Festoon Systems for C-Rails Program 0240

Transcription

1 Festoon Systems for C-Rails

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3 Contents System Arrangement Rails and Mounting Parts....3 Festoon Systems for Flat Cables....3 Festoon Systems for Round Cable....3 C-Rails and Accessories C-Rails Curves...4 Track Couplers....5 Track Couplers, Two-Piece....5 Track Support Bracket, One-Piece, for Ceiling Attachment... 6 Track Support Bracket, One-Piece, with Square Nut for Attachment to Support Arms...6 Track Support Bracket, One-Piece, for Attachment to Existing Steel Structure...6 Track Support Brackets, Three-Piece, for Ceiling Attachment... 7 Track Support Brackets, Three-Piece, with Square Nut for Attachment to Support Arms...7 Track Support Brackets, Three-Piece, for Attachment to the Existing Steel Structure....7 Track Support Bracket for Attachment to the Existing Steel Structure...8 Track Support Bracket and Coupler, One-Piece, for Ceiling Attachment....8 Track Support Bracket and Coupler, One-Piece with Square Nut for Attachment to Support Arms...8 Track Support Bracket and Coupler, One-Piece for Attachment to the Existing Steel Structure....8 Track Support Brackets for Attachment to the Existing Steel Structure...9 Track Support Bracket, bare to weld on Track Support Bracket and Coupler, bare to weld on Track Support Bracket for Direct Attachment below I-Beams...10 Bolt Complete Support Arms x x punched...11 Support Arms x x unpunched...11 Permissible Load for Support Arms Bracket for Support Arms x x 2.5 to be bolted with 2-Hole Connecting Plate Bracket for Support Arms x x 2.5 to be bolted with 4-Hole Connecting Plate Console Brackets to be bolted with 4-Hole Connecting Plate Brackets, bare to be welded...13 Girder Clips, Clamping Thickness 4-20 mm Girder Clips, Clamping Thickness mm Girder Clips, Twist-Secured, Clamping Thickness 6-25 mm Girder Clips, Reinforced Type, Clamping Thickness 6-21 mm Girder Clips, Reinforced Type, Clamping Thickness 6-30 mm Application Examples for Support Arm and C-Rail Fastening with Support Arms unpunched Application Examples for Support Arm and C-Rail Fastening with Support Arms punched...16 Application Example for Support Arm and C-Rail Fastening with Welded Brackets...16 End Stop with Rubber Buffer...17 End Stop without Rubber Buffer...17 Application Example for End Stop Assembly Towing Arms End Caps CI-Rail Reinforced Type, Wall Thickness 3.0 mm Track Coupler...19 Track Support Bracket CV-Rail Reinforced Type, Wall Thickness 3.0 mm Track Coupler...20 Cable Trolleys for Flat Cables Steel Cable Trolley with Plastic Cable Support...21 Steel Cable Trolleys, Light Series without Buffer Steel Cable Trolleys, Light Series with Buffer...22 Steel Cable Trolleys, Heavy Series Cable Trolleys for Round Cables Steel Cable Trolleys with Ball Joint for Cable Clips , Light Series without Buffer...24 Steel Cable Trolleys with Ball Joint for Cable , Heavy Series with Buffer Steel Cable Trolleys with Bracket for Cable Clips , Heavy Series with Buffer Cable Clips for Fixation at the Ball Joint Cable Clips for Fixation at the Bracket...26 Additional Cable Clips for Combinations with Sizes and 63 of Types Hose Clip for Fixation at the Ball Joint...27 Hose Clip for Fixation at the Bracket...27 Cable Trolley with Cable Clips, Heavy Series, Rotatable...28 Steel Cable Trolleys, Heavy Series for Clamping of Round Cables with a max. Difference in Diameter of 6 mm Steel Cable Trolleys, Heavy Series for Clamping of Round Cables with a max. Difference in Diameter of 16 mm

