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Contents
System Arrangement Program 0240
Rails and Mounting Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Festoon Systems for Flat Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Festoon Systems for Round Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Contents
Cable Trolleys and Accessories for Traversing, Program 0240
Transfer Guide for C-Rail 024100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Cable Trolleys for Flat Cables with Additional Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cable Trolley for Applications with Increased Horizontal Forces | Program 0240
Cable Trolleys with Horizontal Guide Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Helpful Hints
Calculation of the Load Capacity of C-Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Load Diagram for C-Rail 40x40x2.5 (024100 / 024104 / 024109) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Load Diagram for CI-Rail Reinforced (024052-6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Load Diagram for CV-Rail Reinforced (024030-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
End Clamp
Flat Cable
Cable Trolley
Towing Arm
End Clamp
Round Cable
Cable Clip
Towing Arm
14 32
Order No.
Material
Length [mm]
Thickness s [mm] 2 .5 2 .5
e [mm] 21 .6 21 .6
Weight [kg/m] 2 .5 2 .5
90- Curves
90
Order No.
Material
R [mm]
Developed Length [mm] 1570 1885 2200 2510 2830 3140 1570 1885 2200 2510 2830 3140
Loop Depth max. 0.35 x R [mm] 350 420 490 560 630 700 350 420 490 560 630 700
for max. Trolley Length [mm] 160 160 200 200 280 280 160 160 200 200 280 280
Weight [kg] 3 .9 4 .7 5 .5 6 .3 7 .1 7 .9 3 .9 4 .7 5 .5 6 .3 7 .1 7 .9
024102-01000 024102-01200 024102-01400 024102-01600 024102-01800 024102-02000 024115-01000 024115-01200 024115-01400 024115-01600 024115-01800 024115-02000
1000 1200 1400 1600 1800 2000 1000 1200 1400 1600 1800 2000
41
18.4
Order No. 024105 024186 Note A track coupler must be provided at each track joint .
125 12 4 28 69
14.5
18 40
40.5
18.4 41.3 4 50
41
Track Support Bracket, One-Piece, with Square Nut for Attachment to Support Arms
110 80 6 40 M10
18.4 41.3 4 50
41
55
18.4 41.3 4 50
max. 20
41
18 40
Type without locking screw with locking screw without locking screw with locking screw
Track Support Brackets, Three-Piece, with Square Nut for Attachment to Support Arms
112 80 7 50 M10
18 4 40
Type without locking screw with locking screw without locking screw with locking screw
40.5
Track Support Brackets, Three-Piece, for Attachment to the Existing Steel Structure
112 80 7 50 M10
18 4 40
Type without locking screw with locking screw without locking screw with locking screw
max. 20
40.5
45
Order No. 024125 Material: galvanized steel Perm . Load: 100 kg Weight: 0 .320 kg
max. 20
18.4 41.3 4 50
41
60
Order No. 024141 Material: galvanized steel Perm . Load: 250 kg Weight: 0 .660 kg
18.4 41.3 4
41
125
Track Support Bracket and Coupler, One-Piece with Square Nut for Attachment to Support Arms
110 80 40 M10
Order No. 024142 Material: galvanized steel Perm . Load: 250 kg Suitable for support arm type: 020186 and 020276 Weight: 0 .750 kg
41
18.4 41.3 4
125
Track Support Bracket and Coupler, One-Piece for Attachment to the Existing Steel Structure
