Multipole Conductor Rail

MultiLine Program 0831

 ProShell Support Profile
conductix.com for AS/RS and Transfer Cars
An Option for Conductix-Wampfler Conductor Rail Systems

ProShell - the modular carrier profile as a system supplement for program 0812 and 0831
ProShell catalog KAT0800-0003-E available for download at www.conductix.com

General Hints
We reserve the right to carry out any modification of the product at any time in the course of technical progress without prior notice. All our equipment is in accordance
with CE. Our general terms of business are effective. We shall send them to you on request. Reprint, even of extracts, is only permitted with our approval.
Contents

Description / Technical Data

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Conductor Rails
Rails complete with pre-mounted Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Feeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hanger Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Anchor Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
End Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Gap Insulating Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pick-up Guides for Transfer Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Expansion Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Current Collectors with Accessories

Collector Support Brackets for current collector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Support Spring Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connection Cable... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Current Collector Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Double Current Collector Units.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Wearing and Spare Parts

Rail Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Current Collector Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Stabilizing Springs for Current Collector Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Mounting / Accessories
Support Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Girder Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Weld-on Bracket for Support Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Others
Arrangement Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Program Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3
 Description

Conductix-Wampfler Multipole Conductor Rail Program 0831

The Conductix-Wampfler multipole conductor rail program 0831 is protected against direct contact and designed as a flat profile. This system is recommended for high
storage bays, cranes, transport trolleys and special machinery. The Conductix-Wampfler multipole conductor rail can be used for energy and data transmission on indoor
and weather protected outdoor applications with straight track layouts.

• 3, 4 and 5-poles • little

space consumption / combinable with ProShell Support Profile
• 10 - 125 A (100% Duty cycle) • installationvertical and horizontal
• protected against direct contact • quick installation due to connector plug-in system and universal steel clamp fasteners

CONDUCTOR RAILS POWER FEED

The conductor rail poles are enclosed in high-quality plastic profiles in 3, 4 and Power feeds are available as end feed or in-line feed up to
5 pole type. There are different versions for a current load from 10 up to 125 A 35 mm² cross section, as well as flat centre feed up to 35 mm² cross section.
nominal current. The phase spacing of the multipole profiles is 18 mm. With a In-line feeds can be installed at each rail joint. The power feeds are rail segments
combination of different multipole profiles every number of multipole conductor with a length of 1000 mm, except for the end feeds.
systems is possible.
The standard length is 4000 mm, shorter lengths are available. It is possible to EXPANSION JOINTS
combine different conductor rail types within the compact profiles. Datametal Expansion joints are used as expansion compensators in systems which are
conductor rails will be used for a reliable data transmission. In special cases exceeding a total length of 200 m (see page 13/14).
please ask for assistance. In case you need expansion joints please ask for assistance.

SUPPORT / HANGER CLAMPS RAIL CONNECTORS

The conductor rail segments have to be fastened at least at 2 points. The support The rail segments are connected with a special connector plug-in system.
distance is max. 1000 mm. The plastic hanger clamps can be mounted on cus- The rail connector is already included at the end of each rail segment.
tomers supporting beams or runway profiles as well as on Conductix-Wampfler
support arms. With universal steel clamp fasteners they can be mounted on PICK-UP GUIDES FOR TRANSFER POINTS
the beam flanges. The multipole conductor rail will be snapped into the hanger A reduced travel speed will increase the lifetime. A limit of max.
clamps which are designed as sliding hanger clamps. 85 m/min is recommended.

SUPPORT / ANCHOR CLAMPS INSTALLATION

To control the expansion an anchor clamp will be installed, which holds the For detailed information please refer to our installation instruction
multipole conductor rail in position in the hanger clamp, due to an additional (MV0831-0006-E).
screw. The anchor clamp will preferably be located in the middle of an
installation. Critical installation situations, optional locks / safety ropes are available.

Current Collectors
The current collector unit with or without terminal box is installed on the mobile power consumer. It consists of fully insulated current collectors which are moveable in
all directions. The earth collector is marked green/yellow and not interchangeable with a phase collector. Collector shoes can be checked without disassembling and can
be replaced quick and easily. In special cases please ask for assistance.