4 Contents Cable Trolleys and Accessories for Traversing, Transfer Guide for C-Rail Cable Trolleys for Flat Cables with Additional Rollers...31 Cable Trolley for Applications with Increased Horizontal Forces Cable Trolleys with Horizontal Guide Rollers Ideal Control Unit Trolleys Ideal Control Unit Trolleys with Plug and Socket Connection Basic Configuration Ideal Control Unit Trolleys with Plug and Socket Connection Pre-Assembled Ideal Control Unit Trolley with Plastic Terminal Box Basic Configuration...34 Ideal Control Unit Trolleys with Plastic Terminal Box Pre-Assembled Ideal Control Unit Trolleys with Terminal Box of Steel Basic Configuration...35 Control Trolley Upper Parts Basic Ideal Control Unit Trolleys for Round Cables...36 Accessories for Festoon Systems Application Examples Towing Ropes Pre-Assembled Ropes Shackles Spring Safety Hook Rope Thimbles Rope Clip Rope Eyes Cable Clamps...39 Brake Glider Brake Trolley.... Cable Trolley Upper Parts Plastic Trolleys 2 Rollers Plastic Trolleys 4 Rollers Steel Trolley 2 Rollers Steel Trolley 4 Rollers without Buffer...42 Steel Trolley 4 Rollers with Buffer...43 S-Hook Spring Safety Hook Cable Collar, Plastic...43 Strap for Cable Bundle Cable Clips with Bracket Helpful Hints Calculation of the Load Capacity of C-Rails...45 Load Diagram for C-Rail x x 2.5 ( / / ) Load Diagram for CI-Rail Reinforced (0252-6)...46 Load Diagram for CV-Rail Reinforced (0230-6)...46 Technical Data Formulas to Determine the Number of Loops, Cable Length and Loop Depth...47 Definition of the Cable Arrangement and Cable Trolley Selection...48 Cable Factors

5 System Arrangement Rails and Mounting Parts Support Arm Girder Clip Track Support Bracket C-Rail Track Coupler End cap End Stop Festoon Systems for Flat Cables Towing Trolley End Clamp Flat Cable Cable Trolley Towing Arm Ideal Control Unit Trolley Festoon Systems for Round Cable Towing Trolley End Clamp Round Cable Cable Clip Towing Arm Ideal Control Unit Trolley 5

6 90º C-Rails and Accessories C-Rails 2.5 e X X Material Length sendzimir galvanized steel stainless steel V4A Thickness s I x [cm 4 ] Static Values W x [cm 3 ] e [kg/m] Other lengths or stainless steel V2A (1.4301) on request 90 - Curves R Material R Developed Length Loop Depth max x R for max. Trolley Length sendzimir galvanized steel stainless steel V4A Other curves or stainless steel V2A (1.4301) on request 6 Design in stainless steel V4A

7 C-Rails and Accessories Track Couplers Track Coupler C-Rail Material galvanized steel stainless steel V4A Note A track coupler must be provided at each track joint. Track Couplers, Two-Piece max. Strap for attachment provided by customer ø 9 Material galvanized steel stainless steel V4A Design in stainless steel V4A 7

8 C-Rails and Accessories Track Support Bracket, One-Piece, for Ceiling Attachment ø 11 Track Support Bracket, One-Piece, with Square Nut for Attachment to Support Arms 110 M10 Track Support Bracket, One-Piece, for Attachment to Existing Steel Structure 110 M10 41 max Material Perm. Load galvanized steel stainless steel V4A Material Suitable for support arm type Perm. Load galvanized steel , stainless steel V4A , Material Perm. Load galvanized steel stainless steel V4A Design in stainless steel V4A

9 C-Rails and Accessories Track Support Brackets, Three-Piece, for Ceiling Attachment 112 ø Type Material Perm. Load without locking screw 0.3 galvanized steel with locking screw without locking screw 0.3 stainless steel V4A with locking screw Track Support Brackets, Three-Piece, with Square Nut for Attachment to Support Arms 112 M Type Material Suitable for Support Arm Type Perm. Load without locking screw 0.4 galvanized steel , with locking screw without locking screw 0.4 stainless steel V4A , with locking screw 0.4 Track Support Brackets, Three-Piece, for Attachment to the Existing Steel Structure 112 M10.5 max Type Material Perm. Load without locking screw galvanized steel with locking screw without locking screw stainless steel V4A with locking screw Design in stainless steel V4A 9

