MOTIV-8 FLEXIBLE CABLE SYSTEMS

MOTIV-8 FLEXIBLE CABLE SYSTEMS www.conductix.com.au

CONDUCTIX FLEXIBLE CABLE SYSTEMS Designed and manufactured in Australia. Proven in applications throughout the world for over 25 years. Full range of capacities and track profiles. Ex-stock or custom designed. Manufactured from plastic, mild steel or stainless steel. Broad range of high quality rollers. Carrying capacity from 6 to 500kg per trolley. All accessories including cable, glands and buffers available. Systems available pre-assembled. Your local Conductix distributor: VICTORIA Head Office: 14 England Street Dandenong VIC 3175 Phone: (03) 9706 8844 Fax: (03) 9794 9298 NEW SOUTH WALES 4/ 77 Newton Road Wetherill Park NSW 2164 Phone: (02) 9604 9800 Fax: (02) 9604 9844 QUEENSLAND 52 Lysaght Street, PO Box 6211 Acacia Ridge D.C. QLD 4110 Phone: (07) 3219 6911 Fax: (07) 3344 5377 WESTERN AUSTRALIA 592 Albany Highway, Victoria Park, WA 6100 Phone: (08) 9355 2077 Fax: (08) 9355 2088 info@conductix.com.au www.conductix.com.au

CONTENTS System Selection Enquiry Sheet Carrying Capacity kg Recommended Maximum Speed (m/min) Wire Rope Systems 6 30 C-Track Systems: - Standard Duty 15 70 - Medium Duty 25 70 - Heavy Duty 50 90 Square Track Systems: - Standard Duty 25 80 - Heavy Duty 80 100 I-Beam Systems: - Standard Duty 25 30 - Medium Duty 50 100 - Heavy Duty 125-500 240 Extra Heavy Duty Systems 125-500 240 Accessories: - Cable - Cable Glands - Rubber Buffers - Pre-Assembled Systems For higher speeds please contact Conductix 1

SYSTEM SELECTION System selection can be carried out by following the steps below, or, by completing the Enquiry Sheet and forwarding it to Conductix for recommendation: 1. In selecting the correct system the following should be taken into consideration, length of travel, available ambush, depth of cable loop, speed, duty cycle and environmental condition. 2. Determine the quantity and size of cables required and allow for possible future additions. 3. Prepare a layout of the cable stack with the largest cable on the top. Select a saddle to suit the cable stack allowing for bending radius of the largest cable. 4. Calculate the cable load per trolley as follows:- load = loop depth x 2 x total cable weight per metre. Select a suitable system for the calculated load and environmental conditions. 5. Determine the number of trolleys required as follows:- LOR + L/F N = N = DOL x 2 Where: N = number of trolleys LOR = length of run including ambush L/ F = loop factor (10% nominal) DOL = depth of loop 6. Determine the number of track lengths and joiners required, and allow for end stops, end clamps and track supports. 7. Select any required accessories such as cable glands, cable cleats, tow ropes or shock damping devices. 8. Recommended bracket spacing for C-track and Square track systems are as shown in the table below. The spacings indicated are based on the loadings within the ambush length and may be increased towards the opposite end. Cable Trolley Load as a Percentage of the Systems Catalogued Carrying Capacity Recommended Bracket Spacing mm 100 75 50 30 25 10 5 800 900 1000 1500 1750 2000 2500 2 For high speed, heavy duty and curved systems please consult your Conductix representative.

ENQUIRY SHEET Customer Name: Contact: Project: Phone/Fax: System Requirements: Application: Preferred Track Profile: I-beam Size: Mean Running Time/Day Maximum Speed m/min Maximum Acceleration m/s 2 Environment: Indoor Outdoor Dusty Corrosive Operating Temp: min o C max o C System Voltage: V Active Travel: m Total Track Length: m Available Storage Distance: m Maximum Loop Depth: m Cable: Quantity No. and size of Conductors W x T of Flat Cable O.D. of Round Cable Other Cable Termination Lengths: m Accessories: Cable Cleats: Tow Ropes: Shock Cords: Pre-assembly: System Diagram: 3

WIRE ROPE SYSTEMS END STRAINER SCREW ASS'Y. SINGLE WHEEL TROLLEY o6 WIRE ROPE TOWING ARM END CLAMP END STRAINER CABLE CLIP CABLE TROLLEYS CABLE CLAMP TOWING TROLLEY CABLE FLAT CABLE SYSTEM Part No. Description Part No. Description 99755 6mm Dia. PVC Covered Wire Rope 10K58 Double Wheel Cable Trolley 99747 End Strainer Screw Assembly T58 Towing Trolley 99752 End Strainer Bracket 19/380 Towing Arm, 380mm long A58 End Clamp ROUND CABLE SYSTEM Part No. Description Part No. Description 99755 6mm Dia. PVC Covered Wire Rope 19/380 Towing Arm, 380mm Long 99747 End Strainer Screw Assembly RC0509 05-09mm Dia. Cable Clip 99752 End Strainer Bracket RC0914 10-14mm Dia. Cable Clip A58H End Clamp RC1519 15-19mm Dia. Cable Clip 5K58H Single Wheel Cable Trolley 99270 10-16mm Dia. Cable Clamp 10K58H Double Wheel Cable Trolley 99271 17-25mm Dia. Cable Clamp T58H Towing Trolley 99272 26-36mm Dia. Cable Clamp Cable Trolley 5K58H Cable Trolley 10K58 4

