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Enclosed Conductor Rail Boxline Program 0842: WWW - Conductix.Us
Enclosed Conductor Rail Boxline Program 0842: WWW - Conductix.Us
Rail Curves
Horizontal Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Vertical Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Order Number Code for Curve, System AN (Angle Clamping). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
In-line Feeds
In-line Feeds with Single Core Cable Entry up to 60 A and In-line Feeds Joint Covers AN (Angel Clamping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
In-line Feeds with Terminal Box up to 140 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Expansion Elements
General Expansion Element Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Example: Setting the Expansion Element Depending on the Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Expansion Elements (with 100 mm Expansion) for System CS (Continuous Strip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Expansion Elements (with 100 mm Expansion) for the Systems PL, JT and AN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pick-up Guides
Pick-up Guides for Transfer Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Conversion Retrofit Kits to Add a Power Feed Point to Pick-up Guides/Transfer Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pick-up Guides for Entrance Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pick-up Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly Tools
Strip Insertion Trolley for System CS (Continuous Strip). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
De-coil Unit for Simplified Strip Insertion - Optional (System CS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bending Device for Chamfering the Copper Strip for System AN (Angle Clamping). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Positioning Block for System AN (Angle Clamping) and Insertion Tool for Sealing Lip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Support Arm (Optional), Girder Clip (Optional) and Weld-on Bracket for Support Arm (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Program Overview
Conductor Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3
The established, universally applicable system is used on crane systems, transfer carriages, tasksaver systems, electric hoisting equipment,
theater applications and a variety of other mobile consumers for indoor and outdoor use, ideally suited for straight tracks.
The Advantages
The system 0842 is mainly characterized by the following features:
• Enclosed profile with captured collector
• Collector cable exits the system from the lower slot
• High variability by 4 different types of system connection
• Fast and safe assembly by adjustable and rotating snap-in hanger clamps and
other innovative details
• Supplied in easy to handle 4 m sections
• High protection against direct contact and compliance with
international standards
• Broad selection of accessories
Snap-in assembly
Collector trolley
The roller-guide collector trolleys are available as 4, 5 and 7 pole types.
Copper graphite carbon shoes are used for energy and control voltages
over 35 V. For the data transmission and low voltage below 35 V we re-
commend silver graphite carbons in connection with a datametal conduc-
tor. Double collectors are used to improve the quality of the contact and
for transfers (for further information refer to the collector section.
Towing arm
Towing arms are designed as the attachment point between the moving
machine and the collector. They are available in „fork“ or chain versions,
both of which are designed for straight, uninterrupted tracks or a special
spring-loaded design is available for systems with pick-up guides/iso-
lation sections.
Connection Alternatives
High flexibility by various techniques for joining parts for each required system.
Plug-in type (system PL)
Characteristics:
• Simple plug-in
• Ideal for short systems
• From 35 A up to 60 A (100% ED)
Note
For adding the profile joints, it is required to use a positioning tool (see page
22). This tool prevents a step misalignment of the conductor strips (angle clam-
ping). It is recommended to order the tool for all connecting systems. It serves
in general as „third hand“ while adding the profile joints and allows for a faster
and easier assembly.
Basic Variants / Lengths of Profile 4, 5 and 7 poles / 4 m (sub-lengths: 1 m, 2 m, 3 m)
Nominal Voltage 35 ... 690 V
Installation Position slot downwards; as shown below
Support Spacing max. 2000 mm (500 mm curves)
External Dimensions 56 x 90 mm
Travel Speed up to 150 m/min straight track (< 85 m/min on transfers)
Standard Current Strip Arrangement Plastic casing
4 poles: 4
L1, L2, L3, PE
5 poles: L1 L3 L1
L1, L2, L3, 4, PE
7 poles ²): L2
L1, L2, L3, ④, ⑤, ⑥, PE L2 PE yellow-green
L3 PE yellow-green
2) In case of system extension please check the pole disposition. Systems built before 2000 have a different pole disposition (see also MV0842-0020DEF
or the respective documentation of the system).
PE 6 5 9 8 7
10 1, 2, 3, 4 12 11 13
For straight systems (L1, L2, L3, PE) of limited length at low/medium load it is recommended to use 4 pole-“plug-in type”
with standard components.
