Insulated Conductor Rail

SinglePowerLine Program 0813

Table of Contents
System Description 5

Technical Data 6

General Instructions 7

System Structure 8
Components and their use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Advantages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Insulated Conductor Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Comparison of different Conductor Rail Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hanger Clamps 11
Hanger Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hanger Clamps with Insulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rail Connectors and Power Feed Connectors 12
Rail Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power Feed Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tubular Cable Lugs see page 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Anchor Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
End Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tubular Cable Lug for Power Feed Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Expansion Units 15
Expansion Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Expansion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pickup Guides for Intersections 17

Current Collectors 18
Current Collectors 250 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation Examples see page 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dual Current Collectors 500 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Current Collectors – Installation Instructions 20
Installation of the PE conductor Current Collector for installations without Pickup Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation of the PE conductor Current Collector for installations with Pickup Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drilling Jig 08-W100-0223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dimensioning and Layout of Conductor Rail System 22
Correction factors for the voltage drop U at different ambient temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
System Layout 25
Layout Schematic and Component Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Layout Examples 27
Standard Current Collector Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Offset Current Collector Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mounting Accessories 28
Support Arms 40 × 40 × 2,5 mm - perforated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Permissible load for Support Arms 40 x 40 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Holder for Support Arms 40 × 40 × 2,5 for screw mounting with 2-holed connector plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Holder for Support Arms 40 × 40 × 2,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Girder Clips, clamping thickness 4 - 20 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Girder Clips, clamping thickness 18 - 36 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Girder Clips, non-twistable, clamping thickness 6 - 25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Towing Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
End Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mounting Comb 081046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tools and Assembly Accessories 33
Grounding- and Short-circuit Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Contact Grease for Connection Points (Aluminum rails/CopperECO ||| rails) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassembly Tool (Set) for Hanger Clamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Replacement Parts 34
Sliding Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replacement Parts for Current Collectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3
4
System Description

The SinglePowerLine 0813 conduc- alloy with stainless steel tread are The plastic insulation of the conduc-
tor rail system is used as a standard available, as well our special material tor rails is colored warning yellow in
product in the area of bridge, portal CopperECO |||. CopperECO ||| offers accordance with general marking
and process cranes, but also in a wide you an alternative between copper and regulations, and the PE conductor rail
variety of other applications such as aluminum-stainless steel with good components are green and yellow
amusement rides and people movers. corrosion protection for high current (continuous green colour strips).
For over 35 years, it is a specified, requirements, even during standstill Other colours are available upon
reliable and approved product in these operation. request (note minimum order
applications. quantities).
With the partial expansion compensa-
As an insulated single-pole safety tion system (compensation for thermal Safety conductor rail with a
conductor rail, the contact-protected expansion in every rail part), systems finger-safe design. Testing of
system meets requirements for con- up to 200 m in length can be imple- contact protection with IEC /
ductor rails according to European (CE) mented without the use of additional UL / NEMA jointed test fingers
and current international standards expansion elements.1) (12 mm foreign bodies).
and is listed and approved for use
in the United States and Canada by The safe, refined connector system
Underwriter Laboratories UL, CSA as and clip-on rail holders, in combina-
well as GOST-R. tion with optional mounting brackets,
permit fast, economical assembly.
With different insulation materials,
applications can be covered with con- With the SinglePowerLine 0813 system
ductor temperatures of up to 115°C. and the 0813 product line extension
This corresponds to a permanent for higher power ranges, Conductix-
ambient temperature of 85°C at 100% Wampfler offers a reliable, proven and
duty cycle under continuous load. robust solution for your
The conductor rail can temporarily application. Present around the world,
withstand up to 125°C. our representatives and sales partners
are glad to be at your side from
For conductor materials, copper, planning to implementation and
and aluminum in sea-water resistant service.

System advantages: • self-extinguishing insulation • Special seamless and corrosion-

compliant with UL-94 standard resistant process for connection of
• available in different conductor • Yellow safety-color aluminum rails and stainless steel
materials contact surfaces
• Designed for 100% duty cycle
• finger-safe design according to European standards
• used around the world • Self-aligning hanger clamps
• modular, expandable system • Seawater-resistant

1)
Take arrangement and ambient temperature into consideration.

