Cable Trolleys for C-Rails Program 02 0 0260
Contents C-Rail and Accessories Program 02 C-Rail x... 4 Track Coupler... 4 End Stops... 4 Track Support Brackets... 4 Support Arm and Girder Clip... Brackets... Cable Trolleys Program 02 Cable Trolleys for Flat Cables... 6 Cable Trolleys for Round Cables... 7 Pairs of Rollers for Cable Trolleys... 7 C-Rail and Accessories Program 0 C-Rail 63 x 63... 8 Track Coupler... 8 End Stops... 8 Track Support Brackets... 8 Support Arm and Girder Clip... 9 Brackets... 9 Cable Trolleys Program 0 Cable Trolleys for Flat Cables... 10 Cable Trolleys for Round Cables... 11 Pairs of Rollers for Cable Trolleys... 11 C-Rail and Accessories Program 0260 C-Rail x... 12 Track Coupler... 12 End Stop... 12 Track Support Bracket... 12 Brackets... 13 Cable Trolleys Program 0260 Cable Trolleys for Flat Cables... 14 Cable Trolleys for Round Cables... 1 Pairs of Rollers for Cable Trolleys... 1 Cable Trolleys Light Version Cable Trolleys for Flat Cables... 16 Cable Trolleys for Round Cables... 16 Trolleys with 4 Rollers... 17 Spring Safety Hook... 17 End Stops... 17 Accessories for Festoon Systems Program 02, 0 and 0260 Towing Ropes... 18 Damping Devices... 18 Round Cable Clamps... 19 Spacers... 19 Flat Cable Organizer... 20 Helpful Hints / Spare Parts Helpful Hints... 21 Wear Parts... 3
C-Rail and Accessories Program 02 C-Rail x 3. 16 38.6 6000 0100* Material: sendzimir galvanized steel Weight: 4.36 kg/m Stanrd Length: 6 m l x = 17.8 cm 4 ; W x = 6.4 cm 3 Track Coupler 4 2 160 010* 1. Weight: 1.0 kg End Stops M10 170. 108 0110 without Rubber Buffer 0111* with Rubber Buffer ø 37 67 Weight: 1.0 kg 43 60 To avoid system mage we recommend the fitting of a securing bolt as illustrated. Track Support Brackets 130 100 ø 11 40 0121 4 2 1. 8 Perm. Load: 320 kg Weight: 0.8 kg 130 100 M 10 40 0123 1. 4 2 8 4 Perm. Load: 320 kg Weight: 0.9 kg 4
C-Rail and Accessories Program 02 Track Support Bracket 130 100 M 10 40 0122* 1. 4 83 8 Hardware: galvanized steel Perm. Load: 320 kg Weight: 0.9 kg Support Arm and Girder Clip l ød 60 min. 7 Girder clip Support arm Track support bracket C-Rail Description l Weight Support arm 020277-1000* 1000 4.4 Material: sendzimir galvanized steel Description ø d Weight Girder clip 0201-12/* M12 0.3 Material: galvanized steel Brackets 1 ø17 160 8 l l Material 020191-00 0 3.8 galvanized steel 020191-00 0.1 Weight
Cable Trolleys Program 02 Cable Trolleys for Flat Cables lw ø 40 k 106 Max. Load Capacity: kg Max. Travel Speed 100 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm ø 40 Ordering Example: Cable Trolley for Flat Cable 2 112 162 Towing Trolley le le - 23 a 24 238 Example: Order a cable trolley with stanrd-rollers for a flat cable package with a size of 110 x 4 mm (width x thickness). Selected: Cable Trolley with d a = 1 mm (According to minimum bend diameter of cable) b 2 = 130 mm s = mm : Cable Trolley : 02-2x160 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a 02-160x100* 1.7 0260-200x100* 2.7 0240-160x100* 1. 100 70 160 84 3 200 74 02-160x160* 1.9 0260-200x160* 3.1 0240-160x160* 1.8 160 130 02-200x100 1.9 0260-200x100 2.7 0240-200x100 1.8 100 70 200 124 200 100 114 02-200x160* 2.2 0260-200x160* 3.1 0240-200x160* 2.0 160 130 02-200x160* 2.3 0262-200x160* 3.2 0242-200x160* 2.2 200 124 160 130 30 200 100 114 02-2x100 2.3 0262-2x100 3.1 0242-2x100 2.2 100 70 1 02-2x160* 2.6 0262-2x160* 3. 0242-2x160* 2. 2 174 160 130 2 1 164 02-2x200 3.0 0262-2x200 3.8 0242-2x200 2.9 200 170 03-2x160* 2.9 0263-2x160* 3.8 0243-2x160* 2.8 17 130 160 2 174 40 2 1 164 03-2x200 3.2 0263-2x200 4.0 0243-2x200 3.1 21 170 l w k b 1 b 2 s l m l e a 6
