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 technical information

  • Conversion Table of Horse Power

      Full Load Current Table of 3 Phase Alternating

power-rail-p2-1 

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

power-rail-p2-2

 

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 

 

3P&4P&5P

power-rail-p3-1

power-rail-p3-2

 

 

3P Safety power rail

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power-rail-p4-2

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power-rail-p4-4

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4P Safety power rail

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power-rail-p5-2

 power-rail-p5-3

power-rail-p5-4

power-rail-p5-5

5P Safety power rail

power-rail-p6-1

 power-rail-p6-2

power-rail-p6-3

power-rail-p6-4

power-rail-p6-5

 

6P Safety power rail

 power-rail-p7-1

power-rail-p7-2

power-rail-p7-3

power-rail-p7-4

power-rail-p7-5

3P 200A Safety power rail 

power-rail-p8-1

power-rail-p8-2

power-rail-p8-3

 

power-rail-p8-4

power-rail-p8-5

 

4P 200A Safety power rail

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power-rail-p9-2

power-rail-p9-3

power-rail-p9-4

power-rail-p9-5

High Temperature Durable Box Safety Power Rail 

 power-rail-p10-1

power-rail-p10-2

power-rail-p10-3

power-rail-p10-4

power-rail-p10-5

 

3P、4P、5P、6P Installments Diagram

Step 1 Supports design

power-rail-p11-1

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

power-rail-p11-2

(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)

 power-rail-p11-3power-rail-p11-4

 

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

power-rail-p11-5 power-rail-p11-6

4-1                                                                                  4-2

power-rail-p11-7power-rail-p11-8

4-3                                                                                 4-4

power-rail-p11-9 power-rail-p11-12

4-5

 power-rail-p11-10power-rail-p11-11

 

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.

power-rail-p12-1power-rail-p12-2

Current Collector Installation

power-rail-p12-4power-rail-p12-5

power-rail-p12-3

Twin type current collector : Add one more V-shaped clamper

* Twin current collectors are choosed for undulated, rounded, or special profile.

power-rail-p12-6

 

3P Rail connector and middle power in

power-rail-p13-1 

1. Cut off the PVC material at 35mm from the end of safety power rail.

2. Bend upward copper material in vertical 90angle.

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.

power-rail-p13-2

 power-rail-p13-3power-rail-p13-4

 

Current Collector Unit

power-rail-p13-5power-rail-p13-6

 

I type safety power rail installment diagram

power-rail-p14-1

power-rail-p14-2

                                     power-rail-p14-3

 

I type safety power rail

power-rail-p15-1

power-rail-p15-2

power-rail-p15-3

power-rail-p15-4

power-rail-p15-5

power-rail-p16-1

power-rail-p16-2

power-rail-p16-3

power-rail-p16-4

power-rail-p16-5

 

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 

power-rail-p17-1power-rail-p17-2

 Linear Case                                                                                       Curve Case

power-rail-p17-3

  • Around type

power-rail-p17-4

 

  • "S" type

power-rail-p17-5

 

  • Around & Relief type

      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

power-rail-p18-1

Length over 30M

power-rail-p18-2

Step 3 Set & Hanger Clamp

power-rail-p18-3   

Use tool to clip inward Plastic Clip and pull I-type Insulated Conductor Rails out together if necessary.

 

Middle power feed in

 power-rail-p18-41. 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

power-rail-p18-5 

Caution 

power-rail-p18-6

(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

power-rail-P19-1power-rail-P19-2

1. Current Collector Set                                          2. For Hoist 

power-rail-P19-3power-rail-P19-4

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

power-rail-P19-5power-rail-P19-6

5. Amusement Grounds                                         6. Automated Warehouse