10 C-Rails and Accessories Track Support Bracket for Attachment to the Existing Steel Structure Material: galvanized steel Perm. Load: 100 kg : kg Track Support Bracket and Coupler, One-Piece, for Ceiling Attachment ø Material: galvanized steel Perm. Load: 2 kg : kg Track Support Bracket and Coupler, One-Piece for Attachment to the Existing Steel Structure 110 max max Track Support Bracket and Coupler, One-Piece with Square Nut for Attachment to Support Arms M Material: galvanized steel Perm. Load: 2 kg Suitable for support arm type: and : 0.7 kg M Material: galvanized steel Perm. Load: 2 kg : kg

11 C-Rails and Accessories Track Support Brackets for Attachment to the Existing Steel Structure 6 ø Material Perm. Load galvanized steel stainless steel V4A ø Material Perm. Load galvanized steel stainless steel V4A ø Material Perm. Load galvanized steel stainless steel V4A Design in stainless steel V4A 11

12 C-Rails and Accessories Track Support Bracket, bare to weld on Material: bare steel : kg Track Support Bracket and Coupler, bare to weld on Material: bare steel : kg Track Support Bracket for Direct Attachment below I-Beams s h Material: galvanized steel Perm. Load: 160 kg for flange widths mm : 0.0 kg s 200 h Material: galvanized steel Perm. Load: 2 kg for flange widths mm : kg Flange Thickness s Mounting Height h Bolt Complete M10 max Packing Unit [St.] Material x20P 20 galvanized steel x20P 20 stainless steel V4A Design in stainless steel V4A

13 C-Rails and Accessories Support Arms x x punched L1 ø L2 L 1 L 2 Material sendzimir galvanized steel stainless steel V4A Support Arms x x unpunched L L Material sendzimir galvanized steel Design in stainless steel V4A 13

14 f C-Rails and Accessories Permissible Load for Support Arms P Note calculated with σ = 1 N/mm² tension f = appropriate max. resulting deflection I l [m] Support Arm x x P f [cm] Bracket for Support Arms x x 2.5 to be bolted with 2-Hole Connecting Plate ø Material Suitable for Support Arm galvanized steel , Bracket for Support Arms x x 2.5 to be bolted with 4-Hole Connecting Plate ø Material Suitable for Support Arm galvanized steel ,

15 C-Rails and Accessories Console Brackets to be bolted with 4-Hole Connecting Plate ø L Material L galvanized steel Brackets, bare to be welded x Material Suitable for Bracket Fasteners Support Arm bare steel galvanized steel ,

16 C-Rails and Accessories Girder Clips, Clamping Thickness 4-20 mm 60 h s Material galvanized steel stainless steel V4A 0.1 Clamping Thickness s Mounting Height h Girder Clips, Clamping Thickness mm 70 s 8 h Material x36 galvanized steel x36 stainless steel V4A Clamping Thickness s Mounting Height h Girder Clips, Twist-Secured, Clamping Thickness 6-25 mm 8 h s 30 Material galvanized steel Clamping Thickness s 6-25 Mounting Height h 32 - Design in stainless steel V4A 16

17 C-Rails and Accessories Girder Clips, Reinforced Type, Clamping Thickness 6-21 mm 8 60 M10 Girder Clips, Reinforced Type, Clamping Thickness 6-30 mm 10 M12 4kt 25x35 s h s2 h s s2 Material galvanized steel Clamping Thickness s Mounting Height h Clamping Piece 1) s ) is not included with the girder clips Material galvanized steel Clamping Thickness s Mounting Height h Clamping Piece 1) s ) is not included with the girder clips 17

18 C-Rails and Accessories Application Examples for Support Arm and C-Rail Fastening with Support Arms unpunched Support Arm Support Arm 60 Track Support Bracket Track Support Bracket 60 Girder Clip C-Rail Girder Clip C-Rail Support Arm 60 Girder Clip Track Support Bracket C-Rail 60 Application Examples for Support Arm and C-Rail Fastening with Support Arms punched Provided on site Girder Clip Support Arm Track Support Bracket C-Rail Towing Arm Towing Trolley Application Example for Support Arm and C-Rail Fastening with Welded Brackets Main Trolley Bracket for Support Arm Bracket for Support Arm Provided on site Support Arm Track Support Bracket C-Rail Towing Arm Towing Trolley 18