5
 Technical Data
Aluminum with Stainless Steel
Conductor Rails CopperECO ||| Copper
Contact Insert
Type 081313 081314 081319 08131C 08131D 08131I 081315 081316 081317

Current Load [A]

At 100% duty cycle and 35 °C

(rated value) 500 800 1000 500 800 1000 500 800 1250
At 60% duty cycle and 20 °C 510 810 1050 510 810 1050 520 880 1400

Rated voltage [V] 690 (UL 600 V) – min. 24 V / 1A (minimum load)

Protection type Vertical insertion of current collector: IP23 (DIN EN 60529, VDE 0470-1); horizontal insertion of current collector: IP21
Safety level Finger-safe design (collector: finger-safe entry only)
Installation orientation Horizontal with collector entry on bottom side; collector entry sideways optional, for indoor use only
Application area Crane construction, container-stacking cranes, steel mill cranes, process cranes and similar applications
Environment Indoors and outdoors (see protection class)
Rated suspension spacing [m] 2.5 (98 Inches) typically 2.4 bis 2.5
Rail length [mm] 5000 (196.9 Inches) (rated dimensions at 20 °C / tolerance ± 3 mm)
System length [m] unlimited
Exterior dimensions [mm] 32 x 42 (rail cross section)
Rated rail spacing [mm] 80 (3.15 Inches) (minimum spacing can be extended as needed)
Travel speed [m/min] 600 m/min (straight segments without interruptions, such as Pickup Guides, Air Gaps, etc.)
Expansion / expansion connectors Compensation up to 200 m (565 feet) in system length, above 200 m the use of expansion elements is necessary
Permitted ambient temperature 1)
-15 °C to 55 °C (85 °C in heat-resistant design / PPE + SB) [deeper temperatures on request]
Maximum conductor temperature +85 °C (115 °C in heat-resistant design / PPE + SB, temporarily 125 °C)
Storage temperature -30 °C to +40 °C (dry storage; avoid condensation)

Depending on type: electrolytic copper, seawater-resistant aluminum with stainless steel contact surfaces, or our new hybrid
Conductor materials
material CopperECO |||

Rail insulation Stabilized hard PVC (standard material) and PPE + SB (heat-resistant design for interior use)
Overvoltage category III (EN 60664-1-2007/VDEO110-1)
Installation- / Mounting tolerance Distance between isolation items and steel structure : Min. 10 mm (also see system sketch)
Meets requirements for insulation materials in UL 94 V-1;
Flammability / fire safety
Flame retardant and self-extinguishing (IEC 60695-11-10), halogen-free PPE-SB
Local approvals UL / CSA / GOST-R
Coloration Rail insulation in safety warning colour RAL 1018 Zinc yellow or RAL 1021 Rape yellow in heat-resistant design

Program 0813:
Use the power supply of cranes, construction of larger slip ring assemblies, transfer carriages, cable trays outside the public accessible area, out of arm’s indoor and
external applications (IP2x) mounted.

• Current collectors sideways or from below

• Mounting position of the rails horizontally (not vertically / vertical application or consultation hold)
• Additional equipment needed for outdoor use, e.g. insulators, overhead covers, rail-heating elements, must be considered
• Touching the current collectors is prevented by appropriate measures on the plant side. Contact protection class IP23 (with vertical current collector insertion)
or IP21 (with horizontal current collector insertion)

Relevant standards
DIN EN 60664-1, Insulation coordination for electrical equipment in low-voltage installations - Part 1: Principles, requirements and testing (IEC
VDE 0110-1:2008-1 60664-1:2007); German edition EN 60664-1:2007
DIN EN 60204-1, 60204-32, Safety of machines - electrical equipment of machines - Part 1: General requirements (IEC 60204 - 1:2005, modified); Ger-
VDE 0113-1:2007-06 man edition EN 60204-1:2006
DIN EN 60529,
Protection classes using housings (IP code) (IEC 60529:1989 + A1:1999): German edition EN 60529:1991 A1:2000
VDE 0470-1:2000-09
Subject to technical modifications