110 max. 20 80 40 M10
Order No. 024143 Material: galvanized steel Perm . Load: 250 kg Weight: 0 .770 kg
18.4 41.3 4
41
125
10
40 6 11 15 41 18.4 41.3 4 50
40 11 15 6
41
18.4 41.3 4
50
Weight [kg]
0 .300 0 .300
104
104
80
11
18.4
41
40 30 h
steel
18.4 41.3
200 30 s h
41
4
160 125
Order No. 024128 Material: galvanized steel Perm . Load: 250 kg for flange widths 40 - 103 mm Weight: 2 .820 kg
41
18.4 50 4 41.3
10 12 16 20
Bolt Complete
M10 5
max.10
14
20 40
20 L2
Order No. 020186-0250 020186-0315 020186-0400 020186-0500 020186-0630 020186-0800 020186-1000 020186-1250 020488-0400 020488-0500 020488-0630 020488-0800 020488-1000 020488-1250
L1 [mm] 250 315 400 500 630 800 1000 1250 400 500 630 800 1000 1250
L2 [mm] 200 260 340 340 340 340 340 340 340 340 340 340 340 340
Material
Weight [kg] 0 .625 0 .785 1 .000 1 .250 1 .575 2 .000 2 .500 3 .125 1 .000 1 .250 1 .575 2 .000 2 .500 3 .125
L 2.5
40
40
14
Order No. 020276-0315 020276-0450 020276-0550 020276-0650 020276-0840 020276-0950 020276-1000 020276-1150 020276-1340 020276-1520 020276-1800 020276-2000
L [mm] 315 450 550 650 840 950 1000 1150 1340 1520 1800 2000
Material
Weight [kg] 0 .785 1 .125 1 .375 1 .625 2 .100 2 .375 2 .500 2 .875 3 .350 3 .800 4 .500 5 .000
13
Note calculated with = 140 N/mm tension f = appropriate max . resulting deflection
l [m] P [kg] f [cm] 0.25 164 .5 0 .07 0.40 103 .0 0 .20 0.50 82 .0 0 .30 0.65 63 .0 0 .45 0.80 51 .5 0 .70 1.00 41 .0 1 .10 1.25 33 .0 1 .70 1.52 27 .0 2 .50 2.00 20 .5 4 .30
Bracket for Support Arms 40 x 40 x 2.5 to be bolted with 2-Hole Connecting Plate
1 1
110
41
80
41.3
45
125
Bracket for Support Arms 40 x 40 x 2.5 to be bolted with 4-Hole Connecting Plate
41.3
125
100
41
100 125
125
14
40
100
80
40
80 100
Material
galvanized steel
Material
41
15
50
4 31
6 32
8 33
10 34
12 35
16 37
20 40
18 - 20 42 - 44
20 - 24 44 - 48
24 - 28 48 - 52
28 - 32 52 - 56
32 - 36 56 - 60
50
30
6 - 25 32 - 40
16
s2
6 - 14 35 - 41 -
11 - 16 41 - 46 5
16 - 21 46 - 51 10
6 - 14 39 - 47 -
14 - 22 47 - 55 8
22 - 30 55 - 63 16
17
60
Girder Clip
60
60
Girder Clip
60
Support Arm
60
Girder Clip
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
Provided on site Bracket for Support Arm Bracket for Support Arm Support Arm Track Support Bracket C-Rail Towing Arm Towing Trolley
18
30
30
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 .
19
63
40
End Caps
40 35 5 21
40
35
20
25
25
40
40
25
X 41 3
X 40.79
14 32 41
25
Order No. 024052-6 Static values: - Ix = 44 .20 cm4 - Wx = 8 .981 cm3 Material: sendzimir, galvanized steel Weight: 5 .300 kg/m
49.21
49
6000
Track Coupler
6 M8 40 50 40
41.5
25
41
160
M8
50 70
40
21
25 19 31.07
X 3 14 32 41 41
28.93
Order No. 024030-6 Static values: - Ix = 16 .816 cm4 - Wx = 5 .412 cm3 Material: galvanized steel Weight: 3 .646 kg/m Note Type with wall thickness 2 .5 mm on request .
25
10 47.5
10
Track Coupler
Order No. 024040 Material: galvanized steel Weight: 1 .230 kg
18 42 4
61
180
22
110
M6 da
54 80
63
36
Cable Trolley
M6 da
92
54 80
Technical details Trolley body: galvanized steel Cable supports: plastic Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C
10
80 50 M6 da 54 80
Towing Trolley
End Clamp
s [mm] 15 15 36 22
Roller Type 1 2
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 .