C TRACK & FITTINGS SUPPORT BRACKET GIRDER CLIP TRACK COUPLER TRACK SUPPORT TOWING ARM END STOP CABLE TROLLEY TOWING TROLLEY END CLAMP CABLE PENDANT TROLLEY PENDANT (as reqd.) TRACK, TRACK COUPLER & END STOP Duty Track A B C D Length Coupler End Stop Standard 99280 1.6 32 30 4000 99221 99224 Medium 99220 2.0 12 Heavy 99300 45 43 2.5 3000 99301 99303 S/S 27725 32 30 1.6 12 3000 27726 2378 TRACK SUPPORTS Standard & Medium Duty 99225 Standard & Medium Duty 99226 Standard & Medium Duty 99227 Heavy Duty 99304 SUPPORT BRACKET & GIRDER CLIP 20 50 GIRDER CLIP M8 25 MAX. L SUPPORT BRACKET TRACK SUPPORT Description Part No. L 99247/250 250mm Support Bracket 99247/500 500mm 99247/750 750mm 99247/1000 1000mm Girder Clip 99232 Track Support 99225 5

C TRACK FLAT CABLE TROLLEYS TOWING TROLLEY & ARM TOWING ARM Towing Arm 99230 Towing Trolley CABLE TROLLEY PLASTIC 97035 END CLAMP Cable Trolley End Clamp CABLE TROLLEY STEEL Duty Tow Trolley L Cable Trolley L1 A B C max D E F G H dia. End Clamp 97035/072 56 22 99240/072 72 55 99243/072 99241/072 80 15 99240/100 99241/100 100 80 50 99243/100 Standard 125 99240/072 99242/072 72 55 45 99243/072 and 36 46 71 99240/100 99242/100 125 100 80 22 99243/100 Medium 99240/127 99242/127 22 127 104 80 99243/127 99250/127 99251/127 50 56 99250/160 99251/160 160 135 30 135 99243/160 200 200 99340/127 99341/127 127 104 50 80 99343/127 Heavy 70 66 92 32 99340/160 99341/160 160 135 30 135 99343/160 Note: Part number subscript denotes saddle width PENDANT TROLLEYS No.Pins Gal.Steel St.Steel 16 99276 99278 24 99277 99279 6 Standard & Medium Duty 97036 Standard & Medium Duty 99246 Heavy Duty 99346 Pendant Trolley with Quick Connect Plug

C TRACK ROUND CABLE TROLLEYS TOWING TROLLEY Towing Trolley 99267 to suit Round Cable Clip Towing Trolley 99254 to suit Round Cable Clamp CABLE TROLLEYS Trolley C/W Swivel Hook Part No. A B C D 99264 80 99265 125 72 68 25 Trolley C/W U Bolt Part No. A B C D 99261 80 99262 125 72 96 52 Single Wheel Trolley 99260 END CLAMPS End Clamp 99266 to suit Round Cable Clip End Clamp 99253 to suit Round Cable Clamp ROUND CABLE CLIPS ROUND CABLE CLAMPS Part No. Cable Dia. Min. Max. RC0509 5 9 RC1014 10 14 RC1519 15 19 Part No. Cable Dia. Min. Max. 99270 10 16 99271 17 25 99272 26 36 7

STANDARD & HEAVY DUTY SQUARE TRACK & FITTING TRACK SUPPORT SUPPORT BRACKET GIRDER CLIP TRACK COUPLER END CLAMP CABLE TROLLEY TOWING TROLLEY PENDANT TROLLEY END STOP TOWING ARM CABLE GLAND CABLE PENDANT (as reqd.) TRACK, TRACK COUPLER & END STOP Duty Type Track A B Length Coupler End Stop Drill Jig Galv. 99420 30 2.6 4000 99421 99424 Standard 99428 S/S 99410 31.8 1.6 6000 99411 99414 Heavy Galv. 99520 40 3.0 4000 99521 99524 99528 TRACK SUPPORTS Duty Material Type Part No. A B C Track Support, Square Nut Type Z/P Sq. Nut 99425 Z/P Hex. Nut 99426 Standard 42 M6 46 S/S Sq. Nut 99415 S/S Hex. Nut 99416 Galv. Sq. Nut 99525 Heavy 58 M8 52 Galv. Hex. Nut 99526 Track Support, Hex. Nut Type DRILLING JIG SUPPORT BRACKET & GIRDER CLIP M8 L Description Part No. L 99247/250 250mm Support 99247/500 500mm Bracket 99247/750 750mm 20 50 GIRDER CLIP 25 MAX. SUPPORT BRACKET TRACK SUPPORT 99247/1000 1000mm Girder Clip 99232 Track Support 99425 8