Current Collectors Current Collector Units

single
without
Terminal Box
Max. Current at 100% Duty Cycle [A] 55 80 54 80
Part No. 083102-... 083106-... 083103-... 083107-...
(page 15) (page 16) (page 18) (page 19)
... also for Pick-up Guides
yes yes yes yes
... for Transfer Points

4
Technical Data

Conductix-Wampfler Multipole Conductor Rail Program 0831

Conductor Rail Galvanized Copper Data-

steel metal
Type 083112 083115 083116 083117 083118
Nominal Current at 100% duty cycle and 35°C [A] 32 60 100 125 1) 10
Cross Section of Conductor [mm²] 25 16 25 35 25
Resistance at 35°C [Ω/m] 0.005506 0.001182 0.000745 0.000540 0.029313
Impedance at 18 mm rail spacing [Ω/m] 0.005507 0.001185 0.000750 0.000548 0.029314

Nominal Voltage [V] 500

Min. Operating Parameters Umin 24V, Imin 1A (manufacturer recommendation)
Support Spacing max. [mm] 1000
Rail Length [mm] Standard 4000; intermediate lengths 3000, 2000, 1000
External Dimensions [mm] 3-poles: 26 x 62
4-poles: 26 x 80
5-poles: 26 x 98 (see picture)

PE (green stripe), ground wire mark

Speed max. [m/min] 400 (without cone)

Ambient Temperature max. 55°C
Ambient Temperature min. 6°C;
-30° to +6°C solutions available on request
Max. Temperature Difference 50°K
Relevant Norms VDE 0110-1:2008-01 Insulation coordination for electrical equipment in low voltage systems -
Part 1: Principles, requirements and tests (IEC 60664-1:2007);
German version EN 60664-1:2007

DIN EN 60204-1; Machine Safety - Electrical Equipment of Machines - Part 1: General

VDE 0113-1:2019-06 requirements (IEC 60204-1:2016, modified); German version EN
60204-1:2018

DIN EN 60204-32:2009-03 Machine Safety - Electrical Equipment of Machines - Part 32: Require-
VDE 0113-32:2009-03 ments for leverage (IEC 60204-32:2008, modified); German version EN
60204-32:2008

DIN EN 60529:2014-09 Systems of protection through housing (IP-Code) (IEC 60529:1989 +

VDE 0470-1:2014-09 A2:2013); German version EN 60529:1991 A1:2013

Flammability / fire safety Meet requirements for insulation materials in UL 94 V-0;

Flame retardant and self-extinguishing (IEC 60695-11-10)
Air and Surface Creepage depending on degree of pollution; surface creepage
distance 30 mm to DIN VDE 0110 Part 1 + 2
Protection Type IP 23 with horizontal arrangement
IP 21 with vertical arrangement
Chemical Resistance of the Profile at an Benzine resistant Sodium hydroxide 25% resistant
Ambient Temperature of +45°C Mineral oil resistant Hydrochlorid acid resistant
Grease resistant Sulphuric acid up to 50% resistant

The materials of the conductor rail systems are weather resistant and have got a high resistance against
certain chemicals. For special applications please contact us.
Please be careful with solvents and contact sprays as well as flavors (Special material on request)
Local approvals UL / CSA / GOST-R
Note: Additional informations on request.

5
 Conductor Rails

Rails complete with pre-mounted Connector (083112-... / 083115-.... / 083116-... / 083117-... / 083118-...)

41
18
4000 55 B

Ground wire
PE mark
Insulation Fin
Technical details
• The table below refers to standard insulation fins.
• Intermediate lengths are available!

Multipole Power Supply with PE Controls without PE Poles B Weight

Conductor Rail Part No. Part No. [mm] [kg]
083112-4x3x12 083112-4x3x11 3 72.5 6.280
Galvanized Steel
083112-4x4x12 083112-4x4x11 4 90.5 8.370
32 A
083112-4x5x12 083112-4x5x11 5 108.5 10.460
083115-4x3x12* 083115-4x3x11* 3 72.5 5.600
Copper
083115-4x4x12* 083115-4x4x11* 4 90.5 7.474
60 A
083115-4x5x12* 083115-4x5x11* 5 108.5 9.348
083116-4x3x12* 083116-4x3x11* 3 72.5 6.590
Copper
083116-4x4x12* 083116-4x4x11* 4 90.5 8.786
100 A
083116-4x5x12* 083116-4x5x11* 5 108.5 10.982
083117-4x3x12* 083117-4x3x11* 3 72.5 7.520
Copper
083117-4x4x12* 083117-4x4x11* 4 90.5 10.034
125 A
083117-4x5x12* 083117-4x5x11* 5 108.5 12.540
083118-4x3x12 083118-4x3x11 3 72.5 6.300
Datametal
083118-4x4x12 083118-4x4x11 4 90.5 8.402
10 A
083118-4x5x12 083118-4x5x11 5 108.5 10.504
* Standard range Short lengths (SAP CONFIG 3129410)

Order Example: Multipole conductor rail program 0831

steel 32 A
4-poles
for power supply
4 m long

0831 12 - 4x 4x 12
with PE = 12 (without PE = 11)
number of poles = 4
length = 4 m
conductor rail for 32 A
program 0831

Note
Plastic and metal (conductive material) have a different expansion behavior. To compensate for rail- and insulation at the reference temperature of 20° C are of different
lengths (2 mm shorter rail, as insulation).
A gap in the assembled state, between the rails, of 2 to max. 8 mm. is possible, depending on temperature.
For applications below + 5 ° C (cooling applications), there are special rails are available. Please contact us.

