System FABA 100

Standard Components

Current Collector EAS-L Spring Pressure approx. 4 N

Standard Type

Order-No. Fig. Identification Weight

241 035 030 1 One-arm 20 A one-pole; Cu carbon shoe ; without feed cable 0.029
current collector Head in black, other insulated parts in orange
241 035 056 Ground yellow All insulated parts in yellow 0.029

2
241 040 702 2 Feed cable 20 A black 1.5 mm , outer-∅ 4.0, single-core, halogen free 0.029
1 m long highly flexible;
2
241 040 710 20 A black 2.5 mm , outer-∅ 4.5, 1000V; one side with DIN- 0.038
plug;
2
241 040 712 Ground green-yellow 2.5 mm , outer-∅ 3,9, (other lengths by request) 0.033

241 035 250 3 Head with pivot 20 A black Cu collector shoe; with spade connector as spare only 0.014
241 035 265 and shoe Ground yellow and head (delivered only as unit) 0.014
251 035 001 4 Collector Body 20 A black plastic; spring CrNi as spare only 0.015
251 035 006 without Fig. 3 Ground yellow 0.015
Order base plate and bolting material for fastening the current collectors: separately (see page 25)
For Data Transfer
Order-No. Fig. Identification Weight
241 035 057 1 Data-collector one-pole; Silver collector shoe; without feed cable 0.028
basic unit orange; head grey
2
Shielded grey; 0.5 mm ; outer-∅ 3.6; with shielding;
241 040 520 2 Feed cable single-core; highly flexible; one side with DIN-plug; 0.020
1 m long (other lengths by request)

241 035 266 3 Data head grey; Silver collector shoe; with plug connection; as spare 0.013
only
251 035 001 4 Basic unit less standard design: plastic-orange as spare 0.015
head only
Order base plate and bolting material for fastening the current collectors: separately

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 System FABA 100
Hanger Clamps

Hanger-Clamp screw-type assembly

Order-No. Weight
241 006 138 2-poles 0,008
241 006 129 3-poles 0,012
241 006 128 4-poles 0,015
241 006 127 5-poles 0,019
241 006 137 6-poles 0,023
241 006 126 7-poles Fig. Height 0,026
241 006 130 8-poles 1 27 mm 0,030
241 006 131 9-poles 0,034
241 006 132 10-poles 0,038
241 006 133 11-poles 0,042
241 006 134 12-poles 0,045
241 006 135 13-poles 0,049
241 006 136 14-poles 0,053

Order-No. Weight
241 009 211 2-poles 0,006
241 009 212 3-poles 0,009
241 009 213 4-poles 0,012
241 009 214 5-poles 0,015
241 009 215 6-poles 0,018
241 009 216 7-poles Fig. Height 0,021
241 009 217 8-poles 2 32 mm 0,024
241 009 218 9-poles 0,027
241 009 219 10-poles 0,030
241 009 220 11-poles 0,033
241 009 210 12-poles 0,036

Order-No. Weight
241 006 017 8-poles Fig. Height 0,030
3 32 mm

Order-No. Weight.
241 009 223 4-poles 0,020
241 009 224 5-poles Fig. Height 0,025
241 009 225 6-poles 4 40 mm 0,030
241 009 226 7-poles 0,035
241 009 227 8-poles 0,040

Order-No. Fig. Weight

241 013 003 5 Screw Set M6 x 25 für clamp fig. 1 with washer orange, spring set; zinc-plated, 0,010
washer and nut; in bag
241 013 001 6 Screw Set M6 x 20 for clamp fig. 3+4 with spring washer and nut; set; zinc-plated, 0,008
in bag
241 013 022 Screw Set M6 x 12 0,008
with washer, spring washer set; zinc-plated,
241 013 023 7 Screw Set M6 x 16 for clamp fig. 2 0,009
and plate with thread hole in bag
241 013 024 Screw Set M6 x 20 0,010

Technical Information
a) Permissible continuous ambient temperatures:
- 30 °C to + 80 °C.
b) Center separation 15 mm.