STANDARD DUTY SQUARE TRACK FLAT CABLE TROLLEYS TOWING TROLLEY & ARM TOWING ARM Towing Trolley Towing Arm 99230 CABLE TROLLEY END CLAMP Cable Trolley End Clamp Tow Trolley Cable Trolley End Clamp A B C D E Zinc Plated Stainless Steel Zinc Plated Stainless Steel (max) Zinc Plated Stainless Steel 99480/072 99470/072 99484/072 99474/072 72 55 20 50 99443/072 99473/072 99480/100 99470/100 99484/100 99474/100 100 82 20 50 100 99443/100 99473/100 99480/127 99470/127 99484/127 99474/127 127 104 10 80 99443/127 99473/127 99481/072 99471/072 99485/072 99475/072 72 55 30 50 99443/072 99473/072 99481/100 99471/100 99485/100 99475/100 100 82 30 50 122 99443/100 99473/100 99481/127 99471/127 99485/127 99475/127 127 104 20 80 99443/127 99473/127 99482/072 99472/072 99486/072 99476/072 72 55 40 50 99443/072 99473/072 99482/100 99472/100 99486/100 99476/100 100 82 40 50 144 99443/100 99473/100 99482/127 99472/127 99486/127 99476/127 127 104 30 80 99443/127 99473/127 PENDANT TROLLEY No.Pins Gal.Steel St.Steel 16 99449 99434 24 99450 99435 Pendant Trolley C/W Junction Box (Zinc Plated 99448) (Stainless Steel 99436) Pendant Trolley with Quick Connect Plug 9

STANDARD DUTY SQUARE TRACK ROUND CABLE TROLLEYS TOWING TROLLEY CABLE TROLLEY END CLAMP Towing Trolley Upper Cable Trolley Upper End Clamp Upper Zinc Plated 99455 Stainless Steel 99456 Tow Trolley Cable Trolley Upper End Camp A Zinc Plated Stainless Steel Zinc Plated Stainless Steel Zinc Plated Stainless Steel 99453 99454 99487 99477 100 99496 99497 99488 99478 122 99455 99456 99498 99499 99489 99479 144 Swivel Hook Zinc Plated 99468 Stainless Steel 99469 U Bolt Assembly Zinc Plated 99269 Stainless Steel 99788 ROUND CABLE CLIPS Part No. Cable Dia. Min. Max. RC0509 5 9 RC1014 10 14 RC1519 15 19 ROUND CABLE CLAMPS Part No. Cable Dia. Min. Max. 99270 10 16 99271 17 25 99272 26 36 10

HEAVY DUTY SQUARE TRACK FLAT CABLE TROLLEYS TOWING TROLLEY TOWING ARM Towing Trolley Towing Arm 99230 CABLE TROLLEY END CLAMP Cable Trolley End Clamp Tow Trolley Cable Trolley L A B C max. D End Clamp 99540/072 99541/072 72 52 52 50 99543/072 99540/100 99541/100 160 100 80 50 50 99543/100 99540/127 99541/127 127 104 40 80 99543/127 99550/072 99551/072 72 52 70 50 99543/072 99550/100 99551/100 100 80 70 50 99543/100 99550/127 99551/127 200 127 104 50 80 99543/127 99550/160 99551/160 160 135 30 135 99543/160 99560/127 99561/127 127 104 75 80 99543/127 99560/160 99561/160 250 160 135 50 135 99543/160 99560/200 99561/200 200 175 40 160 99543/200 99570/160 99571/160 160 135 90 135 99543/160 99570/200 99571/200 320 200 175 75 160 99543/200 996570/250 99571/250 250 225 50 200 99543/250 For round cable systems consult your Conductix representative. 11

STANDARD DUTY BEAM TROLLEYS END CLAMP TWO WHEEL CABLE TROLLEY CABLE TROLLEYS TOWING TROLLEY TOWING ARM CABLE TOWING TROLLEY CABLE TROLLEY (3 WHEEL) Towing Trolley Cable Trolley END CLAMP End Clamp Wheels Tow Trolley L A B C max. D E min. E max. Cable Trolley End Clamp 99600/072 72 55 99601/072 99604/072 2 62 15 99600/100 100 80 99601/100 99604/100 50 99600/072 72 55 99602/072 99604/072 30 3 99600/100 100 80 99602/100 99604/100 40 160 99600/127 127 104 20 80 99602/127 99604/127 124 99600/072 72 55 99603/072 99604/072 30 50 4 99600/100 100 80 99603/100 99604/100 96600/127 127 104 20 80 99603/127 99604/127 ROUND CABLE TROLLEYS AND CLAMPS Part No. Description 99600 4 Wheel Round Cable Towing Trolley 99605 2 Wheel Round Cable Trolley 99606 3 Wheel Round Cable Trolley 99607 4 Wheel Round Cable Trolley Part No. Description 99608 End Clamp RC0509 05-09mm Dia. Cable Clip RC1014 10-14mm Dia. Cable Clip RC1519 15-19mm Dia. Cable Clip Part No. Description 97270 10-16mm Dia. Cable Clamp 97271 17-25mm Dia. Cable Clamp 97272 26-36mm Dia. Cable Clamp 12

MEDIUM DUTY BEAM TROLLEYS WITH FLANGED ROLLERS TOWING TROLLEY TOWING ARM Towing Arm 99230 Towing Trolley CABLE TROLLEY END CLAMP Cable Trolley End Clamp Tow Trolley Cable Trolley L A B C max. D E F End Clamp 99620/072 99621/072 72 52 52 50 99623/072 230 290 99620/100 99621/100 160 100 80 50 50 99623/100 99620/127 99621/127 127 104 40 80 260 320 99623/127 99624/072 99625/072 72 52 70 50 99623/072 230 290 99624/100 99625/100 100 80 70 50 99623/100 200 99624/127 99625/127 127 104 50 80 260 320 99623/127 99624/160 99625/160 160 135 30 135 320 380 99623/160 99626/127 99627/127 127 104 75 80 260 320 99623/127 99626/160 99627/160 250 160 135 50 135 320 380 99623/160 99626/200 99627/200 200 175 40 160 340 400 99623/200 99628/160 99629/160 160 135 90 135 320 380 99623/160 99628/200 99629/200 320 200 175 75 160 340 400 99623/200 99628/250 99629/250 250 225 50 200 380 440 99623/250 For round cable systems consult your Conductix representative. 13

