C-Rail Festoon track systems

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Kristopher Lester
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1 C-Rail Festoon track systems & Hose carrying systems Application C-Rail festoon track systems are the ideal solution for carrying cables supplying power to many types of moving machinery using either flat or round cables, typical uses include power feeds to hoists, factory cranes and pendant control systems. They can also be used to carry hoses for air, water, etc. A complete range of standard fittings is available for these systems along with a comprehensive selection of trolleys with carrying capacities up to 40kg / trolley. Standard track and components are manufactured from zinc plated steel and are suitable for the majority of industrial applications, where extra protection is required most components can be supplied with a polyester / epoxy coating and for extreme applications track and components are also available. C-Rail festoon systems are also available for Ex rated Hazardous areas classified in Group 1 & 2 (Gas) & Group 21 & (Dust) - details of these systems are shown later on in this section. System Calculations (see drawing opposite) System ( size) selection System max cable stack = 58mm x mm, max trolley load = kg System max cable stack = 115mm x 50mm, max trolley load = 40kg Length For correct installation the cable should never be pulled tight, we therefore recommend a % surplus be added to the overall track length, the calculation for cable length is shown below : Total cable length = (overall track length x 1.2 ) + required tail lengths. Example Overall track length =15m Tail at Hoist end = 0.50m Tail at Feed end = 3m Total cable length = (15 x 1.2) = 21.5m Number of Trolleys The number of trolleys required in the system is determined by the cable loop depth, so using the information above we can calculate the number of trolleys Required as follows : No. of trolleys = [(overall track length x 1.2 ) / (2 x Loop depth)] - 1 Example Overall track length =15m Loop depth = 0.m No. of Trolleys = [(15 x 1.2) / (2 x 0.)] - 1 = 11 In addition you require 1 x Tow Trolley & 1 X End Anchor Trolley selection The correct trolleys should be selected by referring to the maximum cable stack, and maximum cable weight information shown on the trolley information on the following pages, maximum recommended cable stacks are calculated to ensure that trolley bodies will come together before the loops of cable clash or foul each other.

C-Rail Festoon track systems & Hose carrying systems Parking Distance (see below) The parking distance is the section of track taken up by the trolleys when collected together at the end of the

m Trolley type 2401-5 (mm body length) Tow trolley 2401-6 (mm body length) end anchor 2331-2 (mm body length) No.

trolley Support arm Installation Installation of the C-Rail festoon system is very straightforward and can easily be carried out by a team of two accomplished installation engineers.

2 C-Rail Festoon track systems & Hose carrying systems Parking Distance (see below) The parking distance is the section of track taken up by the trolleys when collected together at the end of the system, this is a simple calculation determined by the number and type of trolleys. Example Overall track length =15m Loop depth = 0.m Trolley type (mm body length) Tow trolley (mm body length) end anchor (mm body length) No. of trolleys = 11 Parking distance = + (11 x ) + = 1040mm Festoon Assembly Overall track length Parking distance Travel distance profile Endstop Joint support end anchor trolley loop length Towing trolley Support arm Installation Installation of the C-Rail festoon system is very straightforward and can easily be carried out by a team of two accomplished installation engineers. Support centres (as shown below) are 1667mm for system 2331 (5m Lengths) and 1500mm for systems 2500/400 (3m/6m Lengths). A support should always be included within 0mm of a track joint as indicated. A variety of supports & support brackets are available and are detailed on the following pages. Support Details mm (sect 2331) 1500mm (sect 2500) 1667mm (sect 2331) 1500mm (sect 2500) 5000mm Std section length (sect 2331) 00mm Std section length (sect 2500/400) 1667mm (sect 2331) 1667mm (sect 2331) mm (sect 2500) 1500mm (sect 2500) C-Rail Festoon Systems

System 2331 C-Rail Festoon System x mm C-Rail

Length Weight kg/m Finish 2331-1 5 metres 1.

Single Stud Support Finish 2331-A-4-R Galv.

or Threaded plate 36 9 mm x mm x 5mm M8 x

Head Bolt DIN931 35 support arms from 2331-1

CM-2) support arms from 2331-1 CM-2) Support

3 System 2331 C-Rail Festoon System x mm C-Rail & Hose carrying system Profile Standard Length Weight kg/m Finish metres 1.32 Galv SS 5 metres 1. Single Stud Support Finish 2331-A-4-R Galv A-4-R- +Red M8 Galv. or Standard Profile Length = 5 Metres 12 Ceiling Support (Preferred) Finish A Galv A- +Red Galv. or Ceiling Support (Optional) Finish Galv Red Galv. or SS Support Finish Galv Red Galv. or Beam Clip Finish Galv Red Galv. or Threaded plate 36 9 mm x mm x 5mm M8 x 40mm Hex. Head Bolt DIN support arms from track profile (see part no. CM-2) support arms from track profile (see part no. CM-2) Support Arm Finish CM Galv./ Support arm complete for track profile consists of:- 2 x Beam clip x support x 500mm length profile For special lengths substitute required length L for 500 in the part no. e.g. for L = 0mm, part no = CM-2-0 L Bean clip Ref support Ref