Hanger clamps are delivered without screw material. If M6 accessories are required, we request you to inform us about the type. The
number of screw connections depends on the type of hanger clamp and the number of poles. The drawings show examples of screw-
fastenings.

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 System FABA 100
Standard Components

Conductor-Rail

Conductor Rail with Hard PVC Insulation

Order-No. Fig. Identification Length Material Insulation hard-PVC Weight

200 009 299 3m Standard orange 0,720
200 009 499 1 Conductor rail 5m Metal- Standard orange 1,200
FABA 40 rail
200 010 299 3m steel Standard PE Ground yellow with green stripe 0,720
200 010 499 5m galvanised Standard PE Ground yellow with green stripe 1,200

201 009 299 3m Standard orange 0,805

201 009 499 1 Conductor-rail 5m Metal- Standard orange 1,340
FABA 100 rail
201 010 299 3m copper Standard Ground yellow with green stripe 0,805
201 010 499 5m Standard Ground yellow with green stripe 1,340

Conductor Rail with Halogenfree Insulation

Order-No. Fig. Identification Length Material Insulated halogen-free Weight
206 009 299 3m Heat-resistant orange 0,720
206 009 499 1 Conductor rail 5m Metal- Heat-resistant orange 1,200
FABA 40 rail
206 010 299 3m steel Heat-resistant PE Ground yellow with green stripe 0,720
206 010 499 5m galvanised Heat-resistant PE Ground yellow with green stripe 1,200

207 009 299 3m Heat-resistant orange 0,805

207 009 499 1 Conductor-rail 5m Metal- Heat-resistant orange 1,340
FABA 100 rail
207 010 299 3m copper Heat-resistant Ground yellow with green stripe 0,805
207 010 499 5m Heat-resistant Ground yellow with green stripe 1,340

241 000 005 2 Bending strip 1m Hard PVC Ring material Ring material 100 m
black 100 m remains in rail 3,200

241 000 015 2 Bending strip 1m Halogen free Ring material Please specify the length in your
0range 100 m order
241 000 006 3 Bending profile 5m PVC red Straight profile multiple use 0,250
241 045 001 4 Bending machine for manual operation 11,20

518 503 000 without Fine file 0,095

518 505 000 without Hacksaw 0,135
518 505 010 without Blades (spares; 12 Pieces) 0,038

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 System FABA 100
Standard Components

Rail-Connectors (screw-type)

Order-No. Fig Identification Weight

241 002 000 1 Rail connector, screw-type one-pole; complete; Packed unit, in bag 0,017

241 026 005 1 Housing Plastic-black Only as spare 0,003

251 002 000 1 Screw connector Clip with spring-steel and screw M 6 Only as spare 0,014

518 501 010 2 Screwdriver 4 mm for recessed hex-bolt 0,036

Technical Information
• Permissible continuous current 100 A (for 100 % Duty Cycle).
• Permissible ambient temperatures – 30 °C to + 80 °C.

Planning Instructions
• Distance to the next hanger clamp: min. 100 mm; max. 200 mm.
• Preferably for smaller installations.
• Used also for joints of conductor rails in bends.
• The rail connector is remountable / reusable several times.
• A gap of 10 mm remains between the ends of the conductor rails.

Installation Instructions
• Slightly loosen the screw of the screw connector with the screw driver.
• Insert the screw connector
into the already installed
conductor rail.
• Slide on the housing; pay
attention that the housing
embraces the insulating sleeve rims!
• Clip the next conductor rail into the already installed hanger clamp.
• Guide the conductor rail to the joint and slide together until the stop; take care that the housing completely embraces
the insulating sleeve rims!
• Tighten the screw securely using a Allen key screwdriver.
• Inspection : Are both insulating sleeves embraced by both sides of the housing?