Cable Trolleys Program 02 Cable Trolleys for Round Cables lw ø 40 k 11 Max. Load Capacity: kg Max. Travel Speed 100 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm ø 40 Ordering Example: Cable Trolley for Round Cable 2 112 162 Towing Trolley le le - 23 a 24 283 Example: Order a cable trolley with rollers with seal disks for several round cables ø mm and a support width of 200 mm. Selected: Cable Trolley with d a = 2 mm (According to minimum bend diameter of cable) b 2 = 21 mm Roller with Seal Disks 2 RS.../010 : Cable Trolley : 03-320x2/010 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b 1 034-2x160* 3.7 0364-2x160* 4. 0344-2x160* 3.6 17 1 200 2 174 034-2x200* 4.0 0364-2x200* 4.8 0344-2x200* 3.9 21 16 03-320x160* 4.3 036-320x160*.1 034-320x160* 4.2 17 1 2 320 244 03-320x2*.3 036-320x2* 6.1 034-320x2*.2 26 21 037-400x160.1 0367-400x160.9 0347-400x160.0 17 1 320 400 324 037-400x2 6.2 0367-400x2 7.0 0347-400x2 6.0 26 21 b 2 s l m l e a 20 2 1 164 320 160 234 32 400 200 314 Pairs of Rollers for Cable Trolleys Program 02 Description Roller Type Sealing Type Load Capacity Special Roller Additional- Stanrd Roller 2 Z - Ball Bearing, galvanized steel Roller with Seal Disks 2 RS.../010 7
C-Rail and Accessories Program 0 C-Rail 63 x 63 63 6000 63 4 16 0600* Material: sendzimir galvanized steel Weight: 6. kg/m Stanrd Length: 6 m l x = 44.4 cm 4 ; W x = 13.0 cm 3 Track Coupler 6. 200 060* 64. 26 Weight: 1.9 kg End Stops M12 204. 123 120 0610 without Rubber Buffer 0611* with Rubber Buffer ø 36 4 7 Weight: 2. kg 43 To avoid system mage we recommend the fitting of a securing bolt as illustrated. Track Support Brackets 33 18 97 26 6. 64. 33 30 13 60 100 0621 Perm. Load: 0 kg Weight: 1.6 kg 18 130 M 12 60 0623 26 64. 30 60 Perm. Load: 0 kg Weight: 1.8 kg 6. 100 8
C-Rail and Accessories Program 0 Track Support Bracket 18 130 M 12 60 0622* 26 64. 30 Perm. Load: 0 kg Weight: 1.8 kg 6. 100 Support Arm and Girder Clip l ød 60 min. 100 Girder clip Support arm Track support bracket C-Rail Description l Weight Support arm 020273-1000* 1000 6.6 Material: sendzimir galvanized steel Description ø d Weight Girder clip 0201-12/* M12 0.3 Material: galvanized steel Brackets ø17 63 160 63 1 8 l l Material 020192-00 0 4.8 galvanized steel 020192-00 0 6.8 Weight 9
Cable Trolleys Program 0 Cable Trolleys for Flat Cables lw lw 1) ø 2 k 133 Max. Load Capacity: kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 2 Ordering Example: Cable Trolley for Flat Cable 2 112 93 133 Example: Order a cable trolley with stanrd-rollers for a flat cable package with a size of 140 x mm (width x thickness). Towing Trolley Selected: Cable Trolley with d a = 1 mm (According to minimum bend diameter of cable) b 2 = 168 mm s = mm le le - 32 a 30 : Cable Trolley : 0772-2x200 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b 1 0772-220x160* 3.4 0782-320x160* 4.9 0792-320x160* 3. 160 128 220 1) 14 0772-220x200 3.6 0782-320x200.1 0792-320x200 3.8 200 168 1 0772-2x160* 3.6 0782-320x160* 4.9 0792-320x160* 3. 160 128 2 14 0772-2x200* 3.8 0782-320x200*.1 0792-320x200* 3.8 200 168 0773-290x160 4.2 0783-320x160.2 0793-320x160 3.8 17 128 290 1) 224 0773-290x200 4.3 0783-320x200.3 0793-320x200 4.0 21 168 160 0773-320x160* 4.3 0783-320x160*.2 0793-320x160* 3.8 17 128 320 224 0773-320x200* 4. 0783-320x200*.3 0793-320x200* 4.0 21 168 0774-320x160 4. 0784-320x160.3 0794-320x160 4.0 17 128 200 320 224 0774-320x200 4.8 0784-320x200.6 0794-320x200 4.3 21 168 b 2 s l m l e a 40 160 160 204 160 160 204 160 160 204 70 160 160 204 160 160 204 10