CONDUCTIX CABLE TROLLEY FEATURES MAIN ROLLERS Designed to carry high cable loads at high speed. Sized from Ø50 to Ø150mm. Hardened steel or polyurethane tyred with crowned or flanged configuration. Marine-grade aluminium body for light weight and durability and incorporating high quality sealed precision bearings, backed up by a secondary seal to protect against the corrosive environment. Easily replaceable. ANTI-LIFT ROLLERS To keep trolleys tracking truly and for maximum reliability. Sized Ø50mm. Nylon bushing arrangement to prevent locking after being stationary for long periods. RUBBER BUFFERS To provide maximum impact absorption. Manufactured from resilient moulded natural rubber. SHOCK CORDS WITH PROTECTIVE SOCKS To provide smooth operation. Available in Ø16 or Ø20. Wear-resistant nylon outer sheath for maximum life. Unique wear-resistant rubber sock for further extended life. 14

TROLLEY HARDWARE For strength and maintainability. 304ss hardware or optional 316ss. Minimum thread size of Ø10mm. SIDE GUIDE ROLLERS Designed to keep trolleys tracking truly and for maximum reliability. Sized in 45 and 80mm. Hardened steel for maximum life. Bearings sealed for life. CABLE CLAMPS To hold cables gently and firmly. Manufactured from heavy-duty extruded natural rubber. Sliced and perforated design to evenly distribute the clamping force across all cables. Flexible rubber does not overstress cables. 1, 2 or 3 clamps can be fitted per trolley side. ENGINEERING TROLLEY BODY Heavy-duty design. Fully welded with continuous fillet welds for uncompromised strength. Hot dip galvanised for protection against corrosive environments. Most heavy-duty festoon systems have a unique combination of demand factors such as speed, cable load, environment, space constraints, etc. Conductix makes use of over 30 years of experience to provide systems carefully designed to match each application. Years of continuous product advancement have brought product enhancements to maximise durability, reliability and the protection of cables. CABLE ORGANISER To provide maximum protection for cables. Manufactured from nylon and aluminium to be light weight and corrosion resistant. Fixes only two large cables and allows all others to "float" ensuring stresses cannot be transmitted to smaller cables. Smooth and rounded edges throughout to protect cables. Protected bolt heads to ensure they remain tightly in position for life. 15

HEAVY DUTY BEAM SYSTEMS HEAVY DUTY BEAM SYSTEMS WITH FLANGED ROLLERS HEAVY DUTY BEAM SYSTEMS WITH MAIN SIDE GUIDE & ANTI-LIFT ROLLERS CABLE TROLLEY DIMENSIONS ROUND CABLE FLAT CABLE A B C D E F H 160 100 312 300 240 55 175 160 200 512 300 240 55 175 200 100 312 400 280 85 205 200 200 512 400 280 85 205 250 100 312 330 230 25 145 250 200 512 330 230 25 145 250 300 712 330 230 25 145 300 100 312 400 260 30 150 300 200 512 400 260 30 150 300 300 712 400 260 30 150 360 100 312 465 270 36 155 360 200 512 465 270 36 155 360 300 712 465 270 36 155 420 100 312 540 300 42 160 420 200 512 540 300 42 160 420 300 712 540 300 42 160 480 100 312 610 310 48 165 480 200 512 610 310 48 165 480 300 712 610 310 48 165 16 Roller G available in 50, 100 & 150mm. dias. steel or polyurethane tyred

EXTRA HEAVY DUTY SQUARE TRACK SYSTEMS & ACCESSORIES CABLE CLEATS 97837 Round Cable Cleat Dimensions A Dia. B Dia. C MIN MAX MIN MAX MIN MAX D E 15 48 15 48 40 60 50 252 15 48 15 48 40 60 150 452 15 48 15 48 40 60 250 652 TOW ROPES Dia. Gal. Gal. Steel Stainless S/S mm. Steel PVC. Coat Steel PVC Coat 8 99680 90307 90310 90313 10 99681 90308 90311 90314 12 99682 90309 90312 90315 Suffix Part No. with tow rope length SHOCK CORD Dia.mm Part No. 16 97832 24 97834 Suffix Part No. with shock cord length 17

SYSTEM CALCULATIONS Cable required within the system (CS) = TL x Cf (Excludes cable for terminations) Cable required per loop (CL) = CS/N Number of loops (N) = CS 2 (DOL H A Dia.) + (A Dia. x 3.14) Depth of loop (DOL) = (CL A Dia. x 3.14) 2 Ambush length (AL) = (N + 1) D Tow rope length (TRL) = (CL D) X 0.9 Shock cord length (SCL) = TRL x 0.65 + A Dia. + H Cable Loop Factor Cf Speed Depth of Loop ( m.) M / min. 1.5-2 2-5 5-8 0-50 1.15 1.1 1.1 50-100 1.2 1.15 1.1 100-150 1.25 1.2 1.2 150-240 1.3 1.25 1.25 > 240 Consult Sales Office 18