6
Power Feeds

End Feed complete with pre-mounted Connector and Terminal Box (083153-...)

160

A
Technical details
• Connection cable max. 35 mm² 200 35
• Suitable for all types of multipole conductor rails
• Use cable lugs for threaded connection M8 (not included)

41
10

79
Power Supply with PE type “right“ Power Supply with PE type “left“ Controls without PE Poles Gland A Weight
Part No. Part No. Part No. [mm] [kg]
083153-310x12 083153-310x13 083153-310x11 M 50 1.460
083153-311x12 083153-311x13 083153-311x11 3 M 40 72.5 1.430
083153-312x12 083153-312x13 083153-312x11 M 25 1.410
083153-410x12 083153-410x13 083153-410x11 M 50 1.985
083153-411x12 083153-411x13 083153-411x11 4 M 40 90.5 1.955
083153-412x12 083153-412x13 083153-412x11 M 25 1.935
083153-510x12 083153-510x13 083153-510x11 M 50 2.330
083153-511x12 083153-511x13 083153-511x11 5 M 40 108.5 2.300
083153-514x12 083153-514x13 083153-514x11 M 63 2.365

Line Feed complete with pre-mounted Connector (083151-...)

60 x B
15

500 500 56

(1000)

Technical details
• Connection cable max. 10 mm²
• Cable lugs (according to nominal current) are included
• connection screws M 5

In-line Feed Power Supply with PE Controls without PE Poles B Weight

Part No. Part No. [mm] [kg]
083151-32x12 083151-32x11 3 72.5 1.800
for Steel Rail
083151-42x12* 083151-42x11 4 90.5 2.400
32 A
083151-52x12 083151-52x11 5 108.5 3.000
083151-35x12* 083151-35x11* 3 72.5 1.630
for Copper Rail
083151-45x12* 083151-45x11* 4 90.5 2.175
60 A
083151-55x12* 083151-55x11* 5 108.5 2.720
083151-38x12 083151-38x11* 3 72.5 1.800
for Datametal Rail
083151-48x12 083151-48x11* 4 90.5 2.400
10 A
083151-58x12 083151-58x11* 5 108.5 3.000
* Standard range

7
 Power Feeds

Line Feed complete with pre-mounted Connector (083154-...)

140 x B

25
56
500 500

(1000)

Technical details
• Connection cable max. 35 mm²
• Cable lugs (according to nominal current) are included
• connection screws M 6

In-line feed Power Supply with PE Controls without PE Poles B Weight

Part No. Part No. [mm] [kg]
083154-32x12 083154-32x11 3 72.5 1.925
Steel Rail
083154-42x12 083154-42x11 4 90.5 2.525
32 A
083154-52x12 083154-52x11 5 108.5 3.120
083154-35x12* 083154-35x11* 3 72.5 1.750
Copper Rail
083154-45x12* 083154-45x11* 4 90.5 2.300
60 A
083154-55x12* 083154-55x11* 5 108.5 2.850
083154-36x12* 083154-36x11* 3 72.5 2.010
Copper Rail
083154-46x12* 083154-46x11* 4 90.5 2.630
100 A
083154-56x12* 083154-56x11* 5 108.5 3.250
083154-37x12* 083154-37x11 3 72.5 2.240
Copper Rail
083154-47x12* 083154-47x11 4 90.5 2.940
125 A
083154-57x12* 083154-57x11 5 108.5 3.650
* Standard range

Line Feed complete with pre-mounted Connector and Terminal Box (083152-...)
200 x 150
125
26

90 55
Technical details
• Connection cable max. 35 mm² 500 500
• Use cable lugs for threaded connection M8 (1000)
(not included)

In-line feed Power Supply with PE Controls without PE Poles Gland Weight
Part No. Part No. [kg]
083152-323x12 083152-323x11 3 M 32 3.000
Steel Rail
083152-421x12 083152-421x11 4 M 40 3.720
32 A
083152-521x12 083152-521x11 5 M 40 4.600
083152-353x12* 083152-353x11 3 M 32 2.430
Copper Rail
083152-451x12* 083152-451x11 4 M 40 3.190
60 A
083152-551x12* 083152-551x11 5 M 40 3.950
083152-360x12* 083152-360x11 3 M 50 2.680
Copper Rail
083152-460x12* 083152-460x11 4 M 50 3.520
100 A
083152-564x12* 083152-564x11 5 M 63 4.350
083152-370x12 083152-370x11 3 M 50 2.920
Copper Rail
083152-470x12 083152-470x11 4 M 50 3.830
125 A
083152-574x12 083152-574x11 5 M 63 4.730
* Standard range

8
Hanger Clamps

For Conductor Rail Snap-in with Steel Nut (083143-...)

