CRL-1 / CRL-2 CABLE FESTOON SYSTEM Set up of a C-Rail System REQUIRED COMPONENTS

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1 CRL-1 / CRL-2 CABLE FESTOON SYSTEM Set up of a C-Rail System Based on the different cable trolley versions and numerous components you can compile your individual C-rail system. In addition to straight travelling direction we manufacure curved sections for special requirements with a minimal radius of 1000 mm. Depending on the application, the installation is carried out as ceiling or wall assembly to create a rigid system. TECHNICAL TERMS Staking length The staking length is the total length of all cable trolleys in a pushed together state. Travelling distance The travelling distance is the total length of the cable trolley system (without staking length). Sag The sag defines the distance between the bottom edge of the C-rail and the lowest point of the cable or hose. The maximum sag is achieved as soon as the cable trolleys are pushed together. Cable festoon system The whole system ist reffered as the cable festoon system, including the cable trolleys, C-rails und all other components. REQUIRED COMPONENTS For the optimal combination of a cable festoon system you will need the following components in according design and amount: Cables / hoses C-rail Depending on the application area CRL-1 or CRL-2 Rails are used. Cable trolley The cable trolley type is selected according to the C-rail and depends on the cable or hose package, the travelling speed, the weight load and the environmental influences. End support One end support is required for each cable festoon system. Towing attachment One towing attachement is required for each cable festoon system. C-Rail hangers Hangers for wall or ceiling mounting are required in a corresponding quantity depending on the system length, the suspension distance and the C-rail profile. C-Rail joints The required amount of joints depends on the system length and the C-rail profile. Rail stopper For every cable festoon system one rail stopper is required. Endcap For every cable festoon system two endcaps are required. Additional components: Towing trolley Driving trolley for the final connection unit Wall traverses Clamps/traverses for I-beam assembly

2 CRL-1 CABLE TROLLEY / END SUPPORT for Flat Cables, Rigid Plastic Design Art.-Nr / This cable trolley is designed for the CRL-1 C-rail to transport flat cables with a maximum height up to 15 mm. We offer this plastic cable trolley for maximum payload up to 8 kg. CRL-1 cable trolley for flat cables, rigid plastic design and related end support Trolley Support Clamping Material Rollers Pay- Travelling Rail Art.-No. End support length radius width / height load speed Art.-No. 85 mm 36 mm 55 mm 15 mm plastic plastic 8 kg 60 m/min CRL Ø24 R36 R Note: You ll find the related towing attachement (Art-No ) at the according data sheet.

3 CRL-1 CABLE TROLLEY / END SUPPORT for Flat Cables, Swinging Design Art.-Nr /...24 /...25 This cable trolley is designed for the CRL-1 C-rail to transport flat cables with a maximum height up to 15 mm. We offer two different types of cable trolleys, with either steel or plastic rollers, wich are suitable for different payloads. CRL-1 Cable trolley for flat cables, swinging design and related end support. Trolley Support Clamping Material Rollers Pay- Travelling Rail Art.-No. End support length radius width / height load speed Art.-No. 84 mm 25 mm 50 mm 15 mm steel (galvanised) (galvanised) plastic steel kg m/min CRL-1 8 kg Ø 24 R25 R Note: You ll find the related towing attachement (Art-No ) at the according data sheet.

4 CRL-1 CABLE TROLLEY / END SUPPORT for Flat Cables, Rigid Design Art.-Nr /...27 /...30 / /...31 /...34 This cable trolley is designed for the CRL-1 C-rail to transport flat cables with a maximum height up to 25 mm. We offer two different types, either a steel version with plastic or steel rollers, or a plastic version. CRL-1 Cable trolley for flat cables, rigid design and matching end support Trolley Support Clamping Material Rollers Pay- Travelling Rail Art.-No. End support length radius width / height load speed Art.-No. plastic 8 kg mm 25 mm 15 mm mm steel 60 m/min CRL-1 (galvanised) steel 15 kg (galvanised) mm 35 mm 25 mm 80 mm / / 125 1) Ø 24 1 R25 / R35 R25 / R35 1) = The end supports Art.-Nr and will be delieverd including a rail stopper / / / / 80 Note: You ll find the related towing attachement (Art-No ) at the according data sheet.

5 CRL-1 CABLE TROLLEY / END SUPPORT for Round Cables, Swinging Design Art.-Nr /... / /...48 / /...47 /...50 This cable trolley is designed for the CRL-1 C-rail to transport up to three supports for round cables or hoses with max. 28 mm diameter. We offer two different types of cable trolleys, with either steel or plastic rollers, wich are suitable for different payloads. CRL-1 Cable trolley for round cables/hoses, swinging design and related end support. Trolley Round Supports Material Rollers Pay Travelling Rail Art.-No. End support length cable amount / height load speed Art.-No. max. 1x 1 piece steel (galvanised) 15 kg mm 50 mm plastic 8 kg mm max. 2 x 2 pieces steel (galvanised) 15 kg steel 60 m/min CRL mm 100 mm (galvanised) plastic 8 kg max. 3x 3 pieces steel (galvanised) 15 kg mm 130 mm plastic 8 kg Ø24 50 / / Note: You ll find the related towing attachement (Art-No ) at the according data sheet.

