FLEXIBLE CABLE SYSTEMS
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- Wilfrid Pearson
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1 FLEXIBLE CABLE SYSTEMS
2 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.
3 CONTENTS System Selection Enquiry Sheet Carrying Capacity kg Recommended Maximum Speed (m/min) Wire Rope Systems 6 30 C-Track Systems: - Standard Duty Medium Duty Heavy Duty Square Track Systems: - Standard Duty Heavy Duty I-Beam Systems: - Standard Duty Medium Duty Heavy Duty Extra Heavy Duty Systems Accessories: - Cable - Cable Glands - Rubber Buffers - Pre-Assembled Systems For higher speeds please contact Conductix 1
4 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 For high speed, heavy duty and curved systems please consult your Conductix representative.
5 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
6 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 mm Dia. PVC Covered Wire Rope 10K58 Double Wheel Cable Trolley End Strainer Screw Assembly T58 Towing Trolley End Strainer Bracket 19/380 Towing Arm, 380mm long A58 End Clamp ROUND CABLE SYSTEM Part No. Description Part No. Description mm Dia. PVC Covered Wire Rope 19/380 Towing Arm, 380mm Long End Strainer Screw Assembly RC mm Dia. Cable Clip End Strainer Bracket RC mm Dia. Cable Clip A58H End Clamp RC mm Dia. Cable Clip 5K58H Single Wheel Cable Trolley mm Dia. Cable Clamp 10K58H Double Wheel Cable Trolley mm Dia. Cable Clamp T58H Towing Trolley mm Dia. Cable Clamp Cable Trolley 5K58H Cable Trolley 10K58 4
7 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 Medium Heavy S/S TRACK SUPPORTS Standard & Medium Duty Standard & Medium Duty Standard & Medium Duty Heavy Duty SUPPORT BRACKET & GIRDER CLIP GIRDER CLIP M8 25 MAX. L SUPPORT BRACKET TRACK SUPPORT Description Part No. L 99247/ mm Support Bracket 99247/ mm 99247/ mm 99247/ mm Girder Clip Track Support
8 C TRACK FLAT CABLE TROLLEYS TOWING TROLLEY & ARM TOWING ARM Towing Arm Towing Trolley CABLE TROLLEY PLASTIC 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/ / / / / / /100 Standard / / /072 and / / /100 Medium 99240/ / / / / / / / / / /127 Heavy / / /160 Note: Part number subscript denotes saddle width PENDANT TROLLEYS No.Pins Gal.Steel St.Steel Standard & Medium Duty Standard & Medium Duty Heavy Duty Pendant Trolley with Quick Connect Plug
9 C TRACK ROUND CABLE TROLLEYS TOWING TROLLEY Towing Trolley to suit Round Cable Clip Towing Trolley to suit Round Cable Clamp CABLE TROLLEYS Trolley C/W Swivel Hook Part No. A B C D Trolley C/W U Bolt Part No. A B C D Single Wheel Trolley END CLAMPS End Clamp to suit Round Cable Clip End Clamp to suit Round Cable Clamp ROUND CABLE CLIPS ROUND CABLE CLAMPS Part No. Cable Dia. Min. Max. RC RC RC Part No. Cable Dia. Min. Max
10 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 Standard S/S Heavy Galv TRACK SUPPORTS Duty Material Type Part No. A B C Track Support, Square Nut Type Z/P Sq. Nut Z/P Hex. Nut Standard 42 M6 46 S/S Sq. Nut S/S Hex. Nut Galv. Sq. Nut Heavy 58 M8 52 Galv. Hex. Nut Track Support, Hex. Nut Type DRILLING JIG SUPPORT BRACKET & GIRDER CLIP M8 L Description Part No. L 99247/ mm Support 99247/ mm Bracket 99247/ mm GIRDER CLIP 25 MAX. SUPPORT BRACKET TRACK SUPPORT 99247/ mm Girder Clip Track Support
11 STANDARD DUTY SQUARE TRACK FLAT CABLE TROLLEYS TOWING TROLLEY & ARM TOWING ARM Towing Trolley Towing Arm 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/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /127 PENDANT TROLLEY No.Pins Gal.Steel St.Steel Pendant Trolley C/W Junction Box (Zinc Plated 99448) (Stainless Steel 99436) Pendant Trolley with Quick Connect Plug 9