M6 20

≤ 12

15
23.5

33
41
B

Part No. Poles Max. Support Spacing B Weight

[mm] [mm] [kg]
083143-3* 3 72.5 0.023
083143-4* 4 1000 90.5 0.025
083143-5* 5 108.5 0.028

For Conductor Rail Snap-in for Support Arm Installation (083145-...)

25 M6

15
23.5

33
41
B 20

Part No. Poles Max. Support Spacing B Weight

[mm] [mm] [kg]
083145-3* 3 72.5 0.053
083145-4* 4 1000 90.5 0.055
083145-5* 5 108.5 0.058

Safety gear for horizontal installation and installation height > 3 m

32 750 32

34
2

14
4
2
2.3

0831 - 5P
0831 - 4P

110
92
74

Note
The safety rope is attached to the substructure. It serves as a collecting protection of the conductor line eg in the telegrams based with a forklift or other
influences such as chemical damage to the holder. The safety cable prevents the full system crash.
For vertical installation, please contact us.

Part No. Poles Quantity per System B Weight

[mm] [kg]
08-S280-0613 3-5 every second rail 74-110 0.07

9
 Anchor Clamps

For Conductor Rail Snap-in and Fixation with Steel Nut (083133-...)
M6 20

≤12

15
23.5

33
41
Fixing screw

Part No. Poles B Weight

[mm] [kg]
083133-3* 3 72.5 0.027
083133-4* 4 90.5 0.030
083133-5* 5 108.5 0.033
* Standard range

For Conductor Rail Snap-in and Fixation for Support Arm Installation (083135-...)

25 M6

15
23.5

33
41

Fixing screw

B 20

Part No. Poles B Weight

[mm] [kg]
083135-3 3 72.5 0.057
083135-4 4 90.5 0.060
083135-5 5 108.5 0.063

Note
The color coding of the fixed points allowed in a simple server failure detection system and strain concept.
Installation position in the vicinity of the feed, unless otherwise stated in the project design.

10
End Caps

For System Ends (083171-...)

B
10

40

30.5
Part No. Poles B Weight
[mm] [kg]
083171-3* 3 72.5 0.040
083171-4* 4 90.5 0.045
083171-5* 5 108.5 0.050
* Standard range

For Transfer Points (083172-...)

19.5
max. 3
A

Technical details 74.5

• The end cap for transfer points centres the current
M6 9
20

collector and compensates horizontal and vertical

max. 3

deflections of max. ± 3 mm.

55
26

• Not usable in combination with current collector

43

083102

5 -10
Sliding surface

Part No. Poles B Weight

[mm] [kg]
083172-3 3 77 0.160
083172-4 4 95 0.200
083172-5 5 113 0.240

11
 Air Gap Insulating Sections
Pick-up Guides
Air Gap Insulating Sections (083195-...)

A
134
M6

20
55
17
Technical details
• Not usable in combination with
26

current collector 083102

5
35
154

Part No. Poles A Weight

[mm] [kg]
083195-3 3 77 0.342
083195-4 4 95 0.418
083195-5 5 113 0.494

Pick-up Guides for Transfer Points (083181-....)

30 Upper edge of
hanger clamp
0 -10

M5

57
110

52

23.5

90 85
204.5
Sliding surface
Rail end

Technical details
C
B
A

• Use pick-up guides only with

18

“pick-up guide current collector“.

• The pick-up guide compensates vertical or
horizontal misalignments up to ±15 mm. 300
Rail end
Assembly tolerances below ±3 mm are
recommended.

Guides: to be fixed to the substructure and represent a fixed point. A „floating“ use is not recommended.

Part No. Poles A B C Weight

[mm] [mm] [mm] [kg]
083181-3x25 3 18 54 142 0.160
083181-4x25 4 36 72 160 0.200
083181-5x25 5 54 90 178 0.240

12
Expansion Element

Complete with pre-mounted Connector (083161-...)

Hanger clamps1) Hanger clamps1)

Note
Copper-Expansion Element
~ 650 - 700
can be used for all copper
and steel conductor rails.
Maximum permissible
~ 90

continuous emf 98 A.
51

500 250 250 41.5 0-50 250 250 500 52

2000

1) Hanger clamps to be ordered separately! Connecting cables have to be installed flexible.

