Mill Duty Electrification

Welded Cap Conductor Rail

Welded Cap Conductor Rail from Conductix-Wampfler

Mission-critical mill equipment must not go down . . . . .

Low maintenance, long life Welded Cap Conductor Rail can help!

Mill Duty Electrification

Welded Cap Conductor Rail
In modern iron and steel processing

Whether you are electrifying hot metal

Conductix-Wampflers core

facilities, mission-critical equipment

or charging cranes, billet cranes, coil

competence is in the development,

must keep running or you incur

handling equipment, or scrap handling

production, consulting, and installation

unacceptable costs and down time.

systems, the 4000 amp or 6000 amp

of tailor made, engineered solutions

Electrification systems for process

Welded Cap Conductor Rail is a great

that provide energy for our customers

cranes are subjected to challenging

choice for your high current, high

moving machinery.

duty cycles, day in, day out. Yet you

demand mill requirements.

demand maximum availability and

reliability from your equipment.

If you seek a complete and reliable

The rail integrates the hardness and

solution for process crane electrifica-

corrosion resistance of a stainless steel

tion, look no further than Conductix-

running surface with an aluminum body

Wampfler!

for maximum current carrying capacity.

The rail carries US Patent No.
6,983,834 B1.

You should be able to install your

electrification system once, then forget
about it!
Our wide range of mobile electrification
systems can adapt to your unique
requirements. Reliable systems,
optimum efficiency, an experienced,
committed partner; these are good
reasons to choose a mill electrification
system from Conductix-Wampfler.
4000 Amp Welded Cap Rail Conductor Bar System - laterally mounted
- by Conductix-Wampfler.

Welded Cap Conductor Rail

Reliability and Long Life
Welded Stainless Steel Cap
Running surface is virtually wearfree; wears better than aluminum,
copper, or steel surfaces. Cap welds
are on the rail sides to reduce
resistant and improve shoe life.
Replacing a soft rail, like copper
or steel requires grinding to match
the new rail to the old. With the
Welded Cap Conductor Rail this is
unnecessary.
Running surface is corrosion
resistant to enhance conductivity.
Locking stainless steel hardware is
used throughout the system.
Rail body is high-strength,
corrosion-resistant aluminum alloy to
maximize current carrying capacity;
eliminates the need for copper
auxiliary wiring.
Pantograph Collector
Linkage articulates vertically within
a 5.9 (150 mm) range. Horizontally
rigid to accurately track the rail.
Arms rotate on patented fluid
blocks; sealed for life. Eliminates
electrical pitting and joint wear. A
reliable bolted clamp system holds the
shoe in the holder; easy to replace.
4

Welded Cap Conductor Rail from Conductix-Wampfler

Provides reliable power even under the

harshest conditions.

Stainless Steel running surface stays

clean and electrically conductive.

Generous shoe contact with the

stainless steel rail.

Rail clamps and insulators isolate the

current carrying rail.

Specifications

Rails


Splice

Item
4000 amps (50744)
6000 amps (50678)

For 4000 amp (50788)

For 6000 amp (52244)

Parameter

Specification

Body / Cap Materials

6101-T6 Aluminum / 304 Stainless Steel

Cap Thickness

4 mm (4000 amp) or 6 mm (6000 amp)

Cap Hardness

Rockwell 80

Length

39.36 ft (12 m)

Material

High-strength aluminum; locking stainless steel hardware

Vibration and corrosion-resistant stainless steel

Hardware

Material

Pantograph Collector (394196)

Shoe Material

Carbo-bronze or copper graphite

Shunts

Braided Copper - 70mm2

Ampacity - Double Shoe

600 Amps

Max. Speed

656 ft/min (200 m/min)

Vert. Articulation Range

6.9 in. (150mm)

Connections

Can accommodate a number of cables in

various sizes

Hardware

Locking stainles steel (corrosion and

vibration resistant)

Material

Glass reinforced polyester

Max. Temperature

4000 F

Material

Ceramic

Max. Temperature

5000 F +

Material

High-strength aluminum, with locking

stainless steel hardware

Power Feed For 4000 amp rail (50780)