23
125 32
113
M6
54 80
63
da
36
Cable Trolley
M6
da
90
54 80
Technical details Trolley body: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10C to +80C Cable Trolley Order No. 024244-080 024244-125 024245 024850-080 024850-125 024851 Towing Trolley Order No. 024254 024254 024255 024855 024855 024856
13
75 50 M6
da
M6 54 80
Towing Trolley
End Clamp
End Clamp Order No. 023569 023569 023579 023438 023438 023439
lw [mm]
80 125 125 80 125 125
s [mm]
15 36 22 15 36 22
12 .5
50
200 32 44 70
b2
M8
b1
Cable Trolley
135.5
70
58.4
Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range:-30C to +80C
b2
110 85 M8 b2 b1
da
M8
M8
b1
16
Towing Trolley
da
End Clamp
Towing Trolley Order No. [kg] 024279-200x100 024280-200x100 024279-200x160 024280-200x160 0 .905 0 .975 1 .170 1 .240
End Clamp Order No. [kg] 024289-100x038 024290-100x038 024289-160x038 024290-160x038 0 .370 0 .440 0 .635 0 .690
da [mm] 50 80 50 80
b2 [mm] 72 132
s [mm] 35 20 35 20
28
63
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 .
24
44
da
b1
M8
74
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: -30C to +80C Stainless steel rollers: ball bearing, V4A with 2 RS-sealing Temperature range stainless steel: -10C to +80C Cable Trolley Order No. [kg] 024210-100x100 024210-125x100 024210-125x160 024210-135x100 024210-160x100 024210-160x160 024210-200x100 024210-200x160 024212-160x100 024212-160x160 024212-200x100 024212-200x160 024212-250x100 024212-250x160 024213-200x100 024213-200x160 024213-250x100 024213-250x160 024213-250x200 024214-250x160 024214-320x200 024810-125x100 024810-200x100 024812-160x100 024812-250x100 024812-250x160 024913-200x100 024913-250x160 024814-280x160 0 .83 0 .85 1 .09 0 .91 0 .93 1 .17 1 .05 1 .29 1 .05 1 .38 115 1 .48 1 .39 1 .72 1 .30 1 .72 1 .40 1 .82 2 .21 2 .07 2 .76 0 .85 1 .05 1 .05 1 .39 1 .72 1 .28 1 .86 2 .17 024220-200x100 024220-200x100 024220-200x160 024220-200x100 024220-200x100 024220-200x160 024220-200x100 024220-200x160 024222-200x100 024222-200x160 024222-200x100 024222-200x160 024222-250x100 024222-250x160 024223-200x100 024223-200x160 024223-250x100 024223-250x160 024223-250x200 024224-250x160 024224-320x200 024820-200x100 024820-200x100 024822-200x100 024822-250x100 024822-250x160 024923-200x100 024923-250x160 024824-280x160 Towing Trolley Order No. [kg] 1 .65 1 .65 2 .09 1 .65 1 .65 2 .09 1 .65 2 .09 1 .75 2 .28 1 .75 2 .28 1 .99 2 .52 1 .90 2 .52 2 .00 2 .62 3 .01 2 .87 3 .56 1 .65 1 .65 1 .75 1 .99 2 .52 1 .88 2 .66 2 .97
106 80 s 26
da
M8
b1
Towing Trolley
b2 M8
da
b1
End Clamp
Max. Load Capacity [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] da lw11) lw22) b1 b2 s k 0 .70 0 .70 0 .94 0 .70 80 0 .70 0 .94 0 .70 0 .94 0 .80 1 .13 0 .80 125 1 .13 0 .82 1 .15 1 .00 1 .40 11 .0 160 1 .40 1 .85 1 .65 200 2 .22 0 .70 80 0 .70 0 .80 0 .82 125 1 .15 0 .98 160 1 .44 1 .65 200 100 135 125 125 160 160 200 200 160 160 200 200 250 250 200 200 250 250 250 250 320 125 200 160 250 250 200 250 280 100 100 160 100 100 160 100 160 100 160 100 160 100 160 115 175 115 175 215 175 215 100 100 100 100 160 100 160 175 72 72 132 72 72 132 72 132 72 132 72 132 72 132 72 132 72 132 172 132 172 72 72 72 72 132 72 132 132 10 20 20 27 38 38 58 58 15 15 35 35 60 60 18 18 42 42 42 22 58 20 58 15 60 60 18 42 38 46 32