19 C-Rails and Accessories End Stop with Rubber Buffer Material galvanized steel; rubber buffer stainless steel V4A End Stop without Rubber Buffer Material galvanized steel stainless steel V4A Application Example for End Stop Assembly Bolt M 8 x C-Rail Cable Trolley End Stop End Clamp Note The end stop is fixed in the C-rail between the end clamp and the cable trolley. This helps to prevent cable trolleys running into the end clamp. For control supply systems with manually driven ideal control trolleys an end stop mounted at the end of the C-rail prevents the ideal control trolley from travelling out of the rail. Design in stainless steel V4A 19

20 C-Rails and Accessories Towing Arms 63 I ø 9 4 Material l galvanized steel stainless steel V4A End Caps Material: plastic : kg Design in stainless steel V4A

21 C-Rails and Accessories CI-Rail Reinforced Type, Wall Thickness 3.0 mm X 6 X ø Static values: - I x = cm 4 - W x = cm 3 Material: sendzimir, galvanized steel : kg/m Track Coupler Material: galvanized steel : kg Track Support Bracket ø Material: galvanized steel : kg ) 2 holes ø 8.4 mm spaced at mm to be drilled in CI-rail 21

22 C-Rails and Accessories CV-Rail Reinforced Type, Wall Thickness 3.0 mm X 25 X Static values: - I x = cm 4 - W x = cm 3 Material: galvanized steel : kg/m Note Type with wall thickness 2.5 mm on request x = Track Coupler Material: galvanized steel : kg

23 Cable Trolleys for Flat Cables Steel Cable Trolley with Plastic Cable Support lw s da M6 Cable Trolley s M6 54 Technical details Trolley body: galvanized steel Cable supports: plastic Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C 10 s M6 54 da da Towing Trolley End Clamp Cable Trolley Towing Trolley End Clamp d a l w s Max. Load Capacity Max. Travel Speed [m/min] ) Plastic roller and bronze friction bearing 2) Ball bearing, galvanized (ZZ) Note For a better sealing the standard rollers (ZZ) can also be provided with a 2 RS-sealing. The order-no. has to be completed with the variation designation /010. Roller Type 23

24 Cable Trolleys for Flat Cables Steel Cable Trolleys, Light Series without Buffer lw 125 Technical details Trolley body: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10 C to + C s 23 s 13 da da M6 Cable Trolley 75 M6 End Clamp 54 M s 63 da M6 54 Towing Trolley Cable Trolley Towing Trolley End Clamp d a l w s Max. Load Capacity Max. Travel Speed [m/min] Steel Cable Trolleys, Light Series with Buffer s da b2 b Cable Trolley s Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range:-30 C to + C 16 s b2 da Towing Trolley b2 b1 da End Clamp b1 Cable Trolley Towing Trolley End Clamp d a b 1 b 2 s Max. Load Capacity Max. Travel Speed x x x x x x x x x x x x [m/min] Note For a better sealing the standard rollers (ZZ) can also be provided with a 2 RS-sealing. The order-no. has to be completed with the variation designation / Design in stainless steel V4A

25 Cable Trolleys for Flat Cables Steel Cable Trolleys, Heavy Series lw lw k s b da b1 s b2 Cable Trolley Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearing, galvanized with ZZ-sealing Temperature range: -30 C to + C Stainless steel rollers: ball bearing, V4A with 2 RS-sealing Temperature range stainless steel: -10 C to + C 26 s 106 da End Clamp b2 b1 da Towing Trolley b1 Cable Trolley Towing Trolley End Clamp x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x d a l w1 1) l w2 2) b 1 b 2 s k Max. Load Capacity x x x x x x x x x x x x x x x x x x x x x x x x ) without buffer 2) with buffer Note For a better sealing the standard rollers (ZZ) can also be provided with a 2 RS-sealing. The order-no. has to be completed with the variation designation /010. For high speeds up to 100 m/min and/or silent running rollers with polyurethane bandage can be used. The order-no. has to be completed with the variation designation /017. Max. Travel Speed [m/min] (100) (100) (100) (100) (100) (100) (100) (100) (100) Design in stainless steel V4A 25