1)
At temperatures below -10 °C, the mechanical stress due to physical limitation of the breaking strength must be limited.
6 2)
At low temperatures, temperature flexible cables should be used.
General Instructions
Application Area rails and corrections to rated current speci- Please note that the layout of conductor
This product is intended for the supply fications is listed starting on page 22. rails and current collectors between fixed
of mobile consumers in the rated current and moving system parts must maintain a
range up to 1250 A and voltages up to 690 Electrical Safety safety spacing of at least 0.5 m to avoid
V / 1000 V. Target applications are hoist/ Insulated SinglePowerLine 0813 conductor crushing risks, or other safety measures
crane systems, container stacking cranes, rails are designed according to applicable must be taken to prevent this risk.
steel mill- or STS-cranes and similar ap- international standards and guidelines,
plications with one or more mobile units. meet today's requirements for the In exposed installation situations, for exam-
safety of a conductor rail and have contact ple over traffic ways, please ask for details.
The insulation materials are resistant to protection compliant with DIN EN 60529
many ingredients used in the industrial (protection class IP 23). They meet the Use of Conductor Rails
environment, depending on concentration general requirements for classification and The conductor rails of Program 0813 meet
and exposure time. All metal parts are evaluation defined in DIN EN 60204 part current standards and guidelines for the
available in copper or seawater-resistant 32 - Electrical requirements for hoisting intended use of the components. For instal-
aluminum depending on construction type, machines. lation into the final product, the specifica-
and should be evaluated in accordance tions valid for this product must be taken
with the general suitability of these basic Conductor rails and rail components have a into consideration and you must proceed
materials. high level of safety. With contact protec- in accordance with the Machine Directive
tion, direct contact between body parts and or with the guidelines valid for the place of
Before using in critical environmental con- electrically conducting parts is prevented installation.
ditions such as galvanizing plants, pickling (finger protection with DIN VDE and EN /
plants, compost works and locations with NEMA test fingers / 12 mm foreign bodies). Use outdoors
high concentrations of chemicals (e.g. The current collectors are also designed Outdoors, the conductor rail should be
solvents, aromatics, benzols, etc.), please finger-safe when engaged in the rails, but protected from environmental influences
contact us. in areas where they leave the rails, such as much as possible. Use in high humidity
as intersections and switch points, they and low temperature areas runs the risk
Layout must be additionally protected using power of condensation, the formation of frost
There are several decisive factors in the switches, covers or distance. Installations and ice build-up on the contact surfaces.
selection and layout of conductor rails. One with voltages over 25 V DC and 60 V AC In installation in this environment, the
main characteristic is the current load that in publically accessible areas must be rails, in particular aluminum rails, must be
actually occurs (total current to be expected secured by covers, installation away from equipped with an optional rail heater. Our
during operation – not to be confused with accessible areas or other suitable means. sales department will be glad to assist you
the installed power or the resulting maxi- with the layout.
mum current) and the resistance values Installations in which the insulation
of the system. Here we look at the longest characteristics may be reduced by con- Approvals
segment between the power feed and the ductive dust or moisture must be installed The conductor rail product line meets the
position of the consumer during start-up. away from access by people and be product parameters required for interna-
The criterion in question is the resulting marked as high-voltage electrical tional use for these products and has been
voltage drop. Depending on the conductor equipment with warning signs. In areas developed in accordance with the existing
material and cross section, different losses with high operating voltage (> 690 V) and standards and guidelines in the EU and the
can result for the same length and current. installations in a highly contaminated envi- important industrial markets. In addition to
A conductor rail is properly dimensioned ronment with conductive dust or moisture, IEC/EN standard compliance, the product
from the point of view of voltage drop when insulators must be used. line also has local UL/CSA and GOST-R
the drop lies within the permitted tolerance approvals.
range, generally 2-5% and at most 10% The single-pole system can be built with
including the connection feed cable. any number of poles and extended in a
modular manner. Components for the
Conductor rails are classified by their rated protective conductor are marked in green
current. This corresponds to the maximum or green/yellow and may not be used as
continuous current for the conductor rail phase components. Using installed parts
and is based on the standard parameters of and position coding, it is impossible to en-
35 °C ambient temperature and 100% duty gage the PE current collector into a phase
cycle (according to IEC >
_ 10 min ON). If the pole, or to mix phases. We recommend
duty cycle or ambient temperature is lower, laying out the PE contact redundantly with
higher currents can be transmitted. Further two current collectors.
information about the layout of conductor
Mechanical Safety
7
 System Structure

Components and their use

8
6

8 4
3

1 Current Collector: Connects to the moving part of the system. Maintains positive contact with the rail as it slides.
Available in different sizes as single or dual current collector.

