COPPERHEAD CONDUCTOR SYSTEM

PCSPH1

2

Steel-copperhead rails

Standar lengths: 6m

Main application:Conductor system for heavy monorails,down-shop and cross travel supply for medium duty cranes.

Type Copper cross section (mm2) Steel cross section (mm2) Equival total copper conductor (mm2)

Hmm

amm

bmm Weight (kg) Nominal current (A)

PCSPH15002O6PA 100 266 138 36 15 35 2,98 500

PCSPH16302P6PA 150 266 188 38,3 17 35 3,40 630

PCSPH17002Q6PA 200 266 238 40,8 17 35 3,86 700

Standar lengths: 6m

Main application:down-shop and cross travel supply for heavy duty cranes,loading bridges, coking machinery, rapid transit systems, etc

Type Copper cross section (mm2) Steel cross section (mm2) Equival total copper conductor (mm2)

Hmm

amm

bmm Weight (kg) Nominal current (A)

PCSPH16302R6PA 100 356 151 46 15 50 3,66 630

PCSPH17002S6PA 150 356 201 48,3 17 50 4,12 700

PCSPH18002T6PA 200 356 251 50,8 17 50 4,56 800

PCSPH110002U6PA 300 356 351 56,3 18 50 5,46 1000

PCSPH112002V6PA 400 356 451 59,3 20 50 6,36 1200

PCSPH113002Y6PA 500 356 451 64,3 20 50 7,26 1300

PCSPH115002W6PA 600 356 651 65 23 50 8,16 1500

The steel sections can be supplied galvanized or with anticorrosion paint

Accesories of steel-copperhead rails

Type Material Weight (kg)

PCSPH15002OEJ

brass

1,25

PCSPH16302PEJ 1,39

PCSPH17002QEJ 1,48

PCSPH16302REJ

brass

1,58

PCSPH17002SEJ 1,68

PCSPH18002TEJ 1,82

PCSPH110002UEJ 3,08

PCSPH112002VEJ 3,28

PCSPH113002YEJ 3,52

PCSPH115002WEJ 3,76

Type Material Weight (kg)

PCSPH12OPQRJ

cooper

0,42

PCSPH12RSTRJ 0,47

PCSPH12UVYWRJ 1,26

Expansion joints

Rigid joints

3

Accesories of steel-copperhead rails

Type Material Weight (kg)

PCSPH15002OFC

copper

0,19

PCSPH16302PFC 0,17

PCSPH17002QFC 0,22

PCSPH15002RFC

copper

0,23

PCSPH16302SFC 0,23

PCSPH17002TFC 0,21

Type Material Weight (kg)

PCSPH12OPQLCgalvanized

0,12

PCSPH12RSTLC 0,11

Locating clamps

Feeder clamps

Rail holders

Type Material Weight (kg)

PCSPHRH35I steel 0,22

PCSPHRH35II steel 0,38

PCSPHRH35IV steel 0,58

PCSPHRH50II steel 0,22

PCSPHRH50III steel 0,38

PCSPHRH50V steel 0,58

Rail holders

PCSPHRH35I PCSPHRH35II

PCSPHRH35IV

PCSPHRH50III PCSPHRH50V

4

Insulator (≤1000V)

Type or bolt lengths 30-40mmFor rail base Leakage-distance mm Rail mounting possibilities

Mechanical strengths (kp)Material Weight (kg)

Phase Ground Tension Compress Cantilever

PCSPHRIBTL10P PCSPHRIBTL10P

35mm50mm

70 1600 1500 600

resin

0,28

PCSPHRIBTL11P PCSPHRIBTL11P 80 1800 2000 900 0,58

PCSPHRIBTL12P PCSPHRIBTL12P 120 2100 2000 950 0,86

PCSPHRITL13P PCSPHRITL13P 65 1000 1500 450 0,18

PCSPHRIBL14P PCSPHRIBL14P 115 1600 200 650 0,65

PCSPHRITL15P PCSPHRITL15P 115 1600 2000 650 0,65

PCSPHRIBL16P PCSPHRIBL16P 125 2100 2000 950 0,88

PCSPHRITL17P PCSPHRITL17P 125 2100 2000 950 0,88

High voltage insulators

TypeVoltage Leakage-distance

mmRail mounting

possibilities

Mechanical strengths (kp)Material Max. Temperature ºC Weight (kg)