Expansion Elements Poles Material Weight

with PE without PE
Part No. Part No. [kg]
083161-2x6372 083161-2x6371 3 5.610
083161-2x6472 083161-2x6471 4 Copper 7.480
083161-2x6572 083161-2x6571 5 9.350
083161-2x2382 083161-2x2381 3 2.810
083161-2x2482 083161-2x2481 4 Datametal 3.720
083161-2x2582 083161-2x2581 5 4.680
See hints page 14 (dimensioning / quantity).

How to select Expansion Elements

Expansion elements are installed in systems exceeding a total system length of 200 m as shown below, if the ambient temperature variation (ΔT) is more than 20°C
during operation. Expansion joints are not required if the total system length is shorter than 200 m or if the ambient temperature variation (ΔT) is below 20°C during
operation. An anchor clamp in the middle of the system halfes the expansion travel and eases positioning of the hanger clamps.
Pay attention to the distance between the hanger clamps and the rail connectors (System sketch, page 25).

Determination of System Length L:

System length L:
LE L = 2 · LE + m · a

m=0 Number of expansion elements:

L- 200
m= (rounded)
m=1 a
m = number of system part lengths
m=2 with one expansion element

m=3

LE a a a LE Anchor clamp
Expansion element

13
 Expansion Element

Determination Quantity of Expansion Elements

ΔT a System length [m]

[°C] [m] 1) 220 240 260 280 300 320 340 360
65 11 2 4 6 8 10 11 13 15
60 12 2 4 5 7 9 10 12 14
55 14 2 3 5 6 8 9 10 12
50 15 2 3 4 6 7 8 10 11
45 17 2 3 4 5 6 8 9 10
40 20 1 2 3 4 5 6 7 8
35 24 1 2 3 4 5 5 6 7
30 31 1 2 2 3 4 4 5 6
25 40 1 1 2 2 3 3 4 4
20 60 1 1 1 2 2 2 3 3
1) number of needed expansion elements

Diagram to set the Air Gap of Expansion Elements

Air gap to be set 0 - 50 mm during system installation.

85 How to use the diagram (Example below):

1. Draw a connection line from min.
to max. ambient temperature tA (e.g. 5°C to 45°C).
Ambient temperature [°C]

70 2. Mark the ambient temperature during installation tm

(horizonal dotted line).
60 3. Draw a line from the intersection vertically down
tA and read the air gap to adjust.
max 50
Technical details
40 • Highest ambient temp.: 55°C
30 • Lowest ambient temp.:
0 to -18°C; depends on the type of
20 conductor rail. Special designs for
tm
10 deeper temperatures on request.
tA
0 min

-10

-20

-30
0 10 20 30 40 50
+/- 38
Air gap [mm]

Example
Air gap read from diagram: ~ 38 mm

Lowest ambient temperature at Air gap calculated:

5°C
system operation: ΔT2
s = 50 = 38 mm
ΔT1 + ΔT2
10°C = ΔT1
Ambient temperature
∆T 15°C
during installation:

30°C = ΔT2
Highest ambient temperature at
45°C
system operation:

14
Current Collectors
with Accessories
Current Collectors (083102-...)
~200 Sliding surface
150
68

10
5

80
12
Screw connection

Towing arm axis

Technical details
• Collector shoe material: copper graphite
• Max. wearing height: 5 mm ~30
• Contact pressure: 5 N

20
17
~30

• Deflection (horizontal/vertical): ± 30 mm
• Assembly tolerances below ± 10 mm 10
recommended
• Connection cables (highly flexible) to
be ordered separately (see page 17)
• The current collectors are not for use with program 0811!
• Do not use in combination with air gap insulation 083195 and
transfer points 083172

Type with Phase (PH) with Earth (PE) I max. 1) Weight

Part No. Part No. [A] [kg]
Current Collector 083102-0021* 083102-0022 54 0.120
Current Collector for Transfer Points 083102-3021* 083102-3022 54 0.125
* Standard range 1) Depending on cross section and type of connection cable; limit 54 A

Collector Support Brackets 081050-.... (for current collector 083102-...)

A
B

12
15
50

Recess for
earth collector (PE)
C
10
8
24
40

9
5.5

Part No. Poles A B C Weight

[mm] [mm] [mm] [kg]
081050-20x3* 3 80 60 30 0.300
081050-20x4* 4 100 80 40 0.370
081050-20x5* 5 120 100 50 0.440
* Standard range

15
 Current Collectors
and Accessories
Current Collectors 083106-...
284 Sliding surface
210

80

100
12

146
Screw connection

Technical details
• Collector shoe material: copper graphite
Towing arm axis
• Max. wearing height: 8 mm
• Contact pressure: 10 N

17.5

18
~50
• Deflection (horizontal/vertical): ± 50 mm
• Assembly tolerances below ± 10 mm
recommended
~50

• Connection cables (highly flexible) to

be ordered separately (see page 17)
• The current collectors can also be used for transfer points

Current collectors with I Weight

Phase (PH) Earth (PE) max. 1)
Part No. Part No. [A] [kg]

083106-0021* 083106-0022* 80 0.270

* Standard range 1) Depending on cross section and type of connection cable; limit 80 A.