90
transmission in corrosive environments and/or at system
voltage approx. ≤ 35 V
• Standard current strip arrangement see page 4
56
Plastic casing 107
ca. 20
80 Optional sealing lip see page 21
Joint cover
Recommendation: a connector of the AN system should be ordered per system if a division of the tape is necessary during assembly
56
Conductor rail
118
ca. 20
90
56
Plastic casing 118
ca. 20
113
Optional sealing lip see page 21
Joint cover
Important note
• The positioning tool (positioning block) 084295-3 or 08-V015-0466 (page 22) is
mandatory for the connection of the guide wire!
56 The positioning block serves as a counter point for the assembly of
Conductor rail
the connecting position and avoids any offset of the contact strip.
118
ca. 20
113
Optional sealing lip see page 21
Joint cover
Horizontal Curves
R + 28 R + 28
R R
R - 28 R - 28
On request
Outer curve
Inner curve α 2750 ≤ R < 3000 0° - 45°
R
Vertical Curves
R - 41
R + 41
R
R + 41
R - 41
R
On request
Outer curve
Inner curve α 5000 ≤ R < 6000 0° - 22.5°
R
6000 ≤ R On request
Slot 1) See page 21
2) Special collector required for this configuration
20
max. 20
M8
M8
max.
Technical details
• Material: plastic; steel
47
47
• Snap-in type; swivelling
156
156
min. 18
18
• Support distance ≤ 2000 mm
105
105
min.
• Weight: 0.11 kg
7373 4040
max. 38
105
min. 18
• For support arm assembly
• Support distance ≤ 2000 mm
73 40
• Weight: 0.14 kg
Anchor Clamp
Part No. 084231-11
max. 30
min. 10
M8
Technical details
• Material: plastic; steel
• Weight: 0.16 kg
156
107
80 89
30
30 25
25 Part No. 084233-11
M8
M8
Technical details
• Material: plastic; steel
• For support arm assembly
156
156
• Weight: 0.18 kg
max. 38
38
107
107
min. 10
10
max.
min.
80
80 89
89
Type with steel square nut
Technical details
• Material: galvanised steel
• Weight: 0.4 kg
166
• Incl. universal hex and square nuts set for flexible installation
106
110
83
96
Notes
• Hanger clamp with integrated rollers
56.5 70 • Recommended for application with higher temperature range
13
12
29
141
• For joint systems PL and AN few
modifications are required on-site.
• Further details see installation
instructions program 0842
130 130
End Feed up to 100 A for CS (Continuous Strip) and up to 140 A for JT (Joint Clamping)
110 Technical details
• Housing material: plastic
• Cable lugs included
37
200
160 230
End Cap
Part No. 084271
Technical details
115
• Material: plastic
• Weight: 0.13 kg
69 70
Standard type
Technical details
115
• Material: plastic
M20 • Weight: 0.14 kg
69 70
Type for connection of bus terminating resistors 13
33
118
123
113 425 150
1000
4/5 poles
(33)
118
123
Technical details
• Single core
113 225 150 250
• 2 separate feedings
for 7 pole systems 1000
7 poles
In-line Feeds Poles Nom. Current Feeding Control Feeding Weight Part No.
for System [A] [Pc.] L [m] [mm²] [Pc.] L [m] [mm²] [kg]
4 4 2 10 - - - 3.80 084252-040x52
5 up to 60 5 2 10 - - - 4.30 084252-050x53
7 4 2 10 3 2 2.5 4.40 084252-070x55
CS (continuous strip)
4 4 2 10 - - - 4.20 084252-240x32
35
5 5 2 10 - - - 4.90 084252-250x33
4 4 2 10 - - - 4.40 084252-240x52
PL (plug-in type) 60
5 5 2 10 - - - 5.20 084252-250x53
35 4 2 10 3 2 2.5 5.00 084252-170x35
7
60 4 2 10 3 2 2.5 5.40 084252-170x55
AN (angle clamping)
In-line Feeds Poles Nom. Current Feeding Control Feeding Weight Part No.
for System AN [A] [Pc.] L [m] [mm²] [Pc.] L [m] [mm²] [kg]
4 4 2 10 - - - 1.90 084252-140x50
up to 60
5 5 2 10 - - - 2.50 084252-150x50
14
110
200
113 425 150
1000
4/5 poles
160 200
Technical details
• Terminal box
110
• 2 separate cable fittings
200
In-line Feeds Poles Nom. Feeding Control Feeding Weight Part No.