Cable Trolleys Program 0 Cable Trolleys for Round Cables lw ø 2 k 13 Max. Load Capacity: kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 2 Ordering Example: Cable Trolley for Round Cable 2 112 93 13 Example: Order a cable trolley with rollers with seal disks for several round cables ø mm and a support width of 200 mm. Towing Trolley Selected: Cable Trolley with d a = 2 mm (According to minimum bend diameter of cable) b 2 = 211 mm Roller with Seal Disks 2 RS.../01 le le - 32 a 30 : Cable Trolley : 087-320x2/01 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b 1 087-320x200*.3 088-320x200* 6.1 089-320x200* 4.7 21 161 2 320 224 087-320x2*.8 088-320x2* 6.6 089-320x2*.3 26 211 0877-400x200* 6.2 0887-400x200* 7.0 0897-400x200*.7 21 161 320 400 304 0877-400x2* 6.7 0887-400x2* 7. 0897-400x2* 6.2 26 211 b 2 s l m l e a 160 160 204 32 200 200 284 Pairs of Rollers for Cable Trolleys Program 0 Description Roller Type Sealing Type Load Capacity Special Roller Additional- Stanrd Roller 2 Z - Ball Bearing, galvanized steel Roller with Seal Disks 2 RS.../01 11
C-Rail and Accessories Program 0260 C-Rail x 6000 140* 18 6 l x = 117.8 cm 4 ; W x = 27.4 cm 3 Weight: 10.6 kg/m Stanrd Length: 6 m Track Coupler 6 83 2 02610* 82 Weight: 3.6 kg 34 End Stop M12 204. 123 120 40 4 026111* with Rubber Buffer Weight: 2.4 kg ø 7 43 To avoid system mage we recommend the fitting of a securing bolt as illustrated. Track Support Bracket 33 18 97 33 30 13 60 026121* 6 34 83 82 120 Perm. Load: 630 kg Weight: 2.4 kg 12
C-Rail and Accessories Program 0260 Track Support Brackets 18 130 34 82 30 M 12 60 60 026123 Perm. Load: 630 kg Weight: 2. kg 6 83 120 18 130 M 12 60 026122 6 34 83 82 30 120 ø17 200 Perm. Load: 630 kg Weight: 2. kg Brackets 160 10 l l Material 020193-00 0 8.4 galvanized steel 020193-00 0 11.6 Weight 13
Cable Trolleys Program 0260 Cable Trolleys for Flat Cables lw ø 62 k 109 Max. Load Capacity: 1 kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 62 Ordering Example: Cable Trolley for Flat Cable 2 112 109 Example: To order a cable trolley with stanrd-rollers for a flat cable package with a size of 160 x 60 mm (width x thickness). Towing Trolley Selected: Cable Trolley with d a = 160 mm (According to minimum bend diameter of cable) b 2 = 168 mm s = 70 mm le le - 32 a 36 : Cable Trolley : 026273-320x200 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b 1 026272-2x160* 4.6 026282-320x160*.9 026292-320x160* 3.6 17 128 026272-2x200* 4.9 026282-320x200* 6.2 026292-320x200* 3.9 1 2 14 21 168 026272-2x2.2 026282-320x2 6.6 026292-320x2 4.3 26 218 026273-320x160*.2 026283-320x160* 6.1 026293-320x160* 3.7 17 128 026273-320x200.6 026283-320x200 6.4 026293-320x200 4.1 160 320 224 21 170 026273-320x2* 6.0 026283-320x2* 6.8 026293-320x2* 4. 26 218 b 2 s l m l e a 160 160 204 70 160 160 204 14
Cable Trolleys Program 0260 Cable Trolleys for Round Cables lw ø 62 k 148 Max. Load Capacity: 1 kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 62 Ordering Example: Cable Trolley for Round Cable 2 112 148 Example: Order a cable trolley with rollers with seal disks for several round cables ø 32 mm and a support width of 108 mm. Towing Trolley Selected: Cable Trolley with d a = 320 mm (According to minimum bend diameter of cable) b 2 = 211 mm Roller with Seal Disks 2 RS.../01 le le - 32 8 a 36 : Cable Trolley : 026377-400x2/01 79 ø 32 48 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b 1 02637-320x200*.9 02638-320x200* 6.7 02639-320x200* 4.8 21 161 2 320 224 02637-320x2* 6.4 02638-320x2* 7.3 02639-320x2*.4 26 211 026377-400x200 6.8 026387-400x200 7.7 026397-400x200.8 21 161 320 400 304 026377-400x2 7.3 026387-400x2 8.2 026397-400x2 6.3 26 211 b 2 s l m l e a 160 160 204 32 200 200 284 Pairs of Rollers for Cable Trolleys Program 0260 Description Roller Type Sealing Type Load Capacity Special Roller Additional- Stanrd Roller 2 Z - Ball Bearing, galvanized steel 1 Roller with Seal Disks 2 RS.../01 1