Collector Support Brackets 083050-... (for current collector 083106-...)

A 73
B
103

12
75

40

C
10
9
8
24

5.5

Part No. Poles A B C Weight

[mm] [mm] [mm] [kg]
083050-18x3* 3 74 55.0 30 0.300
083050-18x4* 4 92 73.0 40 0.370
083050-18x5* 5 110 91.5 50 0.440
* Standard range

16
Current Collectors
and Accessories
Support Spring Plates 08-F030-...
93 93 Technical details
• Position and type see
current collector unit 083107-...

69.5

69.5
• For horizontal operation of the
current collector unit
105 105 • Use only with collector support
bracket 083050-..

left right

Part No. Support Spring Plate Weight

[kg]
08-F030-0082 left
0.013
08-F030-0079 right

Connection Cable with Multicore Cable End Jacket 081109-...

Multicore cable end jacket

L

Cross Connection Cable with Length1) Weight Cable I Use

Section Phase (PH) Earth (PE) Diameter at 100% Duty Cycle for
[mm²] Part No. Part No. [m] [kg/m] [mm] [A]
1.5 081109-1x1,5x11 081109-1x1,5x32 1 0.014 4 24
2.5 081109-1x2,5x11 081109-1x2,5x32 1 0.023 4 32
4 081109-1x4x11 081109-1x4x32 1 0.037 5 42 083102-...
6 081109-1x6x11 081109-1x6x32 1 0.056 8 54 083103-...
083104-...
1.5 081109-2x1,5x11* 081109-2x1,5x32* 2 0.014 4 24 083106-...
2.5 081109-2x2,5x11* 081109-2x2,5x32* 2 0.023 4 32 083107-...
4 081109-2x4x11* 081109-2x4x32* 2 0.037 5 42
6 081109-2x6x11* 081109-2x6x32* 2 0.056 6 54
* Standard range (SAP KONFIG 3126191) 1) Intermediate lengths are available

Please note:
The connection cable is highly flexible and double insulated and must be ordered in the required length and size.
Amperage for single-core cables installed free in air according to DIN VDE 0298-4:2013-06 Tab.11.

Connection Cable 081109-..., 081209-...

Cross Connection Cable with Length 1) Weight Cable I Use

Section Phase (PH) Earth (PE) Diameter at 100% Duty Cycle for
[mm²] Part No. Part No. [m] [kg/m] [mm] [A]
10 081109-1x10x91 081109-1x10x92 1 0.098 7 73
16 081209-1x16x81 081209-1x16x82 1 0.156 10 98 083106-...
10 081109-2x10x91* 081109-2x10x92 2 0.098 7 73 083107-...
16 081209-2x16x81* 081209-2x16x82 2 0.156 10 98
* Standard range (SAP KONFIG 3126191) 1) Intermediate lengths are available

Please note:
The connection cable is highly flexible and double insulated and must be ordered in the required length and size.
Amperage for single-core cables installed free in air according to DIN VDE 0298-4:2013-06 Tab.11.

17
 Current Collector Units and Accessories

Current Collector Units without Terminal Boxes 083103-...

Technical details
• Shown is the version for „pick-up guides for
transfer points“
• Collector shoe material: copper graphit
• Contact pressure per collector arm: 5 N
• Max. current load:
54 A with 6 mm² connection cable at
100% duty cycle 34 A with 2.5 mm² connection cable at 100% duty cycle
• Deflection (horizontal/vertical): ±30 mm
• Assembly tolerances below ±10 mm
recommended
• The current collector units are not for
use with program 0811!
• Other connection cable cross sections
on request
• To arrange above as double-current-collectors
separate part no. for the complementary units
are required due to PE-orientation.
Please contact sales dpt.