Max. Travel Speed [m/min] 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 80 80 80
024230-100x062 024230-100x062 024230-160x062 024230-100x062 024230-100x062 024230-160x062 024230-100x062 024230-160x062 024232-100x042 024232-160x042 024232-100x042 024232-160x042 024232-100x062 024232-160x062 024233-100x042 024233-160x042 024233-100x042 024233-160x042 024233-200x042 024234-160x042 024234-200x062 024830-100x062 024830-100x062 024832-100x042 024832-100x062 024832-160x062 024933-100x042 024933-160x042 024834-160x042
81 121 81 121 171 121 171 171 241 46 121 81 171 121 171 201
32 32 32 32 32 32 32 32 16 16 16 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 /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 . Design in stainless steel V4A 25
125 32
108 63
12
Technical details Trolley body: galvanized steel Ball joint: plastic Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +60C Stainless steel rollers: ball bearings, V4A with 2RS-sealing Temperature range stainless steel: -10C to +60C Cable Trolley Order No. 024313-80 024313 024860-080 024860-125 Towing Trolley Order No. lw [mm] 80 125 80 125 024314 024861
Cable Trolley
60 M6
11
36
82
80
Towing Trolley
80
40
End Clamp
13
Steel Cable Trolleys with Ball Joint for Cable 020131, Heavy Series with Buffer
lw 32 k 70 58
Cable Trolley
44 11
74
Technical details Trolley body: galvanized steel Ball joint: plastic Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +60C Stainless steel rollers: ball bearings, V4A with 2RS-sealing Temperature range stainless steel: -10C to +60C Cable Trolley Order No. 024310-125 024310-160 024880-125 Towing Trolley Order No. 024311 024881
80
60
M6
Towing Trolley
80
40
End Clamp
13
k [mm] 46 81 46
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 Appropriate
max . 3 cables in separate cable clips, suspended one below the other for cable clips: 020131-16, 020131-35, 020131-36 (only suited for trolley length 125 mm); 020431-16, 020431-35, 020431-36 (only suited for trolley length 125 mm)
26
86
200 32
80
44 47
Cable Trolley
Technical details Trolley body and bracket: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10C to +80C Cable Trolley Order No. 024320-125 024320-160 024320-200 024885-125
106 80 61.5
86 M8
Towing Trolley
End Clamp
k [mm] 46 81 121 46
024321 024886
024322 024887
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 .
27
hmax.
h [mm] 38 47 58 38 47 58
b [mm] 35 50 70 35 50 70
c [mm] 42 50 64 42 50 64
Material plastic . hardware: galvanized steel plastic . acid-resistant . hardware: stainless steel V4A
hmax.
Order No. 020133-16 020133-25 020133-36 020133-50 020133-63 020433-16 020433-25 020433-36
c [mm] 42 50 64 90 100 42 50 64
Additional Cable Clips for Combinations with Sizes 50 and 63 of Types 020133
b c
hmax.
h [mm] 80 105
c [mm] 90 100
Material plastic . hardware: galvanized steel aluminum . hardware: galvanized steel plastic . acid-resistant . hardware: stainless steel V4A
Weight [kg] 0 .050 0 .070 0 .140 0 .280 0 .480 0 .040 0 .060 0 .120
28
Material plastic
104 69
227
Material plastic
29
200 32 121 72
74
Technical details Trolley body and bracket: galvanized steel Cable clips: aluminium Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C 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 /010 .