r Cable Trolleys Light Version Cable Trolleys for Flat Cables 1 D 10 a 4 4 ø d 4 Cable Trolley Main Body: sendzimir galvanized steel Buffer: rubber Support: plastic End Clamp Insulating Plate: plastic Split Nut: plastic Hardware: galvanized steel For C-Rail Program x 02 63 x 63 0 x 0260 Cable Trolley End Clamp D ø d a 0270-1x0* 0.4 0290* 0.20 42 3 0271-1x0* 0.47 0291* 0.23 42 20 0770-1x0* 0.6 0290* 0.20 38 3 32 0771-1x0* 0.8 0291* 0.23 38 20 026270-1x0* 0.8 0290* 0.22 38 3 32 026271-1x0* 0.60 0291* 0. 38 20 s Load Capacity 20 32 32 Cable Trolleys for Round Cables 1 D 60 a I b c hmax. ø d 14 40 Cable Trolley End Clamp Main Body: sendzimir galvanized steel Buffer: rubber Ball Joint: plastic Connecting Plate: plastic Hardware: galvanized steel For C-Rail Program Cable Trolley End Clamp D ø d Load Capacity x 02 0306* 0.3 0308* 0. 70 20 63 x 63 0 06* 0.4 08* 0. 32 66 32 x 0260 026306* 0.48 08* 0.27 If required, it is possible to fit one or more similar or different sized cable clips to a trolley. When fitting different sized cable clips, the largest cable clip must be fitted on top. 16 ø d r l h b c Material Cable clip Fasteners 020131-16* 10-16 70 38 3 42 0.04 Galvanized 020131-* 17-1 100 47 Plastic 0.06 Steel 020131-36* 26-36 1 140 8 70 64 0.12 Weight
Cable Trolleys Light Version Trolleys with 4 Rollers l ø 40 Main body: galvanized steel Roller (ball bearing): galvanized steel Buffer: rubber 10 Spring Safety Hook 9 8 ø 6 60 28 ø 10. For C-Rail Program x 02 Weight l 0440-1 0.42 1 0440-160 0. 160 Load Capacity 02021-60x6 Material galvanized steel End Stops 30 30 3 69 Hardware: galvanized steel Buffer: rubber For C-Rail Program Type x 02 011* 0.20 63 x 63 0 011* with Buffer 0.20 x 0260 02611* 0.22 Weight 17
Accessories for Festoon Systems Program 02, 0 and 0260 Towing Ropes Type B 28 L 28 ød Type C L ød Type C suggested for use with mping devices. Different types and lengths available upon request. ø d Material Rope 020328-06 6 Galvanized Steel B 020329-08 8 Galvanized Steel with PVC Jacket 0203-08 8 Galvanized Steel with PVC Jacket C Type for Program 02, 0, 0260 Damping Devices ød L Different types and lengths available upon request. ø d 020337-10 10 020337-14 14 Material Rope for Program Rubber core with Nylon jacket 02, 0, 0260 18
Accessories for Festoon Systems Program 02, 0 and 0260 Round Cable Clamps Spacer 031946 ø dmax ø d1 ø d2 bi ba ~20 2 40 t s h s ø d max. b i b a 031941-026x100/400 100 236 031941-026x1/400 1 286 26 031941-026x200/400 200 336 031941-026x2/400 2 386 031941-036x100/400 100 6 031941-036x1/400 1 306 36 031941-036x200/400 200 36 031941-036x2/400 2 406 h s Sd 1) 64 30 34 74 40 46 1) A cable separator is required between cables if the sum of the diameters of two adjacent cables is smaller than the value Σd. Material Support Rail Cable Clip Fasteners Aluminum Rubber Stainless Steel Spacers 48 b s t b Material Used with Round Cable Clamp 031946-26 4 18 031941-026x... Plastic 031946-36 3 19 031941-036x... 19