20 205,5 Conductor rail pole number

150
± 30 mm
68 Working 1
9,5

Stroke 2
3
4
80
129

Current collector for engagement from below

± 30 mm
Displacement

Current Collector Units Number of Pole distance Variant Standard For vehicle crossing
Poles a [mm] (side and bottom engagement) (side and bottom engagement)
S1 083103-031520-00,0X0-2 083103-034520-00,0X0-2
3 79
S2 083103-030520-00,0X0-2 083103-033520-00,0X0-2
without connection cable S1 083103-041520-00,0X0-2 083103-044520-00,0X0-2
4 99
with PE S2 083103-040520-00,0X0-2 083103-043520-00,0X0-2
S1 083103-051520-00,0X0-2 083103-054520-00,0X0-2
5 119
S2 083103-050520-00,0X0-2 083103-053520-00,0X0-2
S1
3 79 083103-031020-00,0X0-1 083103-044020-00,0X0-2
S2
without connection cable S1
4 99 083103-041020-00,0X0-1 083103-044020-00,0X0-2
without PE S2
S1
5 119 083103-051020-00,0X0-1 083103-054020-00,0X0-2
S2
Different connection lengths and configurations via configurator (SAP KONFIG 3187375)

18
Current collector Units and Accessories

Current Collector Units without Terminal Boxes 083107-...

Technical details
• Shown is the version for horizontal operation
• Collector shoe material: copper graphit
• Contact pressure per collector arm: 10 N
• Max. current load: 80 A with 16 mm²
connection cable at 100% duty cycle
• Deflection (horizontal/vertical): ± 50 mm
• Assembly tolerances below ± 10 mm
recommended
• Connection cables (highly flexible) to
be ordered separately (see page 17)
• The current collector units can lso be
used for „pick-up guides for transfer points“
• Other connection cable cross sections on request
• To arrange above as double-current-collectors separate
part no. for the complementary units are required due
to PE-orientation. Please contact sales dpt.

18
284
80
± 50 mm
8

Working Conductor rail pole number

Stroke
1
100

2
3
175

± 50 mm
Displacement

Current Collector Units Number of Pole distance Variant For vehicle crossing For vehicle crossing
Poles a [mm] (intervention from below) (lateral intervention)
S1 083107-031520-00,0X0-2 083107-036520-00,0X0-2
3 79
S2 083107-030520-00,0X0-2 083107-037520-00,0X0-2
without connection cable S1 083107-041520-00,0X0-2 083107-046520-00,0X0-2
4 99
with PE S2 083107-040520-00,0X0-2 083107-047520-00,0X0-2
S1 083107-051520-00,0X0-2 083107-056520-00,0X0-2
5 119
S2 083107-050520-00,0X0-2 083107-057520-00,0X0-2
S1 083107-031020-00,0X0-1 083107-036020-00,0X0-1
3 79
S2 083107-030020-00,0X0-1 083107-037020-00,0X0-1
without connection cable S1 083107-041020-00,0X0-1 083107-046020-00,0X0-1
4 99
without PE S2 083107-040020-00,0X0-1 083107-047020-00,0X0-1
S1 083107-051020-00,0X0-1 083107-056020-00,0X0-1
5 119
S2 083107-050020-00,0X0-1 083107-057020-00,0X0-1
Different connection lengths and configurations via configurator (SAP KONFIG 3192589)

19
 Wearing and Spare Parts

Rail Connectors (083121-...)

Technical details
• The rail connector is enclosed in the delivery of the rail

36
segments but can be ordered seperately.

85 x B
105

Steel and Datametal Rail Copper Rail Poles B Weight

Part No. Part No. [mm] [kg]
083121-32 083121-36 3 72.5 0.120
083121-42 083121-46 4 90.5 0.150
083121-52 083121-56 5 108.5 0.180

Current Collector Head 55 A (083002-...)

68 Technical details Note:
51)

10

• Not interchangeable with collector In plants with transfer points 1 set

shoes program 0811 of spacer pieces with screws Art.
No. 08-D002-0592 is to be plan-
ned per collector shoe.
1) Max. wearing height

Collector Shoes Material Colours I for Current Collectors Weight

with Phase (PH) with Earth (PE) and
Part No. Part No. [A] Current Collector Untis [kg]
083002-1x4* 083002-2x4* Copper-Graphite PH: grey 55 083102-... / 083103-... 0.045
083002-1x5* 083002-2x5* Silver-Graphite PE: turquise-green 10 083104-... 0.050
* Standard Range

Current Collector Head 80 A (081001-...)

80
81)

1) Max. wearing height

Collector Shoes Colours I for Current Collectors Weight

with Phase (PH) with Earth (PE) and
Part No. Part No. [A] Current Collector Untis [kg]
081001-12* 081001-22* PH: black; PE: green 80 083106-... / 083107-... 0.090
* Standard Range

Stabilizing Springs for Current Collector Head (RZ-...)