2 Conductor Rails: Stable basic body of conductive material with contact-safe insulated profile.

3 Rail Connectors: Clamping connectors with insulated cap. Can only be removed with a tool (safety requirement).

4 Anchor Clamps: Clamping element for anchoring the system. Forces the rail to expand to either side of the anchor point.

5 Hanger Clamps: Freely rotating and thus self-aligning clip-on holder for quick, safe assembly. Mounting height adjustable.
Allows the rail to slide during thermal expansion.

6 Power Feed Connectors: Used instead of a rail connector. Universal connection of single strands with outer diameters of up to 17 mm.

Expansion Units (not shown): Changing temperature causes the conductor rail system to expand. To compensate for the expansion in systems over 200 m
or systems with multiple fixed points or curves, expansion joints are used.

7 End Caps: Rail terminator as protection against accidental contact.

8 Support Arms

Pickup Guide (not shown): For areas in which the collector must be driven in or out of the conductor rail system.

Air Gap (not shown): For galvanic isolation, for example of segments during maintenance.

System Advantages

• Robust, tried and tested industrial design • Simple installation

• Safe conductor rail with contact protection (finger-safe design) • Optional safety components / functions

• Designed to national and international standards • Rails in safety warning color RAL 1018/1021

• High availability • CE-compliant design

• Expandable • Available with any number of poles

• Partial compensation for thermal expansion

8
System Structure

Insulated Conductor Rails

The standard product line offers the following conductor materials: electrolytic copper, aluminum, and our new special material CopperECO |||.
We therefore offer the ideal solution for every requirement:
• Copper, with its good conductivity and low voltage drop, is the ideal conductor, with restrictions in applications in aggressive or corrosive environments.
Used when high amperage is needed, particularly in standstill operation..
• As a budget-priced alternative, aluminum rails with a stainless steel contact surface are also available. Using a special procedure, stainless steel and saltwater-
resistant aluminum are firmly joined with no gap, combining the advantages of both materials, that is, good conductivity and low wear, without the disadvantages
of other aluminum rails available on the market with stainless steel inserts.
• The portfolio is complemented by our new special material CopperECO |||. This innovation offers a significantly improved conductivity compared to aluminum-stainless
steel and thus allows high power transmission even when the system is in standstill. CopperECO ||| is suitable for demanding outdoor environments including
saltwater areas. Thereby we can offer an excellent price-performance alternative inbetween copper and aluminum-stainless steel.

The conductor rails consist of the conductive rail body and the 32
protective insulation in a contact-safe design.

As insulation material, PVC is used in standard applications

42
For higher ambient temperatures halogen-free PPE+SB is used.

Rated length: 5000 mm

Colour: Safety warning RAL 1018 (PVC) / RAL 1021 (PPE+SB)
PH = Phase
PE = Potential Earth (“grounding”)
NEW
Aluminum (with stainless steel
CopperECO ||| Copper
contact surface)
Rated current (100% duty cycle) 500 A 800 A 1000 A 500 A 800 A 1000 A 500 A 800 A 1250 A
Rated current (60% duty cycle) 510 A 810 A 1050 A 510 A 810 A 1050 A 520 A 880 A 1400 A
Cu figure – – – – – – 1.6 kg/m 2.86 kg/m 4.76 kg/m
Order number Standard insulation for ambient temperatures up to +55 °C
081313- 081314- 081319- 08131C- 08131D- 08131I- 081315- 081316- 081317-
PH
5X11* 5X11* 5X11* 5x11 5x11 5x11 5X11 5X11 5X11*
081313- 081314- 081319- 08131C- 08131D- 08131I- 081315- 081316- 081317-
PE (green color stripes)
5X12* 5X12* 5X12* 5x12 5x12 5x12 5X12 5X12 5X12*