26 Cable Trolleys for Round Cables Steel Cable Trolleys with Ball Joint for Cable Clips , Light Series without Buffer lw Technical details Trolley body: galvanized steel Ball joint: plastic Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to +60 C Stainless steel rollers: ball bearings, V4A with 2RS-sealing Temperature range stainless steel: -10 C to +60 C 12 Cable Trolley 60 M6 End Clamp Towing Trolley Cable Trolley Towing Trolley End Clamp Max. Load Capacity Max. Travel Speed l w [m/min] Steel Cable Trolleys with Ball Joint for Cable , Heavy Series with Buffer lw k Cable Trolley Technical details Trolley body: galvanized steel Ball joint: plastic Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to +60 C Stainless steel rollers: ball bearings, V4A with 2RS-sealing Temperature range stainless steel: -10 C to +60 C 60 M6 End Clamp Towing Trolley Cable Trolley Towing Trolley End Clamp Max. Load Max. Capacity Travel Speed l w k [m/min] Notes For a better sealing the standard rollers (ZZ) can also be provided with a 2 RS-sealing. The order-no. has to be completed with the variation designation /010. For max. 3 cables in separate cable clips, suspended one below the other Appropriate for cable clips: , , (only suited for trolley length 125 mm); , , (only suited for trolley length 125 mm) 26 Design in stainless steel V4A and acid-resistant plastic

27 Cable Trolleys for Round Cables Steel Cable Trolleys with Bracket for Cable Clips , Heavy Series with Buffer lw k Cable Trolley 47 Technical details Trolley body and bracket: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10 C to + C End Clamp 86 Towing Trolley Cable Trolley Towing Trolley End Clamp Max. Load Capacity Max. Travel Speed l w k [m/min] Note For a better sealing the standard rollers (ZZ) can also be provided with a 2 RS-sealing. The order-no. has to be completed with the variation designation /010. Design in stainless steel V4A 27

28 r r r Cable Trolleys for Round Cables Cable Clips for Fixation at the Ball Joint I b c hmax. ø d for Cable-ø d r l h b c Material plastic hardware: galvanized steel plastic. acid-resistant hardware: stainless steel V4A Cable Clips for Fixation at the Bracket I b c hmax. ø d for Cable-ø d r l h b c Material plastic hardware: galvanized steel aluminum hardware: galvanized steel plastic. acid-resistant hardware: stainless steel V4A Additional Cable Clips for Combinations with Sizes and 63 of Types b c hmax. ø d l for Cable-ø d r l h b c Material aluminum, hardware: galvanized steel Design in stainless steel V4A and acid-resistant plastic

29 Cable Trolleys for Round Cables Hose Clip for Fixation at the Ball Joint ~94 59 ø d 227 Material Hardware for Hose-ø d plastic galvanized steel Hose Clip for Fixation at the Bracket ø d 227 Material Hardware for Hose-ø d plastic galvanized steel

30 Cable Trolleys for Round Cables Cable Trolley with Cable Clips, Heavy Series, Rotatable ø d l c ø d Technical details Trolley body and bracket: galvanized steel Cable clips: aluminium Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C For a better sealing the standard rollers (ZZ) can also be provided with a 2 RSsealing The order-no. has to be completed with the variation designation / l Cable Trolley c 94.5 ø d l Towing Trolley c End Clamp Cable Trolley Towing Trolley End Clamp l ø d c x x x x Max. Load Capacity Max. Travel Speed [m/min] 32 Note Can be combined with cable clips and

31 Cable Trolleys for Round Cables Steel Cable Trolleys, Heavy Series for Clamping of Round Cables with a max. Difference in Diameter of 6 mm lw lw k b2 da b1 b2 Cable Trolley Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10 C to + C da b2 b1 da Towing Trolley b1 End Clamp Cable Trolley Towing Trolley End Clamp d a l w b 1 b 2 k Max. Load Capacity Max. Travel Speed [m/min] x x x x x x (100) x x x x x x Note For a better sealing the standard rollers (ZZ) can also be provided with a 2 RS-sealing. The order-no. has to be completed with the variation designation /010. Design in stainless steel V4A 31