Cable Trolley
106 80
l
M8
Towing Trolley
End Clamp
94.5
[kg]
1 .54 1 .74
l [mm] d [mm] c [mm] 200 37-50 90 024527-200x050 250 51-63 100 024527-200x063
30
196.5
44
56
71
72
44
M8
da
b2 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: -30C to +80C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10C to +80C
da
106 80 49
151
56
74
b1
Towing Trolley
M8
M8
da
b2
b1
End Clamp
Cable Trolley Order No. [kg] 024442-160x100 024442-160x160 024443-200x160 024444-250x100 024444-250x160 024943-200x160 1 .30 1 .57 1 .92 1 .70 2 .27 1 .92
Towing Trolley Order No. [kg] 024452-200x100 024452-200x160 024453-200x160 024454-250x100 024454-250x160 024953-200x160 2 .00 2 .37 2 .72 2 .20 3 .07 2 .72
End Clamp Order No. [kg] 024462-100 024462-160 024463-160 024464-100 024464-160 024963-160 1 .10 1 .35 1 .60 1 .30 1 .85 1 .60
32
80 (100)
16
80
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 .
31
lw 32
112
104
b2
52
M8
da
b1
225
Cable Trolley
M8
da
b2
Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Stainless steel rollers: ball bearing, V4A with 2RS-sealing Temperature range stainless steel: -10C to +80C
106 80 M8
b1
Towing Trolley
71
b2 M8
da
b1
End Clamp
Cable Trolley Order No. [kg] 024474-250x160 024474-250x200 024475-320x160 024475-320x200 024477-400x250 024974-250x160 024975-320x250 2 .27 2 .67 2 .72 3 .12 4 .52 2 .27 3 .62
Towing Trolley Order No. [kg] 024484-250x160 024484-250x200 024485-320x160 024485-320x200 024487-400x250 024984-250x160 024985-320x250 3 .07 3 .47 3 .52 3 .92 5 .32 3 .07 4 .42
End Clamp Order No. [kg] 024494-160 024494-200 024495-160 024495-200 024497-250 024994-160 024995-250 1 .85 2 .25 2 .10 2 .50 3 .70 1 .85 3 .00
32
80 (100)
16
80
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 .
32
Order No. 024107 Material: galvanized steel Weight: 1 .200 kg Notes 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
Two
62.5 11
6 127.5
110 80 49
14 125
127.5
127.5
C-Rail
Cable Trolley
Transfer Guide
45
200 32
48
44
max. 58
100
M8
0 8
max. 62 26
Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C
M8
74
72
128
35
72
56
72
100
72
100
End Clamp
8 0
[kg] 1 .03
[kg] 1 .85
[kg] 0 .70
33
Cable Trolley for Applications with Increased Horizontal Forces | Program 0240
Cable Trolleys with Horizontal Guide Rollers
282 211 32 28 121 48 M8 34
282 211 32 28
34
184
b2
104
52
da
b1
Technical details Trolley body and cable supports: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C
Cable Trolley
106 80 26
M8
112
b2
M8
da
b1
Towing Trolley
b2 M8
da
b1
End Clamp
da
b1
b2
[kg] [mm] [mm] [mm] [mm] 0 .70 80 0 .94 80 0 .82 125 1 .15 125 100 160 100 160 72 132 72 132
60
32
63
34
208
400
Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Order No. Number of Poles Connecting Threads
Note Ideal control unit trolley with basic configuration without end clamp and without cable glands
h [mm]
Weight [kg]
024776-16 024776-24
16 + PE 24 + PE
M 25 x 1 .5 M 25 x 1 .5
M 25 x 1 .5 M 32 x 1 .5
275 290
end clamp 023269 and 023299 brake glider 024784 and brake trolley 024785
3 .04 3 .34
Ideal Control Unit Trolleys with Plug and Socket Connection Pre-Assembled
475 32 81
50
208
80
Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Order No. Number of Poles 16+ PE 24+ PE 16+ PE 24+ PE Cable Glands
Note Ideal control unit trolley pre-assembled with end clamp and with cable glands
h [mm]
25 x 42 25 x 42 25 x 29 25 x 29
25 x 21 32 x 29 25 x 21 32 x 29
40
63
35
max .15 2
10
12
200
428
55 115
Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Order No.