4 System 2331 x mm C-Rail & Hose carrying system Joint (Preferred) Finish E Galv E- +Red 50 M5 Bolt heads Galv. or Joint (Optional) Finish Galv Red Galv. or SS M mm dia site 34 1 Endstop Finish 29-2 Galv Red Galv. or Clamp Max Width B-58 58mm B-65 65mm B-90 90mm B mm Other sizes available on request B Welded Beam Fixing Clamp Finish Galv. Use with 2500 Arms M8 x 1 10 x deg Trolley Red Galv. Galv. or Trolley Galv. Galv. or = kg = kg Trolley (Long body) Red 126 Galv. Galv. or = 58 x mm = kg Trolley (Long body) C C- +Red CH -5-SS Red 125 Galv. Galv. or = 58 x mm = kg C-Rail Festoon Systems

5 System 2331 x mm C-Rail & Hose carrying system Towing Trolley Red Galv. Galv. or Towing Trolley Red 2401-C C CH -6-SS +Red Galv. Galv. or = kg = kg = kg = kg Towing Trolley (Long body) Galv. Galv. or Towing Trolley (Long body) Red Galv. Galv. or = kg = 58 x mm = kg = 58 xmm = kg End Anchor Red Galv. or End Anchor 2331-C C C-2 -SS +Red +Red Galv. or = kg Anchor = 58 x mm = kg 2331 Anchor = 58 x mm = kg

System 2331 x mm C-Rail & Hose carrying system Pendant

Gland Pendant Trolley (Plug & Socket) Clip 21-7-C- 10

2331-7-10-10 Pole Plug & Socket 2331-7-16-16 Pole Plug &

Pole Plug & Socket Also available in 4 Wheel Curtain Trolley

S-35 23-D- -SS 23--SS 11 dia 100 70 10 dia 29 50 Max Trolley

4 Material: Zinc plated steel Max load per hook = 16 kg 5

2338-2 End Anchor N/A Galv. dia 60 2338-6 Tow Trolley Galv.

2338+C-2 Tow Trolley 100 70 54 43 Towing attachment from

shown: Trolley 2338+C+B+A+S Holder A B C /Hose dia.

aluminium RAL9006 polyester Black plastic end cap All cable

6 System 2331 x mm C-Rail & Hose carrying system Pendant Trolley (Plug & Socket) & Plate Gland Pendant Trolley (Plug & Socket) Clip 21-7-C C C- 24 & Plate Gland Clip dia 2 dia Pole Plug & Socket Pole Plug & Socket Pole Plug & Socket Pole Plug & Socket Pole Plug & Socket Pole Plug & Socket Also available in 4 Wheel Curtain Trolley & Axles 2 Wheel Curtain Trolley & Axles S Hook 23-D- 23- S D- -SS 23--SS 11 dia dia Max Trolley load = 16 kg 5 dia dia Max load / Trolley = 8 kg 35 4 Material: Zinc plated steel Max load per hook = 16 kg 5 Round / Hose Trolleys Item Trolley Galv End Anchor N/A Galv. dia Tow Trolley Galv dia End Anchor Example shown: End Anchor 2338+C-2 Tow Trolley Towing attachment from zinc Example shown: Tow Trolley 2338+C dia 60 Example shown: Trolley 2338+C+B+A+S Holder A B C /Hose dia. 8mm 15mm 16mm 24mm 25mm 35mm 85 Zinc plated steel + aluminium RAL9006 polyester Black plastic end cap All cable holders manufactured from aluminium C-Rail Festoon Systems

MOTIV- 8 FLEXIBLE CABLE SYSTEMS. www. James Crane.com.au PH:

MOTIV- 8 FLEXIBLE CABLE SYSTEMS. www. James Crane.com.au PH: MOTIV- 8 FLEXIBLE SYSTEMS www. James Crane.com.au PH: 1300 780 420 Email: Robert@jamescrane.com.au CONTENTS System Selection Enquiry Sheet Carrying Capacity kg Recommended Maximum Speed (m/min) Wire Rope