32 Cable Trolleys for Round Cables Steel Cable Trolleys, Heavy Series for Clamping of Round Cables with a max. Difference in Diameter of 16 mm lw lw k b2 da b1 Cable Trolley b2 Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10 C to + C 106 da 71 b2 da Towing Trolley b1 b1 End Clamp Cable Trolley Towing Trolley End Clamp d a l w b 1 b 2 k Max. Load Capacity Max. Travel Speed [m/min] x x x x x x x x x x x x x x (100) 16 Note For a better sealing the standard rollers (ZZ) can also be provided with a 2 RS-sealing. The order-no. has to be completed with the variation designation / Design in stainless steel V4A

33 Cable Trolleys and Accessories for Traversing, Transfer Guide for C-Rail ø Material: galvanized steel : kg Notes Two transfer guides must be mounted at the transfer point with the inlet openings against each other The distance s must not exceed 18 mm Vertical deflection max. 2.0 mm Horizontal deflection max. 5.0 mm All cable trolleys, that pass this transition point must be provided with 3, the towing trolley with 4 pairs of rollers Cable trolleys that do not pass this transition point can be used in standard design s C-Rail Cable Trolley Transfer Guide Cable Trolleys for Flat Cables with Additional Rollers Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C ø 106 Cable Trolley 6-Rollers 26 max max. 58 ø Towing Trolley 8-Rollers ø End Clamp 100 Cable Trolley Towing Trolley End Clamp Max. Load Capacity Max. Travel Speed [m/min] x100/ x100/020x x

34 Cable Trolley for Applications with Increased Horizontal Forces Cable Trolleys with Horizontal Guide Rollers ø 28 ø ø 28 ø s b da Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C 26 s 106 Cable Trolley b2 b1 s da Towing Trolley b2 b1 da End Clamp b1 Cable Trolley Towing Trolley End Clamp d a b 1 b 2 s Max. Load Capacity Max. Travel Speed [m/min] x100/ x100/ x x160/ x160/ x x100/ x100/ x x160/ x160/ x

35 Ideal Control Unit Trolleys Ideal Control Unit Trolleys with Plug and Socket Connection Basic Configuration h Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Note Ideal control unit trolley with basic configuration without end clamp and without cable glands Number of Poles Connecting Threads h possible Attachment Parts PE M 25 x 1.5 M 25 x end clamp and PE M 25 x 1.5 M 32 x brake glider and brake trolley Max. Load Capacity Max. Travel Speed [m/min] 63 Ideal Control Unit Trolleys with Plug and Socket Connection Pre-Assembled h ø 208 Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Note Ideal control unit trolley pre-assembled with end clamp and with cable glands Number of Poles Cable Glands h Type for possible Attachment Parts PE 25 x x flat cables brake glider PE 25 x x PE 25 x x brake trolley 3. round cables PE 25 x x Max. Load Capacity Max. Travel Speed [m/min] 63 35

36 Ideal Control Unit Trolleys Ideal Control Unit Trolley with Plastic Terminal Box Basic Configuration max ø Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Note Ideal control unit trolley with basic configuration without end clamp, cable glands and terminals possible Attachment Parts Max. Load Capacity Max. Travel Speed [m/min] 0247 end clamp , ; brake glider ; brake trolley Ideal Control Unit Trolleys with Plastic Terminal Box Pre-Assembled ø Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Note Ideal control unit trolley pre-assembled with end clamp, cable glands and terminals Number of Poles Cable Glands Type for possible Attachment Parts PE x x flat cables brake glider PE x x PE 32x29 25 x 21 brake trolley 5.30 round cables PE 32 x x Max. Load Capacity Max. Travel Speed [m/min] 63 36

37 Ideal Control Unit Trolleys Ideal Control Unit Trolleys with Terminal Box of Steel Basic Configuration a c b Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + C Stainless steel rollers: ball bearings V4A with 2RS-sealing Temperature range stainless steel: -10 C to + C Note Ideal control unit trolley with basic configuration without end clamp, cable glands and terminals a b c possible Attachment Parts x end clamp , x brake glider ; brake trolley x end clamp x , Max. Load Capacity Max. Travel Speed [m/min] Control Trolley Upper Parts Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30 C to + Stainless steel rollers: ball bearings V4A with 2RS-sealing Temperature range stainless steel: -10 C to + C Note For a better sealing the standard rollers (ZZ) can also be provided with a 2RS-sealing. The order-no. has to be completed with the variation designation / / Design in stainless steel V2A / V4A 37