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 System FABA 100
Standard Components

Hanger-Clamp screw-type assembly

Order-No. Fig. Identification Height a b Assembly weight

241 006 128 4-poles 60 30 0,015
241 006 127 5-poles 75 15 0,019
241 006 137 6-poles 90 30 0,023
241 006 126 7-poles 105 30 One piece 0,026
241 006 130 8-poles 120 15 0,030
241 006 131 1 Hanger- 9-poles 27 mm 135 30 0,034
241 006 132 clamp 10-poles 150 30 0,038
241 006 133 11-poles 165 15 Plastic-orange 0,042
241 006 134 12-poles 180 45 0,045
241 006 135 13-poles 195 45 0,049
241 006 136 14-poles 210 15 0,053

241 003 000 2 Hanger-clamp 1-polig 32 mm continues One piece; Plastic-orange 0,004

241 009 211 2-poles 30 0,006

241 009 212 3-poles 45 0,009
241 009 213 4-poles 60 0,012
241 009 214 5-poles 75 One piece; 0,015
241 009 215 6-poles 90 0,018
241 009 216 3 Hanger- 7-poles 32 mm 105 0,021
241 009 217 clamp 8-poles 120 0,024
241 009 218 9-poles 135 Plastic-orange 0,027
241 009 219 10-poles 150 0,030
241 009 220 11-poles 165 0,033
241 009 210 12-poles 180 0,036

241 009 223 4-poles 60 0,020

241 009 224 5-poles 75 One piece; 0,025
241 009 225 4 Hanger- 6-poles 40 mm 90 0,030
241 009 226 clamp 7-poles 105 Plastic-orange 0,035
241 009 227 8-poles 120 0,040

241 013 000 5 Screw set M6 x 12 For threaded hole With spring washer; Set; zinc-plated, in bag 0,005

241 013 001 6 Screw set M6 x 20 For through hole With spring washer and nut; Set; zinc-plated, in bag 0,008

241013 003 7 Screw set M6 x 25 For clamp Fig. 1 With washer orange, 0,010
spring washer and nut Set; zinc-plated, in bag

241 013 022 Screw set M6 x 12 For clamp Fig. 3 With washer, spring washer 0,008
241 013 023 8 Screw set M6 x 16 and plate with thread hole 0,009
241 013 024 Screw set M6 x 20 Set; zinc-plated, in bag 0,010

241 046 021 9 Dismantling wedge For removing rail from hanger clamps 0,014
Plastic-orange

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 System FABA 100
Standard Components

Power-Feeds

Order-No. Fig. Identification Weight

241 015 000 1 Splice-feed one-pole; complete; Packing unit, in bag; 0,030
100 A for assembly height from 32 mm; for feed cable up to 16 mm²

241 015 050 2 Splice-feed one-pole; complete; Packing unit, in bag; 0,024
50 A for assembly height from 27 mm; for feed cable up to 6 mm²

241 015 090 3 End-feed one-pole; complete; Packing unit, in bag; 0,029
100 A for assembly height from 27 mm; for feed cable up to 16 mm²

241 040 045 16 mm² 10,7 outer-∅ 1000 V black Single-core

241 040 039 10 mm² 8,3 outer-∅ 1000 V black flexible cable 1 m long
241 040 026 6 mm² 6,5 outer-∅ 1000 V black One side titted with
241 040 037 4 mm² 5,3 outer-∅ 1000 V black Terminal M6;
241 040 460 4 Feed cable 2,5 mm² 4,5 outer-∅ 1000 V black 1 m long
241 040 057 16 mm² 9,2 outer-∅ Ground green-yellow (other lengths
241 040 040 10 mm² 7,9 outer-∅ Ground green-yellow on request)
241 040 051 6 mm² 6,3 outer-∅ Ground green-yellow
241 040 038 4 mm² 4,9 outer-∅ Ground green-yellow
241 040 456 2,5 mm² 3,9 outer-∅ Ground green-yellow

241 026 051 1 Assembly height 32 mm only 0,007

241 015 051 2 Housing Assembly height 27 mm Plastic-black as spare 0,006
241 014 010 3 Face closed 0,005
251 015 000 1 with asymmetric nut only 0,023
241 015 052 2 Screw clamp with square nut M 6 with recessed hex-bolt SW 4 as spare 0,018
251 022 020 3 pair of clips on one side 0,023

506 006 002 Cable shoe >1 - 2,5mm² cable For 0,001
506 006 006 5 DIN 46234 >2,5 - 6mm² cable crimping 0,002
506 006 010 E-Cu galv. >6 - 10mm² cable requirements 0,003
506 006 016 For above feeding clamps >10 - 16mm² cable 0,004

