Introduction
Attention! The copper thickness and width is crucial for power rails selecting!! Some companies reduce the copper to lower the price in the same ampere rating power rails.
Actually, it sacrifices your safety and privilege. Less copper will make your equipment consume more energy and sometimes the overheat will cause the fire!!
KYEC Safety Power Rails |
Type |
Part number |
Capacity
(A)
|
Copper
Thickness
(mm)
|
Copper
Width
(mm)
|
Weight
(Kg/m)
|
Three in one 75A |
KY-AN3007 |
75 |
2 |
10 |
0.8 |
Three in one 100A |
KY-AN3010 |
100 |
2.8 |
10 |
1.03 |
Three in one 150A |
KY-AN3015 |
150 |
3 |
10 |
1.14 |
Three in one 200A |
KY-AN3020 |
200 |
3.8 |
11 |
1.42 |
Four in one 75A |
KY-AN4007 |
75 |
2 |
10 |
1.1 |
Four in one 100A |
KY-AN4010 |
100 |
2.8 |
10 |
1.4 |
Four in one 200A |
KY-AN4020 |
200 |
3.8 |
11 |
1.9 |
Five in one 100A |
KY-AN5009 |
100 |
2.8 |
10 |
1.7 |
Six in one 75A |
KY-AN6007 |
75 |
2 |
10 |
1.64 |
Six in one 100A |
KY-AN6010 |
100 |
2.8 |
10 |
2.06 |
Safety Power Rails
The safety power rails are electrical conductors of various profiles that are used to provide electrical potential to moving systems along a path of travel which have 3-6 poles.
The safety power rails are available for a current load from 75A up to 200A mobile electrification technology for moving transpotation vehicles and equipment. Common application include: manufacturing robots, material handling system, hoist and cranes, automated storage facilities and retrieval systems.
Safety power rail systems are available in a variety of configuration depending on applications requirements. Enclosed conductor systems typically enclosed conductors in a protective conduit meeting safety standard.
General Tech. Info.
General technical information
- Conversion Table of Horse Power
Full Load Current Table of 3 Phase Alternating
Check the steps below first to select the correct current (Amper) of safety power rails and current collector:
1. Calculate the total motor's Horse Power (H.P) required. (ex. 10H.P)
2. Make sure the rated voltage(A.C.) (ex. 220V)
3. Get the current data by checking the above conversion table.(ex.27 Ampere)
- Safety Current Table of Conductor Wire Assembling
The safety current of safety power rails would perhaps be affected if the circuit temperature is over 35℃

Horse power= total kws/0.75; A=Horse Powerx3; (on the assumption 220V)
Total current [A.] x 1.25 = proper current
According to the ampere quantity, choose the type of safety power rail:
90A-200A : 3P-6P safety power rail
150A:I type safety power rail
120A 320A 500A 800A: W type safety power rail
Design
3P&4P&5P


3P Power Rail
3P Safety power rail





4P Power Rail
4P Safety power rail





5P Power Rail
5P Safety power rail





6P Power Rail
6P Safety power rail





3P 200A Power Rail
3P 200A Safety power rail



Test Result


4P 200A Power Rail
4P 200A Safety power rail





Box Power Rail
High Temperature Durable Box Safety Power Rail





Installment
3P、4P、5P、6P Installments Diagram
Step 1 Supports design

Remark:
(1) The lateral design installment recommened when a camber occurs to the 3~6P safety power rail assembly.
(2) The hanger clamps are supposed to be installed every 0.5 meter from the starting point of the turning.
(3) The 3~6P tension part for safety power rails must be installed at the place about 10mm higher than the hanger clamp.
This step prevents water from flowing to the power-in place along the safety power rails; hence the short circuit won't happen.
(4) The silica gel must be coated on the connected place of the power-in part and safety power railas weather protection.
(5) The 3~6P safety power rails are not suitable for outdoor usage or the place with high acid/alkaline environments.
Step 2 End tension & power in parts Remark: (1) Install one end on the ground then lift rail up to estimated location and install another.
Step 3 Hanger clamp

(1) Aim the hanger clamp with power rail and push up. (Below left diagram)
(2) Use a slotted screwdriver to dismantle the hanger clamp. (Below right diagram)


Step 4 End tension & power in parts *Install the end tension after the power rail is settled with the clamps

4-1 4-2


4-3 4-4

4-5


Step 5 Fix square bar/current collector
Remark:
(1)Fix square bar could be welded on the crane or screw used.
(2)Fix square bar’s angle is supposed to be mounted. One diagonal of the bar
must be parallel to ground and safety power rail, another is verticle.
(3)Length could be cut as demand.
(4)If carbon brushes worn, just replace a new one.


Current Collector Installation



Twin type current collector : Add one more V-shaped clamper
* Twin current collectors are choosed for undulated, rounded, or special profile.

3P Rail connector and middle power in
1. Cut off the PVC material at 35mm from the end of safety power rail.
2. Bend upward copper material in vertical 90∘angle.
3. Insert both sides of 90∘verticle angle safety power rail into middle power feeding and connect both sides by screwing up M6 inner hexagon screw bolt on U type copper connector.



Current Collector Unit
Current Collector Unit


I-type installment
I type safety power rail installment diagram



I type Power Rail
I type safety power rail










I type installment
I type safety power rail installment diagram
Step 1. Support Design
A. installment for I type in 30 meters B. installment for I type over 30 meters


Linear Case Curve Case



1. Distance of each hanger clamp must be under 0.5m in around type.
2. The way to pull up rail is use traverse table put on the saddle's beam, pull up the rail when crane moves.
(As the commentary picture no.3 shown in end cover)
Step 2 Length in 30M

Length over 30M

Step 3 Set & Hanger Clamp
Use tool to clip inward Plastic Clip and pull I-type Insulated Conductor Rails out together if necessary.
Middle power feed in
1. Cut off 80mm long of insulated material PVC in the middle of I-type Insulated Conductor Rails for supplying power.
1. Cut off 80mm long of insulated material PVC in the middle of I-type Insulated Conductor Rails for supplying power.
2. Contact Copper Conductor of I-type Insulated Conductor Rails by two piece of Copper Plate and fix it by M6 inner hexagon screw bolt.
3. Drill two holes Ø5mm through both Copper Plate and Copper Conductor of I-Type Insulated Cunductor Rails at the bottom and insert pins to connect and fix them.
Step 4 Set, End Tension & Power in
Step 5 Set, guide & Current Collector
Caution

(1) It is not allowed to incline over 15∘ when install I-type Insulated Conductor Rails.
(2) If I-type Insulated Conductor Rails Still incline after installtion, then it is required to adjust forcedly.
Application
Application


1. Current Collector Set 2. For Hoist


3. Round set 4. For Hoist (5P Power Rail)


5. Amusement Grounds 6. Automated Warehouse