Accessories for Festoon Systems Program 02, 0 and 0260 Flat Cable Organizer Power cables are clamped in upper window s 1, control cables are contained in lower window s 2 with sufficient space (> 2 mm) to allow the cables to move freely. Flat cable clamps are supplied pre-assembled with upper window s 1 of minimum size and lower window s 2 of maximum size. The cable clamps can be adjusted to fit cable packages by transferring spacers from window s 2 to window s 1. Clamped Power Cable Control Cable Contained in Lower Window hmax. s2 s1 hmax. s2 s1 bi 32 bi bi 020126... and 03193... 0319... ba ba 32 b i b a s 1 + s 2 s 1min. h max. Material Cable Clamps Fasteners 020126-04x018 18 0.07 Galvanized 020126-04x028 4 90 28 +2. 3 60 0.08 Steel 020126-04x038 38 70 0.09 03193-084x0/400 60 0.16 03193-084x03/400 3 70 0.17 03193-084x04/400 84 120 4 +2. 0.18 03193-084x0/400 90 0.19 03193-084x06/400 6 100 0.21 03193-136x0/400 60 0.22 03193-136x03/400 3 70 0.23 03193-136x04/400 4 0.24 03193-136x0/400 136 172 +2. 90 0. 03193-136x06/400 6 100 0.26 Plastic 03193-136x07/400 7 110 0.27 Stainless 03193-136x08/400 8 120 0.28 Steel 0319-084x03/400 3 70 0.41 0319-084x04/400 4 0.43 0319-084x0/400 84 220 +2. 90 0.44 0319-084x06/400 6 100 0.46 0319-084x07/400 7 110 0.48 0319-103x0/400 60 0.42 0319-103x03/400 3 70 0.43 0319-103x04/400 4 0.46 103 8 +2. 0319-103x0/400 90 0.47 0319-103x06/400 6 100 0.49 0319-103x07/400 7 110 0.1 Weigth 20
Helpful Hints Determining the Support Distance for C-Rail Program 02 Technical Data / Calculation Assumptions The required support distance of the C-rail can be determined using the diagram below. The following calculation assumptions have been taken into consideration: 1. Simply-supported beam, uniform load symmetrical to middle of the beam 2. The load of one trolley F LW [kg/trolley] is distributed over trolley length l W as a uniform load p [kg/m] 3. Total length of the uniform load results from the cable trolley storage length l b [m] of all trolleys side by side 4. σ b zul = 100 N/mm², without consideration of the lower flange stress. σ V 160 N/mm², reference stress from bending stress and lower flange stress 6. f = I A /2 permissible deflection from the load and net weight of the rail 7. As track support bracket load the load of a field symmetrical to the mounting (bracket) is assumed Example: Given: F LW = Cable Trolley Load: 28 kg (X axis value on the left-hand graph below) l w = Cable Trolley Length: 200 mm (blue line on the left graph) Z = Overall number of Cable Trolleys: 8 l b = Cable Trolley Storage Length: 1.6 m (X axis on the right-hand graph below) (m) = Z x l w / 1000 Load Diagram for C-Rail x x 3. (0100) Cable Trolley Length l w 160 200 2 320 400 40 32 20 16 12. 10 8 6.3 Cable Trolley Load F LW [kg/trolley] 4 3.2 2. 0 400 320 2 200 160 1 100 63 40 32 20 16 12. p [kg/m] 1. 1.4 1.6 1.8 2.0 2.24 2. 2.8 3.2 3.6 4.0 4. 0. 0.32 0.4 0. 0.63 0.8 1.0 1. 1.6 2.0 2. 3.2 4.0.0 Cable Trolley Storage Length l b [m] Support Distance l A [m] Solution for C-Rail x x 3. From diagram: Required Support Distance l A = 1.9 m 21
Helpful Hints Load diagram for C-Rail 63 x 63 x 4 (0600) 0 Length of cable trolley I W 160 200 2 320 400 630 0 400 320 2 200 160 1 100 63 40 32 20 p [kg/m].0 1.4 1.6 1.8 2.0 2.24 2. 2.8 3.2 3.6 4.0 4. Distance between track support brackets I A [m] 160 200 2 320 400 12 1000 0 630 0 400 320 2 200 160 1 100 63 40 32 6.3 1.6 1.8 2.0 2.24 2. 2.8 3.2 3.6 4.0 4..0.6 1 100 63 40 32 20 16 12. 10 8 6.3 0.32 0.4 0. 0.63 0.8 1.0 1. 1.6 2.0 2. 3.2 4.0.0 6.3 63 40 32 20 16 12. 10 8 6.3 4 0.32 0.4 0. 0.63 0.8 1.0 1. 1.6 2.0 2. 