6 CRL-2 CABLE TROLLEY / END SUPPORT for Flat Cables, Swinging Design Art.-Nr /...54 /...57 / /...62 /...65 /...66 This cable trolley is designed for the CRL-2 C-rail to transport flat cables with a maximum height up to 30 mm. We offer a steel version with two different clamping widths and support radii suitable for payloads up to 15 kg. CRL-2 Cable trolley for flat cables, swinging design and related end support Trolley Support Clamping Material Rollers Pay Travelling Rail Art.-No. End support length radius width / height load speed Art.-No. 120 mm 25 mm 35 mm 60 mm mm 100 mm steel steel 15 kg 60 m/min CRL-2 60 mm (galvanised) (galvanised) mm 100 mm Ø 33 Ø 8,5 R25 / R35 R25 / R / / / 100 Note: You ll find the related towing attachement (Art-No ) at the according data sheet. 60 / 100

7 CRL-2 CABLE TROLLEY / END SUPPORT for Flat Cables, Rigid Design Art.-Nr /...79 /...84 / /...85 /...87 This cable trolley is designed for the CRL-2 C-rail to transport flat cables with a maxim height up to 30 mm. We offer a steel version with clamping widths from 60 mm to 150 mm, suitable for payloads up to 35 kg. CRL-2 Cable trolley for flat cables, rigid design and related end support Trolley Support Clamping Material Rollers Pay- Travelling Rail Art.-No. End support length radius width / height load speed Art.-No. 150 mm 35 mm 60 mm mm 100 mm mm 150 mm 30 mm steel steel 35 kg 60 m/min CRL (galvanised) (galvanised) 60 mm mm 100 mm mm / Ø 33 R35 / R50 / R70 R35 / R50 / R / 1 00 / / 100 / 150 Note: You ll find the related towing attachement (Art-No ) at the according data sheet.

8 CRL-2 END SUPPORT / TOWING ATTACHMENT for CRL-2 Cable Trolley for Round Cables, Swinging Design Art.-Nr /...47 This towing attachment and the according end support are required for CRL-2 C-rail systems incl. cable trolley (Art ) for round cables. One end support and one towing attachment are necessary in each system. Towing attachment for round cables, swinging design Towing attachment Material Rollers Payload Travelling Rail Art.-No. length speed 100 mm steel (galvanised) steel (galvanised) 30 kg 60 m/min CRL End support for round cables, swinging design Material Art.-No. Ø33 steel (galvanised) Ø ,5

9 CRL-2 CABLE TROLLEY for Round Cables, Swinging Design Art.-Nr This cable trolley is designed for the CRL-2 C-rail system to transport supports for round cables and/or hoses up to 35 mm diameter and payloads up to 30 kg. Plan your customerspecific system by using the cable supports and the clamp connectors. CRL-2 Cable trolley for round cables and hoses, swinging design Trolley length Material Rollers Payload Travelling Rail Art.-No. speed 100 mm steel (galvanised) steel (galvanised) 30 kg 60 m/min CRL CRL-2 Leitungsklemmen 100 Round cable Material Art.-No mm Ø mm Ø aluminium Ø mm Ø CRL-2 Cable clamp connector for cable supports Art.-No Ø / Ø / Ø ,5

10 DRIVING TROLLEY for CRL-1 or CRL-2 Rail System Art.-No / The driving trolley is available for the CRL-1 as well as for the CRL-2 rail systems. It can be used to control crane systems for exemple. For accurate design we need relevant informations on the used cables and cable trolleys, as well as the intended purpose. Driving trolley Material Wheel Travelling Rail Art.-No. speed plastic / steel (galvanised) steel (galvanised) by hand CRL CRL

11 CARRYING TROLLEY for CRL-1 or CRL-2 Rail System Art.-Nr / / / Our Carrying trolleys are available for the CRL-1 as well as for the CRL-2 rail systems. They are used for workshop equipment, for example welding courtains. Carrying trolley Material Wheel Payload Traveling Rail Art.-No. speed steel (galvanized) steel (galvanised) plastic 5 kg CRL kg by hand CRL kg CRL kg CRL Ø Ø Ø Ø

12 TOWING ATTACHEMENT for CRL-1 or CRL-2 Cable Trolleys Art.-Nr / / Towing attachement for direct mounting onto a CRL-1 and CRL-2 cable trolley. CRL-1 towing attachement Material Wheel Art.-No. steel (galvanised) plastic steel (galvanised) CRL-1 towing attachement plastic Material Wheel Art.-No. plastic plastic Ø R20 CRL-2 towing attachement Material Wheel Art.-No. steel (galvanised) steel (galvanised) Ø R20

13 C-RAIL for CRL-1 or CRL-2 Rail System Art.-No / / C-Rail-Profiles - the basic component for your system. The standard length is 6 m. CRL-1 Rail Material Art.-No. steel (galvanized) stainless steel (1.4571) CRL-2 Rail Material Art.-No. steel (galvanized) stainless steel (1.4571) ,

