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
CRL-1 CABLE TROLLEY / END SUPPORT for Flat Cables, Rigid Plastic Design Art.-Nr. 6600865 /...867 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-1 6600865 6600867 85 78 Ø24 R36 R36 27 15 19 15 55 55 Note: You ll find the related towing attachement (Art-No. 6600866) at the according data sheet.
CRL-1 CABLE TROLLEY / END SUPPORT for Flat Cables, Swinging Design Art.-Nr. 6610023 /...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 84 15 kg 6610024 60 m/min CRL-1 8 kg 6610023 81 6610025 Ø 24 R25 R25 60 60 15 15 52 52 Note: You ll find the related towing attachement (Art-No. 6610038) at the according data sheet.
CRL-1 CABLE TROLLEY / END SUPPORT for Flat Cables, Rigid Design Art.-Nr. 6610026 /...27 /...30 /...33 6610028 /...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 6610026 80 mm 25 mm 15 mm 6610028 50 mm 6610027 steel 60 m/min CRL-1 (galvanised) steel 15 kg (galvanised) 6610030 6610031 125 mm 35 mm 25 mm 80 mm 6610033 6610034 80 / 125 80 / 125 1) Ø 24 1 R25 / R35 R25 / R35 1) = The end supports Art.-Nr. 6610031 and 6610034 will be delieverd including a rail stopper. 1 36 15 / 25 38 15 / 25 50 / 80 50 / 80 Note: You ll find the related towing attachement (Art-No. 6610038) at the according data sheet.
CRL-1 CABLE TROLLEY / END SUPPORT for Round Cables, Swinging Design Art.-Nr. 6610039 /... /...45...46 /...48 /...49...41 /...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 66100 10-28 mm 50 mm plastic 8 kg 6610039 84 mm max. 2 x 2 pieces steel (galvanised) 15 kg 6610046 steel 60 m/min CRL-1 10-28 mm 100 mm (galvanised) plastic 8 kg 6610045 max. 3x 3 pieces steel (galvanised) 15 kg 6610049 10-28 mm 130 mm plastic 8 kg 6610048 6610041 6610047 6610050 84 80 47 Ø24 50 / 130 50 / 130 52 52 Note: You ll find the related towing attachement (Art-No. 6610038) at the according data sheet.
CRL-2 CABLE TROLLEY / END SUPPORT for Flat Cables, Swinging Design Art.-Nr. 6610053 /...54 /...57 /...58 6610061 /...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 6610053 6610061 30 mm 100 mm 6610057 6610065 steel steel 15 kg 60 m/min CRL-2 60 mm (galvanised) (galvanised) 6610054 6610062 20 mm 100 mm 6610058 6610066 120 200 Ø 33 Ø 8,5 R25 / R35 R25 / R35 41 20 / 30 50 20 / 30 60 / 100 Note: You ll find the related towing attachement (Art-No. 6610101) at the according data sheet. 60 / 100
CRL-2 CABLE TROLLEY / END SUPPORT for Flat Cables, Rigid Design Art.-Nr. 6610078 /...79 /...84 /...86...80 /...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 6610078 6610091 6610079 6610092 50 mm 100 mm 6610084 6610098 200 mm 150 mm 30 mm steel steel 35 kg 60 m/min CRL-2 6610086 6610099 (galvanised) (galvanised) 60 mm 6610080 6610093 70 mm 100 mm 6610085 6610097 150 mm 6610087 6610100 150 / 120 200 Ø 33 R35 / R50 / R70 R35 / R50 / R70 46 50 30 30 60 / 1 00 / 150 60 / 100 / 150 Note: You ll find the related towing attachement (Art-No. 6610101) at the according data sheet.