3.2 4.0.0 6.3 Cable Trolley Load F LW [kg/trolley] Cable Trolley Storage Length l b [m] Example: p [kg/m] Distance between track support brackets I A [m] Given: F LW = Cable Trolley Load: 4 kg l w = Cable Trolley Length: 2 mm Z = Overall number of Cable Trolleys: 10 l b = Cable Trolley Storage Length: 2. m (m) = Z x l w / 1000 Solution for C-Rail 63 x 63 x 4 From Diagram: Required Support Distance l A = 2. m Load diagram for C-Rail x x (140) Length of cable trolley I W Cable Trolley Load F LW [kg/trolley] Cable Trolley Storage Length l b [m] Example: Given: 22 F LW = Cable Trolley Load: kg l w = Cable Trolley Length: 400 mm Z = Overall number of Cable Trolleys: l b = Cable Trolley Storage Length: 2 m (m) = Z x l w / 1000 Solution for C-Rail x x From Diagram: Required Support Distance l A = 3.6 m
Helpful Hints Technical Data lb ls e lw LinstM h hges LinstE >0.1m Formulas to Determine the Number of Loops, Cable Length and Loop Depth Number of loops: n = Storage length: f (l s + e) 2 h + 1. d a - f l w l b n l w + e [m] System cable length: Loop length: L Syst = f (l s + l b ) [m] L Schl = L Syst n [m] Total cable length: Loop depth: L Best = L Syst + L inste + L instm [m] h = L Schl 2-0.63 d a [m] d a [m] = cable support diameter e [m] = free space in storage area (recommention 0.1 m) f = recommended cable factor (see table page 24) h [m] = loop depth (measured from top edge of cable support) h ges [m] = loop depth (measured from lower edge of track profile) l b [m] = storage length incl. free space l s [m] = travel distance l w [m] = cable trolley length L Best [m] = total cable length L inste [m] = installation length, end clamp side L instm [m] = installation length, towing side L Schl [m] = cable length per loop L Syst [m] = required cable length (measured from mid of end clamp to mid of towing trolley or towing clamp) n = number of loops 23
Helpful Hints Definition of the cable arrangement and cable trolley selection 4x10 7x2. 4x2. 7x2. 12x1. 12x1. b 4x10 Example for flat cable trolleys Power cables dmax s 1. Formula for calculating the approximate load per trolley F LW 2. 3. 4.. G L [kg/m] F LW 2 h G L = weight of the cable package Selection of the cable trolley type Required cable support diameter based upon minimum bending radius of the cables Select cable support width b 2 to accommote the cable package width Determine length of trolley l w b Example for round cable trolleys For round cables: l w d a + 2 d max + 10 For flat cables: l w d a + 2 s + 10 Cable Factors Travel Speed v [m/min] Cable Factor f at h [m] < 0.8 0.8-1.2 1.3-2 2.1-3.2 3.3 - < 32 1.10 1.10 1.10 1.10 1.10 32-040 1.1 1.10 1.10 1.10 1.10 41-0 1.20 1.1 1.10 1.10 1.10 1-063 1. 1.20 1.1 1.10 1.10 64-0 - 1. 1.20 1.1 1.10 81-100 - - 1. 1.20 1.1 101-120 - - - 1. 1.20 Depending on the operating conditions the cables must be installed with an additional cable length. The additional length is calculated by taking into account the cable factor [f]. We recommend to select the cable factor according to above table. For values outside the gray area, please contact us directly. Special precautions might be required in those cases under extreme operating conditions, such as the installation of shock cords. Permissible Loads of the Rollers Travel Speed V [m/min] Average Running Time per Day [h] < 4-8 8-16 > 16 - - - 2-4 4-8 8-16 > 16-1 - < 2 2-4 4-8 8-16 >16 101-120 - - 2-4 4-8 8-16 Program Steel Roller Ø Permissible Load per Trolley 02 40 63 40 32 0 2 1 100 63 0260 62 200 160 1 100 Program PU Roller Ø Permissible Load per Trolley 02 40 63 40 32 0 2 100 63 40 0260 62 160 1 100 63 The lifetime of the rollers depends on the load (Hertzian stress) and the frequency of operation. The proper selection, based on travel speed, average running time per y (based on one year) and permissible load of the trolleys with various roller types, can be made by using the above table. 24