CABLE & CABLE GLANDS CABLE ROUND CABLE FLAT CABLE No. of Cores x Nominal Cable Current Rating Cable Gland Part No. Cross Section External Dim. Weight Protected from Required (mm2) (mm) kg/m the Sun (Amps) 99813 5 x 1.5 5.1 x 17.7 0.16 15 99758/29 98134 8 x 1.5 5.1 x 27.3 0.25 15 99758/29 F12015PVC 12 x 1.5 5.1 x 40.5 0.37 15 99758/42 F14015PVC 14 x 1.5 5.1 x 46.2 0.42 15 99758/48 98136 4 x 2.5 5.8 x 18.1 0.19 20 99758/21 98137 5 x 2.5 5.8 x 21.6 0.25 20 99758/36 98138 12 x 2.5 5.8 x 49.5 0.55 20 99758/48 98139 4 x 4 6.7 x 20.1 0.27 25 99758/29 98140 4 x 6 7.2 x 22.4 0.36 38 99758/36 98141 4 x 10 9.2 x 28.7 0.71 52 99758/36 98142 4 x 16 11.1 x 37.1 0.84 70 99758/42 98143 4 x 25 13 x 42.5 1.34 95 99758/48 98144 4 x 35 14.5 x 49.6 1.80 115 99758/48 98145 4 x 50 17.5 x 58.4 2.52 140 99808 98146 4 x 70 20.0 x 63.0 3.67 175 99808 CT0815AU* 8 x 1.5 13.0 dia. 0.419 15 99812 CT1615AU* 16 x 1.5 17.0 dia. 0.594 15 99812 CT2015AU* 20 x 1.5 19.0 dia. 0.789 15 99812 CT2510AU* 25 x 1.0 21.0 0.60 10 99812 *Cables complete with two built in steel strainer wires. CABLE GLANDS 99758 Part No. A B C D E F min. F max. G min. G max. 99758/16 6.5 14 7 PG16 22.5 22 13 16 4 6 99758/21 7 15 8 PG21 28.3 28 14 20 4 8.5 99758/29 8 18 0 PG29 37 37 18 28 4 12 99758/36 9 20 10 PG36 47 47 26 40 4 13 99758/42 10 21 11 PG42 54 54 29 45 4 14 99758/48 10 23 12 PG48 59.3 60 40 50 7 8 99812 15 16 26 32mm 32 45 Ø12 Ø24 Note: Cable glands manufactured from zinc plated brass or aluminium (except 99812 which is plastic) 99812 99808 99809 99810 19

RUBBER BUFFERS STUD TYPE Part No. D1 D2 D3 R1 H L T 99725/025 25 18 M6 3 20 10 2 99725/040 40 27 M8 5 32 28 2 99725/050 50 38 M10 5 40 28 2 99725/080 80 57 M12 6 63 37 3 99725/100 100 73 M16 10 80 45 4 99725/125 125 92 M16 13 100 45 4 99725/160 160 114 M20 20 125 48 6 99725/200 200 147 M20 25 160 48 6 99725/250 250 183 M24 32 200 50 8 PLATE TYPE Part No. D1 D2 D3 R1 A B H T 99726/080 80 57 9 6 100 80 63 3 99726/100 100 73 9 10 125 100 80 4 99726/125 125 92 11 13 160 125 100 4 99726/160 160 114 11 20 200 160 125 6 99726/200 200 147 13 25 250 200 160 6 99726/250 250 183 13 32 315 250 200 8 BUFFER SELECTION STEP 1 STEP 2 STEP 3 Calculate the kinetic energy to be absorbed using one of the following formulas. Note: Crane lift loads should not be added to W1 or W2 if the load is able to swing freely. Divide the kinetic energy by the number of buffers to be used. Select the appropriate buffer from the following chart. Part No. Maximum E (J) Compression Stud Type Plate Type Length (mm) 99725/025 25 10 99725/040 50 16 99725/050 100 20 99725/080 99726/080 400 32 99725/100 99726/100 800 40 99725/125 99726/125 1600 50 99725/160 99726/160 3200 63 99725/200 99726/200 6400 80 99725/250 99726/250 12500 100 Buffer Calculation Formulas: Crane Bridge Crab E = (1/2W1+W2) x V1 2 E = 1/2W1 x V2 2 2 Where: W1 W2 V1 V2 E = Crane Bridge Weight in kg. = Crab Weight in kg. = Crane Bridge Speed in m/s. = Crab Speed in m/s. = Kinetic Energy in Joules. Or consult your Conductix representative 20

PRE-ASSEMBLED SYSTEMS Conductix offers complete factory pre-assembled systems carefully assembled by experienced personnel working under ideal conditions. Pre-assembly reduces potential field problems as well as installation time and expense. Typical control system shipped in a box. Note that control trolley is also pre-wired which reduces installation time. Completed system prepared for a ship-unloader. Shipping systems by flatbed trailer facilitates unloading and hoisting of the system into position. Heavy Duty I-Beam festoon in shipping frame. Heavy Duty C-Track in crate with control trolley.