for System Current Cable Cable Lugs Cable Cable Lugs
[A] Gland [Pc.] [mm²] Gland [Pc.] [mm²] [kg]
4 4 - - - 2.50 084252-042x52
5 up to 60 M32 5 16 - - - 2.60 084252-052x53
7 4 11 3 2.5 3.20 084252-076x55
4 4 - - - 2.40 084252-043x62
CS (continuous strip)
5 100 M40 5 25 - - - 2.50 084252-053x63
7 4 11 3 2.5 3.10 084252-077x65
4 4 - - - 2.90 084252-241x32
35 M25 10
5 5 - - - 3.10 084252-251x33
4 4 - - - 3.30 084252-242x52
PL (plug-in type) 60 M32 16
5 5 - - - 3.60 084252-252x53
4 4 - - - 2.93 084252-141x32
5 35 M25 5 10 - - - 3.03 084252-151x33
7 4 11 3 2.5 3.60 084252-174x35
4 4 - - - 3.20 084252-142x52
AN (angle clamping) 5 60 M32 5 16 - - - 3.40 084252-152x53
7 4 11 3 2.5 4.00 084252-176x55
4 4 - - - 3.65 084252-343x62
100 251)
5 5 - - - 4.04 084252-353x63
M40
4 4 - - - 4.03 084252-343x72
JT (joint clamping) 140 352)
5 5 - - - 4.50 084252-353x73
1) Max. 96A with cable lug 25 mm²
2) Max. 119A with cable lug 35 mm²
15
LE LE a
Ambient
Lowest ambient temperature during temperature [ºC]
5°C
system operation tmin: 50
ΔT 40
Ambient temp during installation tm: 15°C
20
30°C = ΔT1
Highest ambient temperature 20
45°C
during system operation tmax: 10
Air gap read from diagram: s = 75 mm 0
-10
s = 100 ΔT1 = 75 mm -20
Air gap calculated:
ΔT -30
0 20 40 60 80 100
Installation distance K: K = 100 + s = 175 mm
Air gap [mm]
16
L ±50 mm Notes
• Expansion points of the support structure may
1 influence amount and mounting position of rail expansion elements
• Conductor strips are mounted continous
123
Part No. Poles Length Weight
L
[mm] [kg]
K (100 ... 200)2)
084260-5x62 4.5 1.90
1) Hanger clamp to be ordered separately 1000
2) Reference dimension K (see page 14) 084260-7x65 7.0 1.97
Expansion Elements (with 100 mm Expansion) for the Systems PL, JT and AN
L ±50 mm
1
123
160
max. 13
35 110 M8
min. 53
29,5
161
115
98
425 150 90
8
1000
Technical details
• Permissible rail misalignment:
4/5 poles - type “left“ for CS (continuous strip)
Vertical ± 3 mm
Lateral ± 3 mm 160
max. 13
• Pick-up guide spacing: ≤ 10 mm 35 110 min. 53 110 M8
• For the installation of pick-up guides apply
29.5
161
feeds; see description for pickup guides for
115
98
transfer points
• Safety conditions
(see collector) 385 150 150 90
1.5
1000
CS (continuous strip)
Conversion Retrofit Kits to Add a Power Feed Point to Pick-up Guides/Transfer Points
Scope of delivery
Part No. Poles Nom. Current Weight
up to [A] [kg] Exchange cover with cable glands including connecting parts
and fasteners (without cable).
084283-5 5 0.38
60
084283-7 7 0.75
18
250
max. 13
min. 67
125 110 M8
44
194
141
124
425 150 124
1000
max. 13
min. 67
Vertical ± 3 mm 125 110 110 M8
Lateral ± 3 mm
• Use spring-loaded towing arm 084291-4
for the collectors
44
194
see description for pick-up guides for
148
131
transfer points
• Safety conditions
(see collector) 385 150 150 124
1000
CS (continuous strip)
63
129
147
41
56 Connection cable
Collector 5 poles
204 32
61
116
135
41
75
Connection cable
Technical details
• Cable length: 1, 3 and 5 m for connection to • Collector shoe material: copper graphite • Conductor rail radius: horizontal arrangement: Rmin = 2750 mm
the terminal box provided by the customer • Alternative cable for low temperature on request vertical arrangement: Rmin = 5000 mm
320
Note
A sufficient quantity of collectors must be used in arrangements that contain pick-up guides or isolations sections to ensure
that collectors are not overloaded as other collectors exit the system (i.e. at pick-up guides).