518 501 010 6 Screwdriver Allen key 4 mm For recessed hex-bolt M 6 0,036

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 System FABA 100
Standard Components

Transfer-Caps

Order-No. Fig. Identification Weight

Feed Stagger of
possibility heights and sides
241 017 045 1 Transfer cap Without Permiss. ± 2 mm plug-type; plastic-orange 0,004
241 017 055 2+6 Transfer cap With Permiss. ± 2 mm screw-on type; packing unit, in bag; 0,025
with clip, fig. 6 for cable up to 2.5 mm²

241 017 048 3 Transfer cap Without Permiss. ± 4 mm plug-type; plastic-orange 0,005
241 017 155 4+6 Transfer cap With Permiss. ± 4 mm screw-on type, packing unit, in bag; 0,025
with clip, fig. 6 for cable up to 2.5 mm²
241 015 025 5+6 Transfer cap With Permiss. ± 2 mm plug-type; packing unit, in bag; 0,029
with clip, fig. 6 for cable up to 2.5 mm²
241 040 415 6 mm² outer-∅ 6,5 1 kV black 0,110
241 040 412 4 mm² outer-∅ 5,3 1 kV black single-core,
241 040 421 7 Feed cable 2,5 mm² outer-∅ 4,5 1 kV black halogen-free; 0,044
241 040 417 6 mm² outer-∅ 6,3 Ground green yellow flexible; 1 m long 0,070
241 040 423 4 mm² outer-∅ 4,9 Ground green yellow (other lengths
241 040 408 2,5 mm² outer-∅ 3,9 Ground green yellow on request) 0,036

241 017 035 2 Transfer cap For feed clamp 0,004

241 017 038 4 Fig. 5 plastic-orange as spare only 0,005
241 017 060 5
251 022 010 6 Screw-type feed clamp with square nut as spare only 0,021

518 502 000 8 Philips screwdriver for countersunk screw M 5 0,088

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 System FABA 100
General Information

D. Electrical Transmission of Power

Since the system is employed for varying purposes, we restrict ourselves to general, however
important facts which should be considered.

1. Current capacity of the conductor rails - refer to Table 1 :

In determining the total current - i.e. all users - the following is to be considered :
a) How often or at which points is the system to be supplied ?
b) How are the users (or is the user) utilised, or how large is the duty cycle (DC) ?
c) How high is the expected maximum ambient temperature ?
Table 1 = Conductor rails permissible continuous current [A] for 100 % Duty cycle
for continuous ambient temperature up to [°C]
Insulation 35 40 45 50 55 60 65 70 75 80
FABA 40 Standard 40 36 32 28 24 -- -- -- -- --
steel Heat-resistant 40 40 40 40 40 35 30 25 20 15
FABA 100 Standard 100 90 80 70 60 -- -- -- -- --
copper Heat-resistant 100 100 100 100 100 90 80 70 60 50

2. Potential drop :
a) The potential drop for conductor rails is in general not to be more than 3 %.
b) It is to be considered how often or at which points the system is to be supplied.
c) The resistance of the conductor rails increases with higher ambient temperatures - refer to table 2.
We have listed the most unfavourable values; they were determined under continuous currents
of 40 A for FABA 40 and 100 A for FABA 100.
Table 2 = Conductor rails Resistance [Ohm/km]
for continuous ambient temp. up to [°C]
for 35 40 50 60 70 80
Altern. current (impedance); 50 Hz;
FABA 40 15 mm center separation 5.32 5.48 5.85 6.25 6.73 7.28
Direct current 4.93 5.08 5.38 5.80 6.24 6.75
Altern. current (impedance); 50 Hz;
FABA 100 15 mm center separation 0.78 0.83 0.95 1.05 1.18 1.34
Direct current 0.77 0.82 0.94 1.04 1.16 1.32

3. Conductor rail for the ground conductor :

a) Whether and when the ground conductor rail is employed is to be determined for the individual installation -
e.g. users with small protective voltage? User protectively insulated?
b) Consider the ambient temperature possibly developing; standard- or heat-resistant insulation ?
c) Do not use ground conductor rails for control purposes.
d) Arrangement may be carried out individually. We suggest to locate it in the front if there is danger of contact.