Part No. for Current Collector Carbon Length

[mm]
08-RZ-056I 083102-... / 083103-... / 083104-... 68
08-RZ-081GI 083106-... / 083107-... 80

20
Accessories
Bracket
Directly to console With C-rail 240 crosswise
500

506

• Configurable console
• 2 x dowels 04-41001
• C-Rails Type 240 crosswise
Configurable console • Fastener
with C-rail transverse 020176-10X20P
• Console ProShell incl. dowels • track support bracket 0831
• track support bracket 0831 105 with hexagon nut
with hexagon nut • Suspension distance up to 3 m
• Suspension distance up to 1 m Order number: 3198155
• See also catalogue • See also catalogue
104 ProShell KAT0800-0003 C-Rails KAT0240-0003

In ProShell
500

• In ProShell 128 or 206

• Console ProShell incl. dowels
• Track support bracket ProShell
• Suspension distance up to 3,2 m
• See also catalogue
122 ProShell KAT0800-0003 21
 Mounting
Accessories
Tool for easy assembly of 0831

Assembly tool/knocking block for jointing the rail connection

90
55

20
ø10

41
15

60 36±0,1
12,5 49

5
R2,
5
18

Designation Pole Order number

Mounting block 3-pole 3 08-V015-0492-003
Mounting block 4-pole 4 08-V015-0492-004
Mounting block 5-pole 5 08-V015-0492-005

22
 System Sketch

System length L
4000 1000 4000
min. 200 max. 1000
max. 400 500
40 M6 40
Arrangement Examples

50 – 100 min.

25

80
100
123

153
138
conductor rail

129.5
183
175
end cape connector with
hanger clamp line feed insulation profile

150 anchor point 84

71 210
current collector current collector
083102-... 083106-...

Only fine-stranded, highly flexible cables are to be used as connection cables. The cables are to be laid without directional force and must not hang in.
Bundling or additional fixing to the arm is not permitted.

23
 Program Overview

Conductor Rails

Program Nominal Current1) Voltage Grade Support Spacing Rail Length Outside-Dimensions

10-100 A 500 V 0.4-1.0 m 4m 14.7 x 15.5 mm

0811
Single Pole Insulated Conductor Rail

100 A 500 V 0.5 m 4m 9.6 x 15.2 mm

0815

1,5 m
25-400 A 690 V 4m 18 x 26 mm
(3.2 m)1)

0812

200-1250 A 690 V 2.5 m 5m 32 x 42 mm

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

690 V
35-140 (4/5 pole)
(160 A at 2m 4m 56 x 90 mm
80% duty cycle) 400 V
(7 pole)
0842

1) 3.2 m in combination with support structure ProShell

24
 Conductix-Wampfler – the complete program

Your Applications – our Solutions

The solutions we deliver for your applications are based on your specific requirements. In many cases, a combination of
several different Conductix-Wampfler systems can prove advantageous. You can count on Conductix-Wampfler for hands-on
engineering support together with the optimum solution to safely meet your needs.

Cable and Hose Reels Festoon Systems Conductor Rails Inductive Power Transfer IPT®
Motor driven and spring driven reels Conductix-Wampfler cable trolleys can Available as enclosed or multiple The no-contact system for
by Conductix-Wampfler provide be used in virtually every industrial unipole systems, Conductix-Wampfler transferring energy and data.
energy, data and media over a variety application. They are reliable, robust conductor rails reliably move people For all tasks that depend on
of distances, in all directions, fast and available in an enormous variety and material. high speeds and absolute
and safe. of dimensions and designs. resistance to wear. Flexible
installation when used with
Automated Guided Vehicles.

Non-insulated Conductor Rails Radio Remote Controls Reels, Retractors and Balancers Jib Booms
Robust, non-insulated aluminum Safety remote control solutions Available for hoses and cables, as Complete with tool transporters, reels
conductor rails with stainless steel customized to meet our customer classical reels or high-precision or an entire media supply system –
cap provide the ideal basis for power needs with modern ergonomic design. positioning aids for tools, we offer a safety and flexibility are key to the
supply of people movers and transit complete range of reels and spring completion of difficult tasks.
networks. balancers.

Slip Ring Assemblies Mobile Control Systems ProfiDAT

Whenever things are really “moving Mobile control solutions for your This data transfer system is a
in circles”, the proven slip ring plant – wether straightforward or compact slotted waveguide and
assemblies by Conductix-Wampfler intricate. Control and communication furthermore can be used as
ensure the flawless transfer of energy systems from LJU have been tried Grounding rail (PE) as well as
and data. Here, everything revolves and tested in the automotive industry positioning rail at the same time.
around flexibility and reliability! for decades.
 www.conductix.com
© Conductix-Wampfler | 2021 | subject to technical modifications without prior notice

Conductix-Wampfler
has just one critical mission:
To provide you with energy and
data transmission systems that
will keep your operations up
and running 24/7/365.

To contact your nearest

sales office, please refer to:
www.conductix.contact
KAT0831-0001p-EN