38 Ideal Control Unit Trolleys Basic Ideal Control Unit Trolleys for Round Cables max. 182 Technical details Trolley body and bracket: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Cable clips: plastic Temperature range: -30 C to + C for Cable-ø Note These control trolleys are used if the round cable is installed directly and without an additional terminal box up to the control station. 38

39 Accessories for Festoon Systems Application Examples End Clamp Rope Eye End Stop C-Rail Cable Trolley Terminal Box Cables Tension Relief Rope Mounted with Cable Reserve Factor Tension Relief Rope Cable Clamp Mounted with Cable Reserve Factor Tension Relief Rope Cable Clamp 0201 Cable Clamp Cable Clamp 0201 ø da Note ø b2 ø da Special pendant station round cables with extruded steel ropes, that do not require separate tension relief devices, are listed in our cable catalog KAT ø b2 min

40 Accessories for Festoon Systems Towing Ropes Pre-Assembled 21 L L ø d 32 ø d ø d Type A (Shackle) Type B (with spring safety hook) ø d Type Material [kg/m] A plastic ,5 2.5 B steel. PVC-covered /0 6.0 A acid-resistant plastic 0.14 Ropes ø d ø d Material [kg/m] plastic ,5 2.5 steel. PVC-covered acid-resistant plastic stainless steel V4A Shackles d b d b Package Size [pc.] Material P M galvanized steel P/1 M stainless steel V4A Spring Safety Hook 12 Material ø x4 galvanized steel x4 stainless steel V4A Rope Thimbles b a a b c Material c galvanized steel stainless steel V4A Design in stainless steel V4A or acid-resistant plastic

41 Accessories for Festoon Systems Rope Clip 14 7 Simplex Rope Clip Material galvanized steel stainless steel V4A Duplex Rope Clip Material galvanized steel stainless steel V4A Rope Eyes Material galvanized steel stainless steel V4A Cable Clamps ø d Cable Clamp ø d Material plastic, hardware: galvanized steel ø d Cable Clamp ø d Material plastic, hardware: galvanized steel Design in stainless steel V4A 41

42 Accessories for Festoon Systems Brake Glider Basic material: plastic Hardware: galvanized steel : kg Brake Glider and hardware Basic material: plastic Hardware: galvanized steel : kg Brake Trolley Material: galvanized steel Hardware: galvanized steel Brake hammer: cast iron : kg

43 Accessories for Festoon Systems Cable Trolley Upper Parts lw a 55 b Cable Trolley Upper Parts without Buffer l w b a Material Max. Load Capacity galvanized steel lw 6 38 k b 10.8 a Cable Trolley Upper Parts with Buffer l w b 8.5 a Material k 46 Max. Load Capacity x x x galvanized steel x x x

44 Accessories for Festoon Systems Plastic Trolleys 2 Rollers Type of roller: plastic roller with friction bearing Max. load capacity: 4 kg Max. travel speed: 20 m/min : kg ø Plastic Trolleys 4 Rollers 0244 Ball bearing: plastic roller with friction bearing Max. load capacity: 10 kg Max. travel speed: 20 m/min : 0.0 kg Steel Trolley 2 Rollers ø Ball bearing: galvanized steel Max. load capacity: 12.5 kg Max. travel speed: m/min : 0.1 kg Steel Trolley 4 Rollers without Buffer Ball bearing: galvanized steel Max. load capacity: 32 kg Max. travel speed: m/min : kg ø 7 ø Ball bearing: galvanized steel Max. load capacity: 32 kg Max. travel speed: m/min : 0.3 kg 32 ø

45 Accessories for Festoon Systems Steel Trolley 4 Rollers with Buffer l 32 ø Type of Roller Max. Load Capacity Max. Travel Speed [m/min] ball bearings: galvanized steel S-Hook x4 Material: galvanized steel : kg 45 ø Spring Safety Hook ø x6 Material: galvanized steel : kg 8 Cable Collar, Plastic ø 5.5 Cable-ø d Material d plastic, hardware: galvanized steel Note For attachment to the trolley with S-hook. 45