4. Current capacity of the current collectors - refer to table 3 :

a) The ambient temperature has to be considered.
b) In principle only one current collector is required per conductor rail for the transmission of power.
Table 3 = Current collector Permissible continuous current [A]
for 100 % Duty cycle
for continuous ambient temp. up to [°C]
35 40 50 60 70 80
One-arm current collector 20 20 16 12 8 4
small; with cable 0,75 mm² 10 10 8 6 4 2
with cable 1,5 mm² 16 16 12 9 6 3
Parallel-arm collector with cable..........1,5 mm² 20 20 16 12 8 4
2,5 mm² 30 30 25 20 15 10
4,0 mm² 40 40 33 26 20 14
6,0 mm² 50 50 42 34 26 18

Parallel-arm collector, long arm 1,5 mm² 20 20 16 12 8 4

with cable 2,5 mm² 30 30 25 20 15 10
4,0 mm² 40 40 33 26 20 14
6,0 mm² 50 50 42 34 26 18

5. Current collector for the ground conductor :

As for the transmission of power, only one current collector is required for the ground conductor rail.

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 System FABA 100
Standard Components

Rail-Connectors (plug-in type)

Order No. Fig.. Identification Weight

241 002 010 1 Rail connector, plug-in one-pole; complete; packed unit, in bag 0,008

241 026 006 1 Housing Plastic-black only as spare 0,003

241 026 015 1 Plug-in connector Bronze spring-steel only as spare 0,005

241 046 020 2 Installation handle Metal end with bore of ∅ 8,5 0,135
241 046 010 3 Connecting vice 1,296

Technical Information
• Permissible continuous current 100 A (for 100 % Duty Cycle).
• Permissible ambient temperatures – 30 °C to + 80 °C .

Planning Instructions
• Distance to the next hanger clamp: min. 100 mm; max. 200 mm.
• Preferably for quick installation of extensive systems.
• Do not use in bends.
• The rail connector is not remountable / reusable.

Installation Instructions
Insert the plug connector into the installation handle.
Press the plug connector to the stop into the not yet
mounted conductor rail.
Slide the housing onto the end of the conductor rail (over
the plug connector) until the stop.
Clip the rail into the already installed hanger clamps.
Guide the rail to the one already installed.
Slide on the housing; take care that the sides of the housing embraces both insulating sheaths!
Fix the connecting vice to both sides of the joint :
tighten both tongues; hold the tongue which grips the already installed rail with the left hand; using the right hand push the
handle so that the conductor rails are drawn completely together (to be reversed for "left-handed" persons).
Inspection : Are both insulating rims embraced by both sides of the housing?
Disassembly :
If the connection of the conductor rail has to be separated, it has to be cut out – approx. 60 to 70 mm. With a fine-toothed
hacksaw from the side of the conductor surface - refer to "shortening" of conductor rail.

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 System FABA 100
FABA 30 Conductor
Rail

Conductor Rail

der No. Fig. Description Length Weight

200 501 499 5m Metal Insulating Orange 0.530
1 FABA 30 coductor rail rail jacket
200 502 499 5m Copper Hard PVC Ground Yellow with green stripes 0.530

241 000 007 2 Bending Grey 5m PVC With brass strip Remains in curved piece 0.460
profile
241 000 006 3 Bending Red 5m PVC Can be used repeatedly 0.250
profile

241 045 001 4 Bending machine ( Identical to FABA 40 / 100 ) For manual operation 11.20
518 503 000 Fine file 0.095
518 505 000 with- Hacksaw ( Identical to FABA 40 / 100 ) 0.135
out
518 505 010 Saw blades 12 pcs; for replacement 0.038

Technical Information

• Allowable ambient temperatures With continuous ambient temperature

- 30 °C to + 55 °C. up to [ °C]
• Metal rails and insulating jackets are
equally long; lengthwise displacements 35 40 45 50 55
relative to each other are not possible Allowable continuous current [A] 30 27 24 21 18
(as if extruded together). at 100 % Duty cycle
• Metal rail cross-section 5 mm². Resistance with alternating current 4.42 4.75 5.08 5.39 5.66
(impedance)
• Linear coefficient of expansion [Ohm/km] with direct current 4.22 4.53 4.85 5.14 5.41
-6 -1
α = 17 ⋅ 10 [K ].