TELFORD 1386 Picture credit cover Digital Vision

Product Overview Festoon-Systems I-Beams

2 Conductix-Wampfler Festoon-Systems

Count on it! On the go! Cable trolley system program 0350 on a steel mill overhead bridge crane Solutions for a moving world: Wherever you see objects and people in movement, you will find tailor-made Conductix-Wampfler solutions for the flexible transfer of energy, data and media. What makes Conductix-Wampfler truly remarkable are its years of experience and comprehensive know-how in the development and production of festoon systems. These systems carry flat and round cables for the transfer of electrical energy and data. Hoses are also carried for the directing of fluids, air or gases. Conductix-Wampfler festoon systems are employed worldwide in steel mills, ports, zinc coating shops and compost preparation facilities, to name a few applications. Perfected technology and standardization in modular design ensure an above-average operational life of the systems, even in the roughest of environments. Assemblies are easily done on site and within the shortest amount of time; service and maintenance are quick and easy. Conductix-Wampfler festoon systems save time and minimize costs - throughout their operational life. As a system supplier, Conductix- Wampfler offers its customers comprehensive all around service. This includes the delivery of the components, such as the cable trolley, towing trolley and end clamp. Along with competent consulting, the planning of the overall system, the selection and acquisition of the optimal cables and equipment, the right logistical concept and on-site commissioning. Consequently important data and required energy arrive safely, reliably and permanently wherever they re needed. All over the world! Count on it! Open the gates! Cable trolley system program 0330 on a lock Everything from one source: The right cables are always a given at Conductix-Wampfler! Carrying a heavy load! Motorized cable trolley system program 0380 in combination with program 0375 on a STS-container crane. 3

Conductix-Wampfler Festoon-Systems System Layout 1 2 5 7 3 6 1. Towing Trolley / Towing clamp 2. Cable Trolley 3. Cable Organizer 4. Cables 5. Elastic Damping Devices 6. Tow Rope Assembly 7. End Clamp 4 4

Conductix-Wampfler Festoon-Systems Complete overview of cable trolleys S-Line to XL-Line for I-Beams The Conductix-Wampfler product range covers cost-efficient cable trolleys made of plastic for the most basic applications all the way up to motorized cable trolleys with frequency converter control and patented drive concept for heavy dynamic loads. Speed XL S M L Load capacity Design For low mechanical and dynamic loads For medium mechanical and dynamic loads For high mechanical and dynamic loads For maximum mechanical and dynamic loads Typical applications Monorail hoists and overhead bridge cranes Standard and special overhead bridge cranes as well as conveyor systems Ladle cranes, grab cranes, container cranes as well as high-speed conveyor systems Ladle cranes, grab cranes, container cranes as well as high-speed conveyor systems S M L XL Festoon- System Cable weight per cable trolley max. (kg)* Speed max. (m/min) Suitable cable type Multiple saddle Motorized 0314 0320 0325 0330 0350 0360 0365 0370 0375 0380 0385 20 80 125 200 350 500 350 350 800 800 50 100 120 150 160 160 300** 210 300** 300 Flat / Round Flat Round Flat Round Flat Round Flat Round Round Flat Round Round *depending on roller size/roller material **in combination with motorized trolleys Page 6 Page 8 Page 9 Page 11 Page 12 Page 13 Page 15 Page 16 Page 17 Page 18 5

Conductix-Wampfler Festoon-Systems S M L XL Program 0314 Center-loading flat or round cable trolleys made of plastic for lighter cable selections. Flanged guided plastic rollers for simple I-beam applications. Two, three and four rollers. Smooth and wear-resistant operation through plastic rollers, with friction bearings and stainless axle Quick and easy setting to different beam widths through adjustable side shields Simple and quick assembly through patented plastic split nuts These cable trolleys generally run on the same I-beam as the electricitypowered consumer. Main applications: - Electric chain hoists, e.g., on swiveling cranes - Travelling hoists - Standard cranes - Transport systems - Electricity and air supply for machinery End Clamp Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Acid-proof design Resistance to chemicals Curved I-beam 50 m/min 20 kg* diameter: 40 mm design: flanged rollers material: polyamide -20 C... +60 C indoor / outdoor possible special designs on request optional parallel flange / tapered flange *depending on roller arrangement 6

Conductix-Wampfler Festoon-Systems 7

Conductix-Wampfler Festoon-Systems S M L XL Program 0320 Compact round or flat cable trolleys, center-loading, made of galvanized steel for medium speeds and cable weights. Maintenance-free with antifriction bearing rollers and permanent lubrication Minimized shock load with rubber buffers Maximum protection against corrosion with hot dipped galvanized steel parts Main applications: - Standard bridge cranes - Conveyor systems - Electric hoist units - Transport systems End Clamp Maximum bending strength at low weight with one-piece rollformed trolley saddle in different widths and radii Towing Trolley Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 100 m/min* 80 kg* diameter: 40 mm design: flanged / non flanged material: steel / Vulkollan, others on request -30 C... +80 C indoor / outdoor hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 8

Conductix-Wampfler Festoon-Systems Program 0325 Compact round or flat cable trolleys, center-loading, made of hot dipped galvanized steel for medium mechanical and dynamic loads. Maintenance-free with antifriction bearing rollers with permanent lubrication for higher loading capacities and speeds High protection against corrosion with hot dipped galvanized steel parts Maximum bending strength at low weight with one-piece rollformed trolley saddle in different widths and radii S M L XL Main applications: - Bridge cranes - Conveyor applications - Electric hoists - Transport systems End Clamp Towing Trolley Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 120 m/min* 125 kg* diameter: 50 mm design: flanged / non flanged material: steel / Vulkollan, others on request -30 C... +80 C indoor / outdoor hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 9