46 I 828 Accessories for Festoon Systems Strap for Cable Bundle ø Hmax Dmax. D max. H max. Material plastic, hardware: galvanized steel Note For attachment to the trolley with S-hook. Cable Clips with Bracket D D 30 Number of Loops n D Max. Cable-ø per Loop D Total of all Cable-ø max X X X X X X X X Note To be used in combination with trolley l 46

47 Helpful Hints Determination of the Load Capacity of C-Rails Technical details / bases of calculation The permissible load of the C-rails can be determined with the help of the diagrams. The following bases of calculation have been considered:: 1. Beam on 2 supports, loaded by distributed load symmetrical to the beam center 2. σ b zul = 100 N / mm² without consideration of the lower flange stress 3. σ V 160 N / mm², reference stress from bending stress and lower flange stress 4. f = I A / 2 allowed deflection from load and self-weight of the C-rail 5. The loading is considered symmetrically distributed over all the track supports (brackets) Calculation example Given: F LW = Load/trolley 18 kg l w = Length of cable trolley 125 mm Z = Number of cable trolleys 10 L b = Storage length 1.25 m (m) = Z x l w / 1000 Load Diagram for C-Rail x x 2.5 ( / / ) required load capacity of the track support brackets Length of cable trolley lw P [kg/m] Distance between track support brackets la [m] Solution for C-rail x x 2.5 F LW [kg/cable trolley] Storage length I b [m] From diagram Required distance between the track support brackets [I A ] = 1.30 m Required load capacity of the track support brackets = 2 kg 47

48 Helpful Hints Load Diagram for CI-Rail Reinforced (0252-6) Length of cable trolley lw P [kg/m] Distance between track support brackets la [m] F LW [kg/cable trolley] Storage length I b [m] Targets: Load per trolley [F LW ] = 63 kg; Length of cable trolley [I w ] = 0 mm Number of cable trolleys [Z] = 1; Storage length [I b ] = 0.0 m; (m) = Z x l w / 1000 From diagram: Required distance between track support brackets [I A ] = 4. m Load Diagram for CV-Rail Reinforced (0230-6) Length of cable trolley lw P [kg/m] Distance between track support brackets la [m] F LW [kg/cable trolley] Storage length I b [m] 48 Targets: Load per trolley [F LW ] = 18 kg; Length of cable trolley [I w ] = 125 mm Number of cable trolleys [Z] = 10; Storage length [I b ] = 1.25 m; (m) = Z x l w / 1000 From diagram: Required distance between track support brackets [I A ] = 1.85 m

49 Helpful Hints Technical Data lb ls e lw da LinstM h hges LinstE > 0.1 m Formulas to Determine the Number of Loops, Cable Length and Loop Depth Number of loops: n = Storage length: f (l s + e) 2 h 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 d a [m] d a [m] = cable support diameter e [m] = free space in storage area (recommendation 0.1 m) f = recommended cable factor (see table) h [m] = loop depth (measured from top edge of cable support) h ges [m] = loop depth (measured from lower edge of cable support) 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 49

50 Helpful Hints Definition of the Cable Arrangement and Cable Trolley Selection 4 x 10 4 x 10 7 x x x x x 1.5 b Example for flat cable trolleys Power cables dmax s 1. Formula for calculating the approximate load per trolley F LW F LW 2 h G L G L [kg/m] = 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 accommodate 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] < < 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] < 16 < < < < < Type of Roller [ mm] Permissible Load of the Rollers Ball Bearing, galvanized Ball Bearing V4A Ball Bearing with PUR Bandage 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 day (based on one year) and permissible load of the trolleys with various roller types, can be made by using the above table.

51 Conductix-Wampfler the complete program Your Applications - our Solutions! Festoon systems by 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 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 Festoon systems Conductor rails Non-insulated conductor rails 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. 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. Whether they re enclosed conductor rails or expandable single-pole systems, the proven conductor rails by Conductix-Wampfler reliably move people and material. 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 Slip ring assemblies Inductive Power Transfer IPT Reels, retractors and balancers 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. 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! The no-contact system for transferring energy and data. For all tasks that depend on high speeds and absolute resistance to wear. 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.