10 4d
Powerail Enclosed Conductor System KBH 4e
Heavy Enclosed Conductor Systems 5
Trolley Wire and Accessories 6
Cable Tenders 7
Cable Carriers for -tracks 8a
Cable Carriers for Flatform Cable on -beams 8 bF
Cable Carriers for Round Cable on -beams 8 bR
Cable Carriers for -tracks 8c
Conductor Cables and Fittings 8L
Spring Operated Cable Reels 9a
VAHLE POWERCOM® – Data Transmission Systems 9c
CPS® – Contactless Power Supply 9d
SMG – Slotted Microwave Guide 9e
WCS – Position Encoding System 9f
Motor Powered Cable Reels 10
0603 · Printed in Germany · 2006-0904 · DS · 1500 · 4/06
PAUL VAHLE GMBH & CO. KG • WESTICKER STRASSE 52 • D 59174 KAMEN/GERMANY • TEL. (+49) 23 07/70 40
Internet: www.vahle.de • e-mail: [email protected] • FAX (+49) 23 07/70 44 44

Cat 2c E Insulated Conductor Systems U15 U25 U35

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Cat 2c E Insulated Conductor Systems U15 U25 U35

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INSULATED

Conductor code: Conductor spacing: Support spacing:

Type Weight kg Cat.-No.

UV 15 K 4 (1) 0.040 160 102

Standard shroud, color green High temperature shroud, color gray

Weight kg Cat.-No. Weight kg Cat.-No.

Corresponding to UV 15 K Cross-section connection

Type Weight kg Cat.-No. Type Weight kg Cat.-No.

UE 15 K 4(1) 0.040 160 107 UEG 15 K (1) 0.060 160 216

(1) with stainless steel hardware

Insulated hangers(2) Locating clamp

Type Weight kg Cat.-No. Type Weight kg Cat.-No.

UA 15 0.020 160 113 USK 15 K 4 (1) 0.030 160 106

Insulators(2) Rail holders

Type Weight kg Cat.-No. Type Weight kg Cat.-No.

GH 40-M 6 0.100 160 117 UAK 15 0.015 160 121

Compact hangers 2- to 7pole

Type Dim. A Dim. B Cat.-No. Weight kg

KH 15/2 36 – 161 559 0.012

KH 15/3 54 – 161 453 0.018

KA 15/4(2) 72 36 162 010 0.028

KA 15/5(2) 90 36 161 498 0.033

(1) with stainless steel hardware

Transfer guides for monorail systems

c/w feed USE 15 T

max. vertical and horizontal offset: 2 mm

Type feed terminal Weight kg Cat.-No.

US 15 T w/o 0.016 160 840

Anchor bars for monorail transfer guide

(1) with stainless steel hardware

Type feed terminal Weight kg Cat.-No.

(feed plug 6,3 x 0,8 mm) SE 15 feed plug

IT/U 15- 5 M 5 0.003 160 111

Type symbol comprising Weight kg Cat.-No.

Isolating assembly LT/LTE-U15

For ordering feed cable FLA see page 15.

End caps c/w locking pin 3 x 12

Type (1) Weight kg Cat.-No.

(1) Type M = factory assembled

Type A mm B mm C mm D mm Weight kg Cat.-No.

EFT U 15-2 - KSTU 44 130 157 180 2.960 161 747

Tranfer funnels for KSTLU / KDSTLU

570 w/o cond.

Type A mm B mm C mm D mm Weight kg Cat.-No.

EFT U 15-2 - KDSTLU 36 122 148 172 2.860 161 668

(1) Higher speeds on request.

EFT U 15-2 - KSFU 44 102 90 144 1.280 161 629

Type Conductor support spacing for straight runs for curves

Current collector Current collector

6.3 x 0.8 plug ZF 1

(1) Higher speeds on request. 11

(Connecting cable WFLA 2.5 to be ordered separately)

KSF 25-2 2 18 43 – 0.168 2pole – 155 038

other position on request.

Compact current collectors(1) max. 138

Poles a b c Weight Cat.-No.

Compact double current collectors (1)

Current collectors Double current collectors

c/w 2 m cable c/w 2 x 2 m cable