CRL-2 END SUPPORT / TOWING ATTACHMENT for CRL-2 Cable Trolley for Round Cables, Swinging Design Art.-Nr. 6600846 /...47 This towing attachment and the according end support are required for CRL-2 C-rail systems incl. cable trolley (Art. 6600845) 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-2 6600846 100 End support for round cables, swinging design Material Art.-No. Ø33 steel (galvanised) 6600847 78 45 Ø45 54 41 38 45,5
CRL-2 CABLE TROLLEY for Round Cables, Swinging Design Art.-Nr. 6600845 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-2 6600845 CRL-2 Leitungsklemmen 100 Round cable Material Art.-No. 8-15 mm Ø 6600839 16-24 mm Ø aluminium 66008 Ø33 25-35 mm Ø 6600841 CRL-2 Cable clamp connector for cable supports Art.-No. 8-15 Ø / 16-24 Ø / 25-35 Ø 55413 45,5
DRIVING TROLLEY for CRL-1 or CRL-2 Rail System Art.-No. 6710188 / 6680065 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-1 6710188 CRL-2 6680065 391 78 308
CARRYING TROLLEY for CRL-1 or CRL-2 Rail System Art.-Nr. 6610202 /...203 /...204 /...205 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-1 6610203 15 kg by hand CRL-2 6610205 3 kg CRL-1 6610202 10 kg CRL-2 6610204 Ø 24 35 46 Ø 9 3 20 Ø 33 35 45 Ø 9 4 25
TOWING ATTACHEMENT for CRL-1 or CRL-2 Cable Trolleys Art.-Nr. 6610037 / 6610038 / 6610101 6600866 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 6610037 steel (galvanised) 6610038 CRL-1 towing attachement plastic Material Wheel Art.-No. plastic plastic 6600866 Ø24 29 20 63 70 125 R20 CRL-2 towing attachement Material Wheel Art.-No. steel (galvanised) steel (galvanised) 6610101 Ø33 57 98 29 20 63 125 R20
C-RAIL for CRL-1 or CRL-2 Rail System Art.-No. 52681 / 25042 52701 / 47822 C-Rail-Profiles - the basic component for your system. The standard length is 6 m. CRL-1 Rail Material Art.-No. steel (galvanized) 52681 stainless steel (1.4571) 25042 CRL-2 Rail Material Art.-No. steel (galvanized) 52701 stainless steel (1.4571) 47822 32 2 30 2,5 12 26 14 32
CEILING-/WALL SUSPENSION for CRL-1 or CRL-2 Rail Systems Art.-Nr. 6610003 / 6610006 6610004 / 6610007 Ceiling and wall suspensions for CRL-1 and CRL-2 rail systems. Ceiling installation Material Rail Art.-No. steel (galvanized) CRL-1 6610003 CRL-2 6610006 M10 M12 25-35 M8 30-36 M8 30 32 60 60 Wall installation Material Rail Art.-Nr. steel (galvanized) CRL-1 6610004 CRL-2 6610007 max.12 30 max.12 33 8 M8 8 M8 30 32 60 60
TRAVERSE & CLAMP for CRL-1 and CRL-2 Rail Systems Art.-No. 1910039 /... /...90 /...91 /...99 1505927 /...28 /...30 /...31 /...32 910187 /...188 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. 8-16 mm 910187 16-30 mm 910188 CRL1-Traverse Traverse length Drilling Art.-No. 300 mm 1910039 0 mm 19100 600 mm 11 mm 1910099 800 mm 1910090 1000 mm 1910091 CRL2-Traverse Traverse length Drilling Art.-No. 300 mm 1505927 0 mm 1505928 600 mm 13 mm 1505930 800 mm 1505931 1000 mm 1505932 300-1000 M10 15 300-1000 M10 15 a a 11 13 25
RAIL JOINTS for CRL-1 or CRL-2 Rail System Art.-No. 6710182 / 6610008 6610009 Rail joints for CRL-1 and CRL-2 rail systems. Rail joints Material Size Rail A 100 mm CRL-1 6710182 steel (galvanized) 120 mm CRL-1 6610008 120 mm CRL-2 6610009 M8 M8 M8 31 30 15 33 100 32 120 M10 M8 120
RAIL STOPPER and END CAPS for CRL-1 or CRL-2 Rail System Art.-No. 6610010 28801 /...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-2 6610010 End caps Material Wheel Art.-No. plastic CRL-1 28801 CRL-2 28811 30 5 19 30 5 20 M8
WALL TRAVERSE for CRL-1 and CRL-2 Rail Systems Art.-Nr. 57629 /...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 57634 0 mm 57633 600 mm steel (galvanised) 57631 800 mm 57630 1000 mm 57629 80 7 1 13 300-1000 27 13 50
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 ------- + 2 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
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 65 5 5 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.