Wear Parts Replacement Rollers for Program 02 ø 8 13 ø 40 Description Stanrd Roller 0460-21 Roller with Seal Disks 0462-21 Replacement Rollers for Program 0 1 ø 2 Description Stanrd Roller 09-21 Roller with Seal Disks 098-21 Ersatzrollen für Programm 0260 ø 62 Description Stanrd Roller 0264-21 Roller with Seal Disks 026460-21 17 Buffer for Program 02 ø 40 M 8 Description Buffer 02-P014-0024 23 19 Buffer for Program 0 und 260 32 32 Description Buffer 017132-032x/14 20 M8 Shock Cords for Program 03 and 0330 LGum ø d ød Weight [kg/m] 020336-10 10 0.09 020336-14 14 0.17 Note In case of order please state the lengths L Gum of the respective shock cords..
Your Applications our Solutions Cable Trolleys from Conductix-Wampfler represent only one of the many solutions made possible by the broad spectrum of Conductix- Wampfler components for the transport of energy, ta and fluid media. The solutions we deliver for your applications are based on your specific requirements. In many cases, a combination of several different Conductix-Wampfler systems can prove advantageous. You can count on all of Conductix-Wampfler s Business Units for hands-on engineering support - coupled with the perfect solution to meet your energy management and control needs. Cable reels Motorized reels and spring reels by Conductix-Wampfler hold their own wherever energy, ta and media have to cover the most diverse distances within a short amount of time - in all directions, fast and safe. Festoon systems It s hard to imagine Conductix- Wampfler cable trolleys not being used in virtually every industrial application. They re reliable and robust and available in an enormous variety of dimensions and designs. Conductor rails Whether they re enclosed conductor rails or expanble single-pole systems, the proven conductor rails by Conductix-Wampfler reliably move people and material. Non-insulated conductor rails Extremely robust, non-insulated conductor rails with copper heads or stainless steel surfaces provide the ideal basis for rough applications, for example in steel mills or shipyards. Energy guiding chains The Jack of all trades when it comes to transferring energy, ta, air and fluid hoses. With their wide range, these energy guiding chains are the ideal solution for many industrial applications. Slip ring assemblies Whenever things are really moving in circles, the proven slip ring assemblies by Conductix-Wampfler ensure the flawless transfer of energy and ta. Here, everything revolves around flexibility and reliability! Inductive Power Transfer IPT The no-contact system for transferring energy and ta. For all tasks that depend on high speeds and absolute resistance to wear. Reels, retractors and balancers Whether for hoses or cables, as classical reels or high-precision positioning aids for tools, our range of reels and spring balancers take the load off your shoulders. Jib boom Complete with tool transporters, reels, or an entire media supply system here, safety and flexibility are key to the completion of difficult tasks. Conveyor systems Whether manual, semiautomatic or with Power & Free flexibility is achieved with full customization concerning layout and location. 26
www.conductix.com KAT02-0001d-E Conductix-Wampfler 201 subject to technical modifications without prior notice Conductix-Wampfler GmbH Rheinstrasse 27+33 7976 Weil am Rhein Germany Hotline Phone +49 (0) 7621 662-222 Phone +49 (0) 7621 662-0 Fax +49 (0) 7621 662-144 info.de@conductix.com www.conductix.com