Planning Information

• In principle, as for FABA 40 / FABA 100.

• Hanger spacing : max. 600 mm in straight lengths; max. 300 mm in curves.
• Conductor rails can be shortened on location.
• Radii are possible in all directions : from 0.5 m ″on location″.
Grey bending strips necessary only with continuous radii under 0.75 m or with rail separation in the radius.

Assembly Instructions
a) In principle, as for FABA 40 / FABA 100.
b) Hanger spacing: max. 600 mm in straight lengths; max. 300 mm. in curves.
c) Shorten: With fine-toothed metal saw, begin sawing from the sliding surface. Deburr cut surfaces – especially the metal sliding
surface – carefully with a fine file.
d) Curves: Manufacture with bending machine and bending profile; “on location” in general, smallest bending radius 500 mm to all
sides.
• Determine approximate length of curve and mark on the insulating jacket with felt pen. Mark min. 150 mm from
beginning of rail (beginning and end cannot be bent, remain straight).
• When bending over the sliding surface or the rail back, insert grey bending profile.
The ends to be connected must be free of grey bending strips 30 mm each.
• When bending over rail broad side, insert grey bending profile as before and insert red bending profile in the sliding
surface slot.
• Slide rail into the bending machine, until the first curve marking is located centered over one of the lower rollers.
Depending on required radius, tighten the upper roller. Guide rail through machine to the second marking. Correction is
possible by performing again. For same curve, note the scale setting.
• If two rail curves must be joined to each other, shorten the rails to be connected by the straight end (approx. 150 mm).

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 System FABA 100
Standard Components

Cleaning-Collector EAS-R Spring Pressure approx. 4 N

Order-No. Fig. Identification Weight

241 035 063 1 One-arm cleaning collector one-pole; with fibre pad; without connecting cable 0,022

241 035 268 2 Cleaning head plastic with fibre pad; as spare only 0,007
251 035 001 3 Basic unit plastic-orange; spring CrNi as spare only 0,015
Order base plate with bolting material for fastening the current collectors: separately

Technical Information
a) Application:
• in systems with rail collector surface facing down or sideways, in bends from 0,5 m radius;
• also for ground conductor rail;
• one cleaning collector per conductor rail;
• in principal for all electric monorail installations;
• otherwise also if data transfer has been planned or control commands are to be transferred;
• required for the equalization of the rail conductor surface prior to the initial start-up;
• for all installations, in which extreme dirt is to be expected, especially for deposits of non-conductive suspended
particles (such as small fibres / fluff) for example.
b) The collector particularely removes foreign coatings from the conductor surface; the fibre pad has a long lifetime,
does not rust or splinter.
c) The cleaning collector does not serve for the transfer of power and is therefore to be mounted separately on the
mobile equipment.
d) Permissible ambient temperatures – 30°C to + 80°C.
e) Suitable for traveling speeds up to 200 m/min, for back and forth operation.

Planning Instructions
• To assure a perfect contact, the complete installation has to be traversed with the cleaning collectors approx. 20 times
before the initial start-up, following that in regular intervals only if fouling is to be expected.
• For the electric monorail it is sensible to mount it on the follower part of the carrier.
• The console or base plate for mounting the current collectors are to be fastened to the mobile equipment in such a way
as to assure that in installations containing bends the head is in the center of the support- / guide roller.

Installation Instructions
a) Fundamentically identical to the data on the "One-Arm Current Collector".
b) Mount the console and the base plate as usual - refer to base plate.
c) The assembly measurement (with base plate) is 45 + 10 = 55 mm.
d) Replacement of the cleaning head:
• Press the bolt of the joint slightly together (as is done for the one-arm collectors) and pull off the head.
• Insert or clip on the spare head.

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