Conductix-Wampfler Festoon-Systems S M L XL Program 0330 The fastest and strongest round or flat cable trolleys of the M-Line. Made of hot dipped galvanized steel for average speeds and higher loads with four-point suspension. High load capacity with extra large ball bearing diameters Maintenance-free with anti-friction bearing rollers with permanent lubrication for higher loading capacities and speeds Minimized shock load with robust rectangle rubber buffers High protection against corrosion with hot dipped galvanized steel parts Main applications: - Bridge cranes - Conveyor systems - Electric hoists - Transport systems End Clamp Maximum bending strength at low weight with one-piece rollformed trolley saddle in different widths and radii Towing Trolley Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 150 m/min* 200 kg* diameter: 63 mm design: flanged / non flanged material: steel / Vulkollan, others on request -30 C... +80 C indoor / outdoor hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 10

Conductix-Wampfler Festoon-Systems 11

Conductix-Wampfler Festoon-Systems S M L XL Program 0350 Cable trolley with single or multi layer side-loading cable supports for flat cables. Suitable for medium mechanical and dynamic loads including traversing operation with lateral forces. Also suitable for short work cycles and high speeds. High load capacity with extra large ball bearings with special seals for the toughest environmental conditions - maintenancefree with permanent lubrication Precise tracking performance controlled by optimized running gear Safe cable support even with large cable packages via a stable rubber clamp profile Permanent protection against corrosion through stainless steel hardware One-piece cable saddle welded to the center plate for high loads Main applications: - Bridge cranes - Gantry cranes - Stacker cranes (RMG s,rtg s) - Ladle cranes - Stacker and reclaimers - Conveyor systems - Transport systems End Clamp Towing Clamp Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 160 m/min* 350 kg* diameter: 50/63/80/100 mm design: flanged / non flanged material: steel / Vulkollan, others on request -30 C... +80 C indoor / outdoor sea climate hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 12

Conductix-Wampfler Festoon-Systems Program 0360 Cable trolley with single or multi layer side-loading cable supports for round cables. Suitable for high mechanical and dynamic loads including traversing operation with lateral forces. Also suitable for short work cycles and high speeds. High load capacity with extra large ball bearings with special seals for the toughest environmental conditions - maintenancefree with permanent lubrication Permanent protection against corrosion through stainless steel hardware Optimal cable support even with large cable packages via a stable rubber clamp profile Maximum energy absorption of high mechanical and dynamic shock loads with robust hollow rubber buffers - one-or doublesided S M L XL Main applications: - Scrap and ladle cranes in steel mills - STS-container cranes - Heavy-duty scrap cranes in steel mills - High-speed conveyor systems End Clamp Maximum bending resistance at low weight through rollformed cable saddles with maximum bending strength Towing Clamp Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 160 m/min* 500 kg* diameter: 50/63/80/100/112/125 mm design: flanged / non flanged material: steel / Vulkollan, others on request -30 C... +80 C indoor / outdoor sea climate hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 13

14 Conductix-Wampfler Festoon-Systems

Conductix-Wampfler Festoon-Systems Program 0365 High-speed cable trolley with single layer side-loading cable supports for round cables. Suitable for maximum mechanical and dynamic loads including traversing operation with strong lateral forces. Also suitable for short work cycles and high work speeds. For high speeds, in combination with a motorized cable trolley. Smooth operation due to patented roller arrangement Maximum load capacity with extra large ball bearings with special seals for the toughest environmental conditions - maintenance-free with permanent lubrication Low wear and low noise emission even at high speeds with web-guided side guide rollers Optimal guidance under maximum mechanical loads with a special polymer glide plate Maximum stability with a one-piece, continuous center plate up to the saddle Optimal cable support with a double V-lined cable clamp S M L XL Main applications: - STS-container cranes - Ladle cranes - Heavy-duty grab cranes - High-speed conveyor systems End Clamp Towing Clamp Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 300 m/min* (in combination with motorized trolleys) 350 kg* diameter: 112/125 mm design:non flanged material: steel / Vulkollan, others on request -30 C... +50 C indoor / outdoor sea climate hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 15

Conductix-Wampfler Festoon-Systems S M L XL Program 0370 Rugged cable trolley with multiple layer side-loading cable saddles for flat cables. Suitable for maximum mechanical and dynamic loads including traversing operation with lateral forces. Also suitable for short work cycles and high speeds. High load capacity with extra large ball bearings with special seals for the toughest environmental conditions - maintenance-free with permanent lubrication Low wear and low noise emission even at high speeds with web-guided side guide rollers Maximum energy absorption of high mechanical and dynamic shock loads with robust rubber or cellular buffers Optimal cable support with a double V-lined cable clamp Compact design - saddle diameters synchronized with the optimized minimum bending radii of the flat cable packages Main applications: - Casting cranes - Scrap cranes - Ladle cranes - High-speed conveyor systems - Transport systems End Clamp Towing Clamp Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 210 m/min* 350 kg* diameter: 125/160 mm design: non flanged material: steel / Vulkollan, others on request -30 C... +50 C indoor / outdoor sea climate hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 16