Order number Insulation for ambient temperatures up to +85 °C

081313- 081314- 081319- 08131C- 08131D- 08131I- 081315- 081316- 081317-
PH
5X21 5X21 5X21 5x21 5x21 5x21 5X21 5X21 5X21
081313- 081314- 081319- 08131C- 08131D- 08131I- 081315- 081316- 081317-
PE (green color stripes)
5X22 5X22 5X22 5x22 5x22 5x22 5X22 5X22 5X22
Short lengths of 1, 2 and 3 m are available upon request for an additional price for cutting costs
Part No. for semistandard: 0813-__-length X __ (length = 1 for 1 m, 2 for 2 m, and 3 for 3 m), lenghts > 6 m on request – example 1m: 0813XX-1 X 11
* Standard range

Technical Data – Rail Length 5000 mm ± 3 mm

DC resistance
0.092 0.071 0.049 0.092 0.071 0.049 0.097 0.054 0.031
[Ω/1000m] 20 °C

DC resistance
0.097 0.074 0.051 0.097 0.074 0.051 0.104 0.057 0.033
[Ω/1000m] 35 °C

Impedance [Ω/1000m]
0.152 0.140 0.134 0.152 0.140 0.134 0.156 0.134 0.126
20 °C/50Hz

Impedance [Ω/1000m]
0.157 0.144 0.137 0.157 0.144 0.137 0.161 0.136 0.127
35 °C/50Hz
Weight [kg] 6.92 8.36 10.23 6.92 8.36 10.23 10.36 16.9 25.23

9
 System Structure

Comparison of different Conductor Rail Materials

Aluminum-Stainless Steel CopperECO ||| Copper

Conductivity
Conductivity

Corrosion resistance
Corrosion resistance

Price
Price
Suitable for corrosive environments ✔ ✔ –
High amperage
Standard requirements, especially Highest requirements on
Application requirements
requirements in standstill mode current carrying capacity
(e.g. crane hoist/AS/RS)

Application example

Max. Current Carrying Capacity of Current Collectors (250 A) with different rail materials at 30° C ambient temperature
Aluminum-Stainless Steel CopperECO ||| Copper

Current carrying capacity

a) moving (v > 10 m/min) 250 A = Inom 250 A = Inom 250 A = Inom
per current collector

Max. duration ts
of current carrying capacity 5 minutes 15 minutes (no limit)
during brief standstill *
b) brief standstill
Current carrying capacity
125 A = 50% Inom 250 A = Inom 250 A = Inom
per current collector

c) standstill for a longer period Current carrying capacity

75 A = 30% Inom 200 A = 80% Inom 250 A = Inom
(t > ts) per current collector

* thereafter moving the current collector by at least 1 m / cooling off for at least the same duration as previous current load

10
Hanger Clamps

Hanger Clamps

M10

max. 35
M10

max.14

138
12
102

62

86
75
24
45 63 45 63

Part No. Designation Weight [kg]

081341-01* Hanger Clamp galvanized with hex nut 0.115
081343-01* Hanger Clamp galvanized with square nut 0.185
081341-02* Hanger Clamp in stainless steel with hex nut 0.115
081343-02* Hanger Clamp in stainless steel with square nut 0.185
* Standard range

Hanger Clamps with Insulators

M10
SW40

M10 SW40
max.15

max.12
161

161
107

105
132

130

45 45
63 63

Suspension is carried out using freely swivelling clip-on Hanger Clamps that are Note: - Only for suspended installation
self-aligning and permit low-friction slipping in case of thermal expansion. - Rated suspension spacing 2.5
Hanger Clamps are available with hex nuts or square nuts for the mounting of m, - Max. suspension spacing 2.5 m
Support Arms / C-rail (see installation accessories). typically 2.4 to 2.6 m - Hole drilled for mounting ø 11 mm
- Hanger in full metall version for
heavy duty application on request
Part No. Designation Weight [kg]
081341-11 Hanger Clamp galvanized with hex nut 0.210
081343-11* Hanger Clamp galvanized with square nut 0.280
081341-12 Hanger Clamp in stainless steel with hex nut 0.210
081343-12* Hanger Clamp in stainless steel with square nut 0.280 11
* Standard range
 Rail Connectors and Power Feed Connectors

Rail Connectors
303
275

100
44
62

Rails are connected using compact screw connections. The rail connections must have exposed metal on all contact surfaces and be coated with a thin layer of contact
grease (part no. 080021) to protect against corrosion. When mounting clamping screws, use a torque wrench to achieve correct tightening torques.