Note Ideal control unit trolley with basic configuration without end clamp, cable glands and terminals
possible Attachment Parts end clamp 023269, 023299; brake glider 024784; brake trolley 024785
Weight [kg] 4 .3
024780
428
57.5 115
Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Order No. Number of Poles 16 + PE 24 + PE 16 + PE 24 + PE Cable Glands
Note Ideal control unit trolley pre-assembled with end clamp, cable glands and terminals Type for flat cables round cables possible Attachment Parts brake glider 024784 brake trolley 024785 Weight [kg] 5 .35 5 .75 5 .30 5 .61 Max. Load Capacity [kg] Max. Travel Speed [m/min]
50 x 42 50 x 42 32x29 32 x 29
25 x 21 32 x 29 25 x 21 32 x 29
40
63
60 120
Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80C Stainless steel rollers: ball bearings V4A with 2RS-sealing Temperature range stainless steel: -10C to +80C Order No. a [mm] 024781-200x200 024781-300x200 024791-200x200 024791-300x200 200 300 200 300 b [mm] 200 200 c [mm] 338 438 338 438
Note Ideal control unit trolley with basic configuration without end clamp, cable glands and terminals
possible Attachment Parts end clamp 023269, 023299 brake glider 023184; brake trolley 023185 end clamp 023469, 023499
500
Technical details Trolley body and cross bar: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Temperature range: -30C to +80 Stainless steel rollers: ball bearings V4A with 2RS-sealing Temperature range stainless steel: -10C to +80C Order No. 024771 024771/500 Weight [kg] 1 .95 1 .95
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 / 010 .
138
37
Technical details Trolley body and bracket: galvanized steel Hardware: galvanized steel Standard rollers: ball bearings, galvanized with ZZ-sealing Cable clips: plastic Temperature range: -30C to +80C Order No. 024711-16 024711-25 024711-36
for Cable- [mm] 10 16 17 25 26 36 Weight [kg] 0 .640 0 .660 0 .720
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
max. 182
Terminal Box
Cables
Mounted with Cable Reserve Factor Tension Relief Rope Mounted with Cable Reserve Factor Cable Clamp 020143 Tension Relief Rope
da da Note b2 Special pendant station round cables with extruded steel ropes, that do not require separate tension relief devices, are listed in our cable catalog KAT0130-0002. min. 10 b2
39
21
21
32
32
Type A (Shackle) Order No. 020318-06 020329-04 020329-02,5 020318-06/500 d [mm] 6 .0 4 .0 2 .5 6 .0 Type A B A
Type B (with spring safety hook) Material plastic steel . PVC-covered acid-resistant plastic Weight [kg/m] 0 .14 0 .16 0 .14 0 .14
Ropes
d [mm] 6 .0 2 .5 6 .0 2 .0
Shackles
b d
d M6 M5
b [mm] 8 11
21
Rope Thimbles
b a
40
a [mm] 5 .0 6 .5 5 .0 6 .5
b [mm] 11 13 11 13
c [mm] 23 .5 28 .5 23 .5 28 .5
40
20
20
Rope Eyes
30 M8 5 25
50
40 12
Cable Clamps
Cable Clamp Order No.