20
61
116
135
41
Towing Arm
410 (720) Part No. Type a Material Weight
[mm] [kg]
200
150
Steel, galvanized
60 60 (226) 60
084291-12 Double 720 1.28
Notes
Chain towing arm
ø 4,
60 Technical details
• Material: steel, galvanized
84
20
106
20
133
• Weight: 0.37 kg
47
Technical details
84
at a distance of 250 mm
Spring-loaded towing arm • Further spring-loaded towing arms on request
18
70 120
138 150 21
Reinforcing Bracket for Plastic Housing and Storm and Anti-fall guard Safety Device
Note
Part No. Material Weight
[kg] The reinforcing brackets serve to improve the profile rigidity, e.g.
in the area of the vertical curves
084295-1 0.08
Steel, galvanized 1) With additional safety rope as storm and anti-fall guard safety device.
08-S280-0564 1) 0.09 Shall be provided on every second rail.
Conversion Retrofit Kits to Add a Power Feed Point to Pick-up Guides/Transfer Points
Scope of delivery
Part No. Poles Nom. Current Weight
up to [A] [kg] Exchange covers with cable glands including
connecting material and fasteners (without cable)
084283-5 5 0.38
60
084283-7 7 0.75
Half Shells
Notes
• All pick-up units are equipped with replaceable half shells
• Replacement of the complete pick up unit not needed
1
1) Fixing screw for current strip (do not pull tight)
Note
For easy installation of current strips specially “100 A“-strip.
Bending Device for Chamfering the Copper Strip for System AN (Angle Clamping)
Part No. 084295-4
Technical detail
Weight: 0.05 kg
Note
The positioning block serves as a counter point for the assembly of
the connecting position and avoids any offset of the contact strip.
It is required for the assembly of the angle clamping.
Recommended as a „third hand“ for all connecting systems.
Technical details
• Article: insertion tool
• Weight: 0.60 kg
Notes
230
24
30
L2 12
26
40 20 ø9
Width b
Technical details
• Material:
31
33 100
25
Conductor Rails
Program Nominal Current1) Voltage Grade Support Spacing Rail Length Outside-Dimensions
0811
Single Pole Insulated Conductor Rail
0815
1,5 m
25-400 A 690 V 4m 18 x 26 mm
(3.2 m)1)
0812
0813
10-125 A 3-pole: 26 x 62 mm
1m
(140 A at 500 V 4m 4-pole: 26 x 80 mm
(3,2 m)1)
80% duty cycle) 5-pole: 26 x 98 mm
0831
Multipole Conductor Rail
25-200 A
4-pole
(200 A at 690 V 3.2 m 4m
200 x 50 mm
80% duty cycle)
0832
AC Voltage:
Complete system: 230/400 V AC
196 x 48 mm
32 A Earth/Low voltage:
0.8 m 4m (incl. System support
Rail system: min. 24 up to
220 x 50 mm)
100 A 48 V DC/AC
0835
Enclosed Conductor Rail
35-140
(160 A at 600 V 2m 4m 56 x 90 mm
80% duty cycle)
0842
1)
3.2 m in combination with support structure ProShell
26
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27
10102 F Street 1435 Norjohn Court Calle Treviño 983-C Rua Luiz Pionti, 110
Omaha, NE 68127 Unit 5 Zona Centro Vila Progresso
Burlington, ON L7L 0E6 Apodaca, NL México 66600 Itu, São Paulo, Brasil
CEP: 13313-534
Customer Support Customer Support Customer Support Customer Support
Phone +1-800-521-4888 Phone +1-800-667-2487 Phone (+52 81) 1090 9519 Phone (+55 11) 4813 7330
(+52 81) 1090 9025
(+52 81) 1090 9013
Phone +1-402-339-9300 Phone +1-450-565-9900
Fax +1-402-339-9627 Fax +1-450-951-8591 Fax (+52 81) 1090 9014 Fax (+55 11) 4813 7357