Part No. Designation Weight [kg]

081321-1 Connector for copper rails 500/800 A 1.1
081321-2* Connector for aluminum rails/CopperECO ||| rails Galvanized 1.0
081321-3* Connector for copper rails 1250 A 1.6
081321-4 Connector for aluminum rails/CopperECO ||| rails 1.0
081321-5 Connector for copper rails 1250 A Stainless Steel 1.6
081321-6 Connector for copper rails 500/800 A 1.1
080021* Contact grease, one 20 g tube (for approx. 200 connection points) 0.030
* Standard range

Power Feed Connectors

62
355 44

100

The power feed uses a power connector; these replace the normal rail connectors. Note:
Electrical connection is provided using projecting bolts and tubular cable Lugs - Tightening torque max. 31 Nm
(cable and cable lugs not included; please order separately). - Max. outer cable diameter 25 mm
- Use contact grease 080021

Part No. Designation Weight [kg]

081351-2* Connector for aluminum rails/CopperECO ||| rails 1.0
Galvanized
081351-3* Power feed connector for copper rails 1.6
081351-4 Connector for aluminum rails/CopperECO ||| rails 1.0
Stainless Steel
081351-5 Power feed connector for copper rails 1.6
* Standard range

Tubular Cable Lugs see page 12

12
Anchor Clamps and End Caps

Anchor Clamps

The rails are fixed in one place with Anchor Clamps and can expand freely
from that point out. The fixed point is mainly for single feed applications
attached close to the power feed or in the center of the conductor rail
system. If multiple fixed points are planned, for example at intersections
or curves (natural fixed point), the segment between the fixed points must
be decoupled using Expansion Units. Clamps are fastened with a clamping
cone on the rail insulator.

Part No. Designation Weight [kg]

081331-2* Anchor Clamp 0.122
For each fixed point, order two Anchor Clamps per pole
Not recommended for vertical application
* Standard range

End Caps

158 38

60

47
End Caps are used as a rail terminator and contact protection and are fastened to the rails using clamping screws.

Part No. Designation Weight [kg]

081371-2* End Cap – Stainless Steel (DIN parts) 0.136
081373-2* End Cap for aluminum rails 1000 A (DIN parts) 0.136
* Standard range

Tubular Cable Lug for Power Feed Line

Ø10.5
Øb
Øc

e a

Part No. Cross section [mm2] a [mm] b [mm] c [mm] d [mm] e [mm] Weight [kg/1000]
080054-025* 25 34 7,0 10,0 18 12 15,7
080054-035* 35 37 8,5 12,0 19 12 21,3
080054-050* 50 39 10,0 14,0 20 12 30,8
080054-070* 70 44 12,0 16,5 23 12 45,4
080054-095* 95 48 13,5 18,0 26 12 54,0
080054-120* 120 51 15,0 19,5 28 14 65,7
080054-150* 150 56 16,5 21,0 31 14 76,2
080054-185* 185 65 19,0 24,0 35 18 117,5
* Standard range Material: Copper, tin-plated Order lot size 10 pcs. per size
13
 Air Gaps

Air Gaps

1250 1250

8
591

Air Gaps are used for the galvanic isolation of sections, such as mainte-
nance segments that can be supplied with power and turned off separately.
For each separation point, two Air Gaps must be mounted at a suitable
distance to avoid power carryover through the Current Collectors.

Part No. Designation Weight [kg]

081394-2 Air Gap 2.50
081395-2 Air Gap for aluminum rails 1000 A and CopperECO ||| rails 1000 A 2.49
Please note: Air Gaps are delivered as an assembly set (not pre-assembled).

14
Expansion Units

Expansion Units
100

0-45 825 0-45

1170
5000 at
bei20°
20°

To compensate for changes in length due to temperature for systems > 200 m or segments connected between two fixed points such as Pickup Guides on both ends of
the segment, or in curves (natural fixed points), expansion elements are needed to absorb the change in length. The expansion element has two expansion points, each
of which can absorb 45 mm of expansion. The expansion elements / expansion unit parts are, like the rails, designed as 5 m standard components.
Note: The middle part between the two expansion segments must be supported using hanger clamps (not included – order separately). When using expansion units,
the use of dual Current Collectors is recommended.