Phase Ground Tension Compress Cantilever

PCSPHRIHVBTL20P PCSPHRIHVBTL20G 35mm 60 1800 1800 770 resin 90 1,3

PCSPHPIHVBLL21P PCSPHPIHVBLL21G 6KV 220 2500 3000 550porcelain 140

3,35

PCSPHPIHVTL22P PCSPHPIHVTL22G 6KV 220 2500 3000 550 3,35

PCSPHPIHVBL23P PCSPHPIHVBL23G 20KV 400 2000 2500 500porcelain 140

7,2

PCSPHPIHVTL24P PCSPHPIHVTL24G 20KV 400 2000 2500 500 7,2

PCSPHRIBL14P PCSPHRITL15P PCSPHRIBL16P PCSPHRITL17P

PCSPHPIHVBLL PCSPHPIHVTL PCSPHRIHVBTL

5

Heavy duty current collectors

Cat. -NoCapacity A Material Dimensions

(mm) Weight (kg)Phase Ground Neutral

PCSPHCC400S4P PCSPHCC400S4G PCSPHCC400S4N 400 C412 100x140x30 11,82

PCSPHCC400S4MIP PCSPHCC400S4MIG PCSPHCC400S4MIN 400 C412 100x140x30 12,2

PCSPHCC400S4NMIP PCSPHCC400S4NMIG PCSPHCC400S4NMIN 400 C412 100x140x30 11,68

PCSPHCC400S4SMIP PCSPHCC400S4SMIG PCSPHCC400S4SMIN 400 C412 100x140x30 13,56

PCSPHCC400S4MSP PCSPHCC400S4MSG PCSPHCC400S4MSN 400 C412 90x125x15 11,67

Cat. -NoCapacity A Material Dimensions

(mm) Weight (kg)Phase Ground Neutral

PCSPHCC400S8P PCSPHCC400S8G PCSPHCC400S8N 800 C412 100x140x30 15,84

PCSPHCC400S8MIP PCSPHCC400S8MIG PCSPHCC400S8MIN 800 C412 100x140x30 15,69

PCSPHCC400S8NMIP PCSPHCC400S8NMIG PCSPHCC400S8NMIN 800 C412 100x140x30 15,46

PCSPHCC400S8SMIP PCSPHCC400S8SMIG PCSPHCC400S8SMIN 800 C412 100x140x30 18,26

PCSPHCC400S8MSP PCSPHCC400S8MSG PCSPHCC400S8MSN 800 C412 90x125x15 15,75

6

Installation

1. Install brackets to I beam or girder, weld or bolt on 2m (6’ 6’’) centers for L20, A20,C20 rails; 2,5m (8’ 3’’) centers for all other rails.Spacing between EMS rails is 150mm std. (6’’), min. 100mm (4’’) for L20, A20,C20 rails; 150mm std. (6’’), min. 120mm (5’’) for all other types.For high voltage installations: approx. 250mm (10’’) check alignment

2. Secure insulators/rail supports to brackets (in accordance with the mounting instructions) leaving bolts hand tight. for general arrangement see Fig. A. When placing the conductors intop the insulators, make sure that the bayonett clamp (incorporated in most EMS insulators) supports the rail sliding tight to allos forexpansion and contraction.Do not change the position (don’t turn rail holders) when tightening support bolts against steel brackets.

3. Connect the EMS rails by rigid- or expansion joints using the holes provided at the ends of the 6m (19,7’) sections. For systems up to 100m (330’) no expansion joints required. With longer runs use an expansion joint after every 6 standard lengths of 6m (19,7’’) intervals. For special heat environment and strong temperature fluctuations reduce these intervals to 28m (92’). For gap setting see adjacent diagram and example. Provide an extra insulator/rail support close to each expansion joint- approx. 250mm.

4. Anchor EMS rails for controlled sliding in both directions, by fitting two locating clamps close to the center insulator of the run or in the center between two expansion joints (see fig. B + C).

5. Install feeder clamps at feed points. Bolt to web of rail and braise to copperhead.

6. Prepare collector bracket to suite normal working height and fixing studs of current collectors and install collectors securely

Expansion diagram.IThe chart shows orientation lines for the different conductor rails, considering 42m expansion joint intervals.For gap setting move the orientation line in parallel up to the point presenting the anticipated max. ambient temperature.Then connect point of actual ambient temperature during installation tot the right until intersecting with the orientation line.Follow the vertical axis downward to read the air gap dimension in mm.Example:Ambient temperature 25ºCAir gap S - Rail= 19mmAir gap C - Rail= 24mmAir gap A - Rail= 33mm

Symbols:

Rigid Joint Insulator

Expansion Joint Insulator with locating clamps

7

Selection of heating cable

Determine a heating calbe of 30 a 45 W/m capacity.If no suitable result from adjacent diagrams, devide the length of the system into two or more heating sections.Supply lower voltage via a transformer in case of shorter heating sections.

Heating capacity (Watt/m)

2

2'LR

UN⋅

=

U= Supply Voltage (volt)R= Resistance of heating cable (ohm/m)L= Length of heating sections (m)

Wire resistance data:Heating cable: H0,48 0,48ohm/mHeating cable: H0,70 0,70ohm/mHeating cable: H0,90 0,90ohm/mHeating cable: H1,44 1,44ohm/mHeating cable: H2,00 2,00ohm/m Tolerance: ±2,5%Outside diameter: 4mm

Conductor: resistor material CrNi, strandedInsulation: TFE -(teflon-) insulation, natural colour, glass silk sheathSheath: V2a wire

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