For 6000 amp rail (52380)

Insulated Hanger Assy (51980)

Insulated Hanger Assy - High Temp

Anchor Hanger (50839)

Dont see what you need? Contact Conductix-Wampfler! We have extensive custom engineering abilities.
6

Welded Cap Conductor Rail from Conductix-Wampfler

Iron/Steel Companies We are Proud to Serve With

Conductix-Wampfler Electrification Systems

USA

Mexico & Latin America

AK Steel

ACINDAR Argentina

Arcelor Mittal

Aco Minas Gerais Brazil

Crucible Specialty Steels

AHMSA Mexico

Gerdau Ameristeel

Altonorte Foundries Chile

Gerdau Macsteel

ALUAR Argentina

Griffin Wheel

Alumar Brazil

Lone Star Steel

APM Mexico

North Star Bluescope Steel

Bauxilum Venezuela

Nucor

Chagres Foundries Chile

Republic Engineered Products

Cia. Sid. Huachipato Chile

Scott Forge

CSN Brazil

Severstal

HYLSA Mexico

Steel Dynamics

IMSA Mexico

ThyssenKrupp

ISPAT Mexico

United States Steel Corporation

Sider Peru

Wheatland Tube

SIDERAR Argentina

Worthington Steel

SIDOR Venezuela

3.54 (89.9)
REF
3.54
[ 89,9 ]
2.71 (68.9)
REF
2.71
[ 68,9 ]

.164
(4.17)

.164
REF
[ 4,17 ]

4.13
(105)

4.13 REF
[ 105 ]

1.295
1.295
[ 32,89 ]
(32.9)

2.63
2.63
[ 66,7 ]
(66.7)

.465
[ 11,81 ]

.531
(13.5)
.531
THRU
[ 13,49 ]
Holes
BOTH ENDS

1.725
1.725
[ 43,802 ]
(43.8)

1.077
1.077
[ 27,36 ]
(27.4)
3.937

0.710
(18)

.710
[ 18,03 ]

3.937
(100)
[ 100
]
+1.00
472.44
472.44
-.00
+25,4
(12000)
12000
-0,0

0.465
(27.4)

3.15
3.15
REF
[ 80(80)
]

1.969

1.969
(50)]
[ 50,01

4000 Amp Rail

4.15
4.148(105.4)
REF
[ 105,36 ]

3.176
3.176REF
[ 80,67 ]

.236
(6)

.531 (13.5)
Holes

.236 REF
[ 6]

(80.7)

.531
THRU (2)
[ 13,49 ]
BOTH ENDS

4.06
4.06REF
[ 103,2 ]
(103.2)

2.02
2.02 REF
[ 51,3 ]
(51.3)

1.82
1.82
[ 46,2 ]
(46.2)

1.969
1.969
[ 50,013
(50) ]

3.937
3.937
(100)
[ 100 ]
+1.00
472.44
472.44
-.00
(12000) +25

4.875

4.875
REF
[ 123,825
]
(123.8)

12000

-0

6000 Amp Rail

4.92 (125)

Top of Travel
13.78 (350)

Bottom of Travel
7.87 (200)
M10
Customer
Connection

1.97 (50)

M10 Connector with HM10 nut

Two M16x70 bolts and M16 nuts

Max 1.18 (30)

0.689 (17.5)

4.33 (110)

Collector

Conductix-Wampfler Mill Electrification Services

Custom Services!

Our customers can count on us to

meet their specific service needs and
requirements. With Conductix-Wampfler
everything is possible - from initial
design and development to long term
service contracts.
The more complicated your system is,
the greater your expectations are in
terms of service life and operational
reliability - and the more sense it
makes to take advantage of our aftersales service.
When it comes to service, you can
count on Conductix-Wampfler to
perform!