Expansion Units Expansion Units

Standard variant Heat-resistant variant

PH (Phase) PE (Potential Earth) PH (Phase) PE (Potential Earth) Weight [kg]

For aluminum rails 500 A 081362-5X2131* 081362-5X2132* 081362-5X2231 081362-5X2232 10.8
For aluminum rails 800 A 081362-5X2141* 081362-5X2142* 081362-5X2241 081362-5X2242 14.5
For aluminum rails 1000 A 081362-5X2181* 081362-5X2182* 081362-5X2281 081362-5X2282 16.5
For CopperECO ||| 500 A 081362-5X21C1 081362-5X21C2 081362-5X22C1 081362-5X22C2 10.8
For CopperECO ||| 800 A 081362-5X21D1 081362-5X21D2 081362-5X22D1 081362-5X22D2 15.5
For CopperECO ||| 1000 A 081362-5X21I1 081362-5X21I2 081362-5X22I1 081362-5X22I2 16.5
For copper rails 500 A 081362-5X2151 081362-5X2152 081362-5X2251 081362-5X2252 13.8
For copper rails 800 A 081362-5X2161 081362-5X2162 081362-5X2261 081362-5X2262 22.5
For copper rails 1250 A 081362-5X2171* 081362-5X2172* 081362-5X2271 081362-5X2272 31.6
Design: Fastening and DIN parts in stainless steel – rated length 5000 mm (16.40 feet). Hanger Clamps in the middle segment not included in scope of delivery –
please order separately!
Delivery: completely pre-assembled at the factory. Adjustment of the two expansion gaps according to the table on page 15, depending on temperature values.
* Standard range

Layout notes
Changes in ambient temperature and intrinsic heating cause the conductor rails and the insulation to expand differently. The SinglePowerLine 0813 conductor rail sys-
tem has a partial thermal expansion system. The difference in thermal expansion between the insulation and the rails is compensated for in each individual rail. For this
reason, the insulation profile is specified shorter than the rail and the compensation takes place in the area of the connector caps without influencing the contact guard.
By using self-aligning, rotating Hanger Clamps, the rail line can expand without friction and thus be laid out up to a length of 200 m without additional Expansion Units.
If the power feed is in the middle with a fixed point at the power feed, installations of up to 200 m can be laid out without expansion elements by allowing the segment
to expand freely to each side for 100 m from the fixed point.
For installations of greater length, multiple fixed points such as Pickup Guides or curves that also have a fixed position due to a fixed point or mechanical attachment,
expansion joints must be used to absorb the changes in length.
Pickup Guides and curves are to be considered as fixing points.

Mounting instruction
The distance between insulating caps and steel construction should be at least 10 mm.

15
 Expansion Units

Expansion Units
tmax tmin
+110 Legend:
+100
Ambient temperature during installation [°C]

tmin lowest temperature that occurs in the application

+90
1
tmax highest possible working temperature in the application
+80
+70 1. Draw a connecting line from tmin to tmax.
+60 2. Draw the ambient temperature during installation as a horizontal line.
2
+50 3. Draw a vertical line down from the point of intersection of these two
+40 lines, and read off the air gap to be used during installation.
+30
+20
Examples:
+10
1 Temperature range: from -15 °C to +85 °C
0
-10 Ambient temperature during installation: +30 °C
-20 Air Gap: 25 mm
-30
0 5 10 15 20 25 30 35 40 45 2 Temperature range: from 0 °C bis +60 °C
Air gap [mm] Ambient temperature during installation: +10 °C
Air Gap: 37 mm

Number of Expansion Units for systems over 200 m in length

For rail conductor installations over 200 m in length, Expansion Units must be installed at specific intervals, as shown in Diagram 3. In complicated curves and other
special installations, as well as for fixed point arrangements at the end of the system, special intervals must be used. Please contact us.