14 CEILING-/WALL SUSPENSION for CRL-1 or CRL-2 Rail Systems Art.-Nr / / Ceiling and wall suspensions for CRL-1 and CRL-2 rail systems. Ceiling installation Material Rail Art.-No. steel (galvanized) CRL CRL M10 M M M Wall installation Material Rail Art.-Nr. steel (galvanized) CRL CRL max max M8 8 M

15 TRAVERSE & CLAMP for CRL-1 and CRL-2 Rail Systems Art.-No /... /...90 /...91 / /...28 /...30 /...31 / / As a component the traverses serve in combination with the clamps for the side mounting of CRL-1 or CRL-2 C-rails to existing beams. Please select the corresponding traverses and clamps depending on the required rail system. Clamps Clamp width (a) Art.-No mm mm CRL1-Traverse Traverse length Drilling Art.-No. 300 mm mm mm 11 mm mm mm CRL2-Traverse Traverse length Drilling Art.-No. 300 mm mm mm 13 mm mm mm M M10 15 a a

16 RAIL JOINTS for CRL-1 or CRL-2 Rail System Art.-No / Rail joints for CRL-1 and CRL-2 rail systems. Rail joints Material Size Rail A 100 mm CRL steel (galvanized) 120 mm CRL mm CRL M8 M8 M M10 M8 120

17 RAIL STOPPER and END CAPS for CRL-1 or CRL-2 Rail System Art.-No /...11 Rail stopper and end caps for CRL-1 and CRL-2 rails to complete your C-rail systems. Rail stopper Material Wheel Art.-No. steel (galvanized) CRL-1 und CRL End caps Material Wheel Art.-No. plastic CRL CRL M8

18 WALL TRAVERSE for CRL-1 and CRL-2 Rail Systems Art.-Nr /...30 /...31 /...33 /...34 The wall traverses are a basic component for lateral wall mounting of the CRL-1 or CRL-2 C-rail systems. Please choose the according traverse length depending on the required wall distance. Wall traverse Length Material Art.-No. 300 mm mm mm steel (galvanised) mm mm

19 CRL-1 / CRL-2 C-RAIL SYSTEM System Design SYSTEM DESIGN 1 Cables / Hoses Determination of the required cables or hoses. 2 Cable trolley Determination of the ideal kind of cable trolley based on type of cable/hose in considiration of the amount and weight of the cables/hoses. The additional weight of transported goods (e.g. water, oil) in hoses, needs to be considered. Recommended ambient temperature for plastic cable trolleys: - 30 C up to + 50 C for steel cable trolleys: - 30 C up to + 80 C 3 Sag Determination of the sag based on the available space. Local circumstances (Avoid contact with fixed equipment in operation area.) Curved sections (In curved systems the sag has to be smaller than ¹/³ of the curve radius.) We reccomend a sag of 300 mm up to 2000 mm. The bigger the sag, the less cable trolleys are needed. 4 Travelling distance Determination of the travelling distance. 5 Number of cable trolleys Determination the number of cable trolleys based on the travelling distance and the sag by the following formula: travelling dist. (mm) Number of trolleys = 0,55 x sag (mm) The result already includes the towing attachement and the end support - round up to the next higher value if necessary. 6 System length Determination of system length trough adding up the travelling distance and staking length (cable trolley length x amount) 1% in addition for safety. 7 Cable / hose length Determination of the cable or hose length trough adding up the following distances: Connection point end support Staking length + 10% Travelling distance + 10% Towing attachment consumer 8 Rail Determination of the rail based on the chosen cable trolley type. SYSTEM CALCULATIONS Cable / Hose Weight/m (kg) Cable trolley type Length (mm) Length (mm) Sag Length (mm) Travelling distance Total amount cable trolleys (rounded up) travelling distance in mm 0,55 x + 2 sag in mm Number (pieces): Total length (mm): System length (mm) travelling distance + staking length plus 1% Cable / hose length Anschlusspunkt Endtrage Staking length + 10% Travelling distance + 10% Towing attachement consumer Total length (mm): Total weight (kg): Rail Length (mm) CRL-1 / CRL-2

20 CRL-1 / CRL-2 CABLE FESTOON SYSTEM Set up of a C-Rail System Travelling distance = x A² = x A³ Staking distance A¹ A² A³ A¹ Joints Rail stopper Suspension Towing attachement Cable trolley End cap End cap CRL - Rail End support Mounting distance A¹ Mounting distance A² Mounting distance A³ For both systems, CRL-1 and CRL-2, the first Travelling area Staking area suspension is installed in a distance of 200 mm Maximum suspension distance: Suspension distance: to the lateral C-rail end. CRL-1 System = 1500 mm CRL-1 System = 750 mm CRL-2 System = 2500 mm CRL-2 System = 1250 mm Note: The end caps are 15 mm deep in the C-rail profile after assembling. We reccomend to fix the rail stoppers directly behind the end cap. The C-rail profiles are available in a 6 meters standart length and are firmly connected with the according joints. Please have a look at the data sheets for exact measurements.