12 STANDARD DUTY SQUARE TRACK ROUND CABLE TROLLEYS TOWING TROLLEY CABLE TROLLEY END CLAMP Towing Trolley Upper Cable Trolley Upper End Clamp Upper Zinc Plated Stainless Steel Tow Trolley Cable Trolley Upper End Camp A Zinc Plated Stainless Steel Zinc Plated Stainless Steel Zinc Plated Stainless Steel Swivel Hook Zinc Plated Stainless Steel U Bolt Assembly Zinc Plated Stainless Steel ROUND CABLE CLIPS Part No. Cable Dia. Min. Max. RC RC RC ROUND CABLE CLAMPS Part No. Cable Dia. Min. Max
13 HEAVY DUTY SQUARE TRACK FLAT CABLE TROLLEYS TOWING TROLLEY TOWING ARM Towing Trolley Towing Arm CABLE TROLLEY END CLAMP Cable Trolley End Clamp Tow Trolley Cable Trolley L A B C max. D End Clamp 99540/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /250 11
14 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/ / / / / / / / / / / / / / / / / / / / / / / /127 ROUND CABLE TROLLEYS AND CLAMPS Part No. Description Wheel Round Cable Towing Trolley Wheel Round Cable Trolley Wheel Round Cable Trolley Wheel Round Cable Trolley Part No. Description End Clamp RC mm Dia. Cable Clip RC mm Dia. Cable Clip RC mm Dia. Cable Clip Part No. Description mm Dia. Cable Clamp mm Dia. Cable Clamp mm Dia. Cable Clamp 12
15 MEDIUM DUTY BEAM TROLLEYS WITH FLANGED ROLLERS TOWING TROLLEY TOWING ARM Towing Arm 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/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /250 For round cable systems consult your Conductix representative. 13
16 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
17 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
18 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 Roller G available in 50, 100 & 150mm. dias. steel or polyurethane tyred
19 EXTRA HEAVY DUTY SQUARE TRACK SYSTEMS & ACCESSORIES CABLE CLEATS Round Cable Cleat Dimensions A Dia. B Dia. C MIN MAX MIN MAX MIN MAX D E TOW ROPES Dia. Gal. Gal. Steel Stainless S/S mm. Steel PVC. Coat Steel PVC Coat Suffix Part No. with tow rope length SHOCK CORD Dia.mm Part No Suffix Part No. with shock cord length 17
20 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 A Dia. + H Cable Loop Factor Cf Speed Depth of Loop ( m.) M / min > 240 Consult Sales Office 18
21 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) x x / x x /29 F12015PVC 12 x x /42 F14015PVC 14 x x / x x / x x / x x / x x / x x / x x / x x / x x / x x / x x x x CT0815AU* 8 x dia CT1615AU* 16 x dia CT2015AU* 20 x dia CT2510AU* 25 x *Cables complete with two built in steel strainer wires. CABLE GLANDS Part No. A B C D E F min. F max. G min. G max / PG / PG / PG / PG / PG / PG mm Ø12 Ø24 Note: Cable glands manufactured from zinc plated brass or aluminium (except which is plastic)
22 RUBBER BUFFERS STUD TYPE Part No. D1 D2 D3 R1 H L T 99725/ M / M / M / M / M / M / M / M / M PLATE TYPE Part No. D1 D2 D3 R1 A B H T 99726/ / / / / / 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/ / / / / / / / / / / / / / / Buffer Calculation Formulas: Crane Bridge Crab E = (1/2W1+W2) x V1 2 E = 1/2W1 x V2 2 2 Where: W1 = Crane Bridge Weight in kg. W2 = Crab Weight in kg. V1 = Crane Bridge Speed in m/s. V2 = Crab Speed in m/s. E = Kinetic Energy in Joules. 20
23 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.
24 Noremak Industries Pty Ltd 12 Princess Street Beverley SA 5009 PH Fax Picture credit cover Digital Vision TELFORD 1386
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