The Turnkey Solution

As a system supplier, ConductixWampfler offers complete turnkey
solutions to our customers. This
includes the delivery of all necessary
parts to complete the project.
We consider qualified consulting,
project engineering of the complete
system, the choice and selection of the
right components, optimizing the
accessories, the adequate logistic
concept, and the commissioning on
site to be important elements of
Conductix-Wampflers business
activities.
Final Assembly
Planning and Development
Definition of the application
parameters.
Selection of the proper components
for the required system - optimized
to our customers requirements,
application parameters, and
environmental factors.

Conductix-Wampflers specialists provide

complete support from
the initial programming and design
to the final assembly on site
worldwide!

Selection of the optimum energy

supply solution in cooperation with
our customers, as a function of all
considerations including cost,
service life, operating parameters,
installation, and the site.

Supervision of construction, assembly, and mounting on site, or

Complete installation by our trained
specialists.

Service Agreement
Regular maintenance and inspections to increase the operational life
of the facility, ensuring long-term
performance and availability.
All services required on site in the
event of an incident, including spare
parts and replacement materials.
Conductix-Wampfler service agreements: The Worry-Free Package.

10

Conductix-Wampfler - The Complete Program

Other Quality Products from Conductix-Wampfler

Festoon systems
Conductix-Wampfler Cable Trolleys are used in
virtually every industrial application. They are
reliable and robust and avaialble in an enormous
variety of sizes and designs.

The Welded Cap Conductor Rail

system from Conductix-Wampfler is

Motorized Cable reels

Motorized Cable Reels by Conductix-Wampfler

only one of the many products

available from the broad spectrum of

are proven solutions wherever energy and data

cables have to cover a range of distances within
a short amount of time - in all directions, fast

Conductix-Wampfler products for the

and safely.

transmission of energy and data. In

Spring-Driven Cable Reels

every case, the solutions we deliver for

your applications are based upon your
specific requirements.

Conductix-Wampfler offers a complete array of

cable reels powered by spring motors from small
cord reels to large multi-motors units. Smaller
reels are available with popular accessories such
as hand lamps and receptacle boxes.
Conductor Bar

Often, a combination of several

different Conductix-Wampfler systems

Whether enclosed conductor rails or expandable

single-pole systems, the proven Conductor Bar
Systems by Conductix-Wampfler reliably move
people and material.

will be required, which is why you want

to work with a full-line electrification
company.

Push Button Pendants and Radio Controls

Our ergonomic pendants and radios controls are
ideally suited for industrial control applications.
Available in a wide range of configurations for
overhead crane control and other types of
machinery.

You can count on all of ConductixWampflers divisions for hands-on

engineering support coupled with the
perfect solution to meet your energy

Bumpers
Conductix-Wampfler offers a complete range of
bumpers (buffers) including rubber, rubber/metal,
and cellular models, as well as special versions
for vehicles, baggage conveyors and other purposes.

management and control needs.

Inductive Power Transfer IPT
The contactless system for transferring energy
and data. For all tasks that depend on high
speeds and absolute resistance to wear, IPT is
the ideal solution.

11

www.conductix.com

USA

USA

CANADA

MEXICO

10102 F Street

8091 Production Drive

175 Blvd JF Kennedy

Calle Trevio 983-C

Omaha, NE 68127

Florence, KY 41042

St. Jerome, QC J7Y 4B5

Zona Centro

BRO2009.0

Conductix-Wampfler | 2009 | Subject to technical modifications without prior notice.

Apodaca, NL Mxico 66600

Customer Support

Customer Support

Customer Support

Customer Support

Phone: (+1) 800 521 4888

Phone: (+1) 800 326 2899

Phone: (+1) 800 667 2487

Phone: (+52) 81 1090 9519

Fax: (+1) 800 442 9817

Fax: (+1) 800 780 8329

(+52) 81 1090 9025

(+52) 81 1090 9013

Phone: (+1) 402 339 9300

Phone: (+1) 859 814 2100

Phone: (+1) 450 565 9900

Fax: (+1) 402 339 9627

Fax: (+1) 859 814 2110

Fax: (+1) 450 432 6985

info.us@conductix.com

info.us@conductix.com

info.ca@conductix.com

Contact us for our Global Sales Offices

Fax: (+52) 81 1090 9014

info.mx@conductix.com