Conductix-Wampfler Festoon-Systems Program 0375 Cable trolley with multi layer side-loading cable saddles for round cables. Suitable for maximum mechanical and dynamic loads including traversing operation and strong lateral forces. Suitable for short work cycles and high speeds - combinable with powered cable trolleys. High load capacity with extra large ball bearings with special seals for the toughest environmental conditions - maintenancefree with permanent lubrication Low wear and low noise emission even at high speeds with web-guided side guide rollers Easy replacement of the rollers with individually removable side shields Maximum stability with a onepiece, continuous center plate to the bottom saddle Optimal cable support of the round cables with a double V-lined cable clamp S M L XL Main applications: - STS-container cranes - Scrap and ladle cranes in steel mills - High-speed conveyor systems - Transport systems End Clamp Towing Clamp Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals Curved I-beam 300 m/min* (in combination with motorized trolleys) 800 kg* diameter: 125/160 mm design: non flanged material: steel / Vulkollan, others on request -30 C... +50 C indoor / outdoor sea climate hot dipped galvanized steel stainless steel powder-coated painted special designs on request optional parallel flange / tapered flange *depending on roller size/roller material 17

Conductix-Wampfler Festoon-Systems Motorized Festoon-Systems The requirements of today s systems, especially in container handling, often exceed the physical limitations of conventional systems when it comes to speed, acceleration and cable package weight. The application of motorized cable trolleys in combination with nonmotorized cable trolleys allows for controlled acceleration and deceleration. This synchronization with the consumer makes it possible to increase the travel speeds of the entire system enormously. In addition, wear and maintenance work are reduced considerably, increasing the availability of the complete facility and minimizing the overall costs. System sketch Program 0365 or 0375 Motorized Cable Trolley Program 0380 or 0385 Motorized Cable Trolley Program 0380 or 0385 Consumer Motorized Cable Trolley Program 0380 or 0385 Complete frequency converter control including a control panel for a cable trolley system with 3 motorized cable trolleys by Conductix-Wampfler Motorized main cable trolley with magnetic switch for back reach limit stops 18

Conductix-Wampfler Festoon-Systems Program 0380 0385 Motorized cable trolley for round cables with a patented compact drive (Progr. 0380) or with a gear motor (Progr. 0385). The entire system consists of motorized cable trolleys, a frequency converter control for optimizing movement and cable trolleys from programs 0365 and 0375. Compact designed power unit with standard motor, heating element and thermal overload protection Minimization of the most severe mechanical and dynamic shock loads with heavy duty rubber or cellular buffers S M L XL Main applications: - High-speed STS-container cranes of all Panamax classes - Special overhead bridge cranes - Scrap and ladle cranes in steel mills - High-speed conveyor systems - Transport systems Increased capacity range with double gear motor drive Optimal cable support with a double V-lined trolley clamp Standard application data Max. travel speed Max. load capacity Main rollers Ambient temperature Applications Design Resistance to chemicals I-beam 300 m/min* 800 kg* diameter: 125/160 mm design: non flanged material: steel / Vulkollan, others on request -30 C... +50 C indoor / outdoor sea climate hot dipped galvanized steel stainless steel powder-coated painted special designs on request parallel flange *depending on roller size/roller material 19

20 Conductix-Wampfler Festoon-Systems

Conductix-Wampfler Festoon-Systems Perfect Interaction The right equipment is just as important as the right tires on your car. The perfect coordination of the equipment with the cable trolleys allows for the counterbalancing of unfavorable operating conditions. Conductix-Wampfler Accessories are optimally coordinated with the appropriate cable trolley line. Conductix-Wampfler Accessories increase the safety, the availability and the operational life of the entire festoon system. Conductix-Wampfler offers the suitable equipment for every application - longlasting and with the high quality you ve come to expect! The optimal roller for each application is a given at Conductix-Wampfler. Accordingly the available range of rollers is large and flexible. Cable clamps A controlled cable line in the loop prevents cables from twisting or overlapping. Cable clamps for flat and round cables considerably increase the operational life of the cables as well as the functional safety of the system. Tension relief ropes protect the cables from excessive tension. Suitable for every application with their various materials and designs. Elastic damping devices optimize the movement of the system at high speeds and protect the cables. Whether it s hot dipped galvanized or stainless steel, powder-coated or painted - Conductix-Wampfler always offers the right surface. 21

Conductix-Wampfler Festoon-Systems Service - tailor-made Branch-specific competence The scope and depth of the Conductix- Wampfler range of services is based on the requests and requirements of the customers. From planning to long-term agreements, anything is possible - it is entirely up to you. Plus, the more complex the system layout and the expectations of operational life and operational safety, the more sense it makes to utilize our competent service team. Ask for us! Planning - Capture of the application parameters - Selection of the optimal cable trolley technology and suitable cables - optimized to customer requirements, application parameters and environmental factors Pre-assembly - Mounting the cable trolleys on the transport beam - Laying out and aligning the cables - Installing the equipment - Loading and transporting the festoon system to its work location Final assembly & inspection - Ascertaining the correct assembly on site - Complete installation and commissioning by trained and experienced personnel up to inspection Maintenance & service - Regular maintenance and inspections increase the operational life of the facility, ensuring its long-term availability - Conductix-Wampfler service agreements: the complete worry-free package The experts of Conductix-Wampfler accompany their customers from planning through pre-assembly right up to the onsite installation - anywhere in the world! 22

Conductix-Wampfler the complete program Your Applications our Solutions Festoon systems 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, data and media supply systems. The solutions we deliver for your applications are of course 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, data 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 expandable 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, data, 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 data. Here, everything revolves around flexibility and reliability! Inductive Power Transfer IPT The no-contact system for transferring energy and data. 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. 23

www.conductix.com Conductix-Wampfl er AG 2010 subject to technical modifi cations without prior notice Conductix-Wampfler AG Rheinstrasse sse 27+33 79576 Weil am Rhein Germany Customer Support 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 KAT0300-0001c-E