d
d [mm] 11 . . . 16 17 . . . 25 26 . . . 36
Material
d [mm] 10 . . . 16 17 . . . 25 26 . . . 36
Material
41
Order No. 024784 Basic material: plastic Hardware: galvanized steel Weight: 0 .100 kg
108
32
37
108
26.5 35
16
Brake Glider and hardware Order No. 024719 Basic material: plastic Hardware: galvanized steel Weight: 0 .200 kg
155
32
Brake Trolley
55 260 32
Order No. 024785 Material: galvanized steel Hardware: galvanized steel Brake hammer: cast iron Weight: 1 .200 kg
115
65
42
55 b 13
6.8
Cable Trolley Upper Parts without Buffer Order No. 024512-80 024512
lw [mm] 80 125
b [mm] 74 80
a [mm] 13 .0 18 .0
lw 32
6 k 10.8 b a 8.5
Cable Trolley Upper Parts with Buffer Order No. 024510-125x100 024510-125x160 024510-160x100 024510-160x160 024510-200x100 024510-200x160
Material
38
galvanized steel
32
43
18
35
Order No. 024331 Type of roller: plastic roller with friction bearing Max . load capacity: 4 kg Max . travel speed: 20 m/min Weight: 0 .020 kg
Order No. 024504 Ball bearing: plastic roller with friction bearing Max . load capacity: 10 kg Max . travel speed: 20 m/min Weight: 0 .050 kg
34 10 14
10
40
8.5
Order No. 024330 Ball bearing: galvanized steel Max . load capacity: 12 .5 kg Max . travel speed: 40 m/min Weight: 0 .150 kg
10
25
Order No. 024323 Ball bearing: galvanized steel Max . load capacity: 32 kg Max . travel speed: 50 m/min Weight: 0 .320 kg
47
2 8.
30
22
100 32
Order No. 024340-100 Ball bearing: galvanized steel Max . load capacity: 32 kg Max . travel speed: 50 m/min Weight: 0 .380 kg
10.5
10
44
32
10.5
10
32
Order No.
Type of Roller
S-Hook
14
.2 4
45
5.5
Order No. 020111-08 020111-10 020111-11 020111-12.5 020111-14 020111-16 020111-18 020111-20 020111-22 020111-25 020111-28 020111-32 020111-36
Cable- d [mm] 8 10 11 12 .5 14 16 18 20 22 25 28 32 36
Material
Weight [kg] 0 .0070 0 .0077 0 .0077 0 .0081 0 .0084 0 .0085 0 .0850 0 .0100 0 .0100 0 .0110 0 .0120 0 .0130 0 .0140
6.5
4 18
16
28
2 50
Dmax.
Order No. 020117-080 020117-160 Note For attachment to the trolley with S-hook .
Hmax
30
Order No.
Number of Loops nD
Max. Cable- per Loop D [mm] 8-18 8-22 8-22 8-22 8-22 8-22 8-22 8-22
Weight [kg] 0 .055 0 .060 0 .065 0 .070 0 .070 0 .090 0 .090 0 .095
1 1 2 2 3 3 4 5
46
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. 2. 3. 4. 5. Beam on 2 supports, loaded by distributed load symmetrical to the beam center bzul = 100N/mm without consideration of the lower flange stress V 160N/mm, reference stress from bending stress and lower flange stress f = IA/250 allowed deflection from load and self-weight of the C-rail The loading is considered symmetrically distributed over all the track supports (brackets)
Calculation example Given: FLW = Load/trolley lw = Length of cable trolley Z = Number of cable trolleys Lb = Storage length (m) = Z x lw/1000
25
lW [mm]
0 10
0 16
800 630 500 400 320 250 200 160 125 80 63 50 40 32 25 20 16 12.5 10 8 6.3 100
P [kg/m]
3.2 4.0 0.08 0.1 0.125 0.16 0.2 0.25 0.32 0.4 0.5 0.63 0.8 1.0 1.25 1.6 2.0 2.5 3.2 4.0 3.6
Storage length
Ib [m]
Solution for C-rail 40x40x2.5 From diagram distance between the track support brackets [IA] = 1.30m Required load capacity of the track support brackets = 250kg
Required
lA [m]
47
Helpful Hints
Load Diagram for CI-Rail Reinforced (024052-6)
lW [mm]
80 0 5 0 0 0 0 0 0 10 12 16 20 25 32 40 50
80 63 50 40 32 25 20 16 12.5 10 8.0 6.3 5.0 4.0 3.2 2.5 2.0 1.6 1.25 1.0 800 630 500 400 320 250 200 160 125 100 80 63 50 40 32 25 20 16 12.5 10 8 6.3 1.0 1.12 1.25 1.4 1.6 1.8 2.0 2.24
P [kg/m]
6.3 0.1 0.125 0.16 0.2 0.25 0.32 0.4 0.5 0.63 0.8 1.0 1.25 1.6 2.0 2.5 3.2 4.0 5.0 6.3
Storage length
Ib [m]
Targets: Load per trolley [FLW] = 63kg; Length of cable trolley [Iw] = 400mm Number of cable trolleys [Z] = 1; Storage length [Ib] = 0.400m; (m) = Z x lw/1000
From diagram: Required distance between track support brackets [IA] = 4.80m
Storage length
Ib [m]
Targets: Load per trolley [FLW] = 18kg; Length of cable trolley [Iw] = 125mm Number of cable trolleys [Z] = 10; Storage length [Ib] = 1.25m; (m) = Z x lw/1000 48
From diagram: Required distance between track support brackets [IA] = 1.85m
P [kg/m]
lA [m]
lA [m]
Helpful Hints
Technical Data
lb ls
lw
da
LinstM
h hges
LinstE
Formulas to Determine the Number of Loops, Cable Length and Loop Depth
Number of loops: n = f (ls+e) 2h+1.25 da-flw Storage length: lb nlw+e [m] da [m] = cable support diameter e [m] = free space in storage area (recommendation 0.1m) f = recommended cable factor (see table) h [m] = loop depth (measured from top edge of cable support) hges [m] = loop depth (measured from lower edge of cable support) lb [m] = storage length incl. free space ls [m] = travel distance lw [m] = cable trolley length LBest [m] = total cable length LinstE [m] = installation length, end clamp side LinstM [m] = installation length, towing side LSchl [m] = cable length per loop LSyst [m] = required cable length (measured from mid of end clamp to mid of towing trolley or towing clamp) n = number of loops
> 0.1 m
49
Helpful Hints
Definition of the Cable Arrangement and Cable Trolley Selection
4x10 4x10 s
1. Formula for calculating the approximate load per trolley FLW FLW 2hGL [kg]
GL [kg/m] = weight of the cable package
Power cables
dmax b
2. Selection of the cable trolley type 3. Required cable support diameter based upon minimum bending radius of the cables 4. Select cable support width b2 to accommodate the cable package width 5. Determine length of trolley lW For round cables:: lw da+2dmax+10 [mm] For flat cables: lw da+2s+10 [mm]
Cable Factors
Travel Speed v [m/min] < 32 32 - 40 41 - 50 51 - 63 64 - 80 81 - 100 101 - 120 < 0.8 1.10 1.15 1.20 1.25 0.8 - 1.2 1.10 1.10 1.15 1.20 1.25 Cable Factor f at h [m] 1.3 - 2 1.10 1.10 1.10 1.15 1.20 1.25 2.1 - 3.2 1.10 1.10 1.10 1.10 1.15 1.20 1.25 3.3 - 5 1.10 1.10 1.10 1.10 1.10 1.15 1.20
Depending on the operating conditions the cables must be installed with an additional cable length. The additional length is calculated by taking into account the cable factor [f]. We recommend to select the cable factor according to above table. For values outside the gray area, please contact us directly. Special precautions might be required in those cases under extreme operating conditions, such as the installation of shock cords.
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.
50
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KAT0240-0003a-E