Number of Intermediate
1 2 3 4 5
Expansion Units length a
Material Al* Cu Al* Cu Al* Cu Al* Cu Al* Cu Al* Cu
Total length of the conductor rail [m]
10 400 400 600 600 800 800 1000 1000 1200 1200 200 200
20 387 400 575 600 762 800 950 1000 1138 1200 187 200
30 325 376 450 553 575 729 700 905 825 1082 125 176
40 293 332 387 464 481 597 575 729 669 862 93 132
50 275 306 350 412 425 517 500 623 575 729 75 106
tges

60 262 288 325 376 387 464 450 553 512 641 62 88
70 253 275 307 351 360 427 414 502 468 578 53 75
80 247 266 294 332 340 398 387 464 434 531 47 66
90 242 259 283 317 325 376 366 435 408 494 42 59
100 237 253 275 306 312 359 350 412 387 464 37 53
Al = aluminum, Cu = copper *expansion of CopperECO ||| material comparable to Aluminum-stainless
steel

tges = tU+ tsw

Diagram 3
L ≤ 200 m
t U = Temperature range of the ambient temperature
tsw = Temperature increase due to electric current (electrical thermal load)
Recommended values for tsw:
1 DV
10 °C up to 40% duty cycle
20 °C up to 65% duty cycle 2 DV
30 °C up to 100% duty cycle
3 DV

For longer systems than those in the table above, use: 4 DV

a
L - 200
= number of Expansion Units 5 DV
a
100 m FP (Anchor Clamp) 100 m
DV (Expansion Unit)
a (intermediate length for one Expansion Unit)
L (total length of system)
Note: Intersection Pickup Guides and curves are fixed points, so these
areas must also be taken into consideration when laying out the system. 2 DV ET (Pickup Guide)

16
Pickup Guides for Intersections

For areas in which the collector must be driven in or out of the conductor rail system, Pickup Guides are used in combination with Current Collectors provided for this
purpose. The speed for Pickup Guide entry must not exceed 80 m/min and that Pickup Guides must be considered wearing parts.
Installation tolerances must be taken into consideration. Simultaneous alignment gaps with maximum tolerances in the X and Y directions are not permitted.

58
115
490
615

275

M10
0-10

b
a
20
109,5
109.5

65 65

Dimensions [mm] Number of poles

1 2 3 4 5
a 200 265 330 395 460
b 105 170 235 300 365

- The Pickup Guide centers the Current Collector with a maximum lateral
Type of fastening elements:
and vertical alignment tolerance of ±25 mm. Part No. Weight [kg]
stainless steel
- Settings of less than ±10 mm are recommended.
081382-12 1-pole Pickup Guide 1.86
- In installations with Pickup Guides, a corresponding number of Current Collectors
081382-22 2-pole Pickup Guide 2.63
must be available, and mounted in intervals that ensure that just the necessary
number of Current Collectors needed for momentary power requirements are 081382-32 3-pole Pickup Guide 3.40
in use. 081382-42 4-pole Pickup Guide 4.17
081382-52 5-pole Pickup Guide 4.94
The user must ensure that the Current Collectors between the Pickup 081383-12 1-pole Pickup Guide 1.86
for Aluminum rails /
CopperECO ||| rails

Guides are disconnected from power or are protected against accidental 081383-22 2-pole Pickup Guide 2.63
1000 A

contact. 081383-32 3-pole Pickup Guide 3.40

081383-42 4-pole Pickup Guide 4.17
081383-52 5-pole Pickup Guide 4.94

Installation note
The middle distance between two conductors is 80 mm. This is reduced to 65 mm using the last Hanger Clamp before the Pickup Guide in order to ensure that the
Current Collector enters the Pickup Guide precisely. The Pickup Guide is delivered complete with End Caps. The End Caps are pushed onto the rails with a soft-head
hammer until they hit the end stops. The clamping screws are then tightened firmly.

Hanger Clamp spacing for installations with Pickup Guides

275 560 1700 1700 2500 2500 2500 2500

58

80
65
65

80

Please note also the instructions for mounting the PE Current Collector for installations with Pickup Guides.
17
 Current Collectors

Current Collectors 250 A

125

40
ca.185
465

Technical data
Max. current capacity 250 A (30 °C / 100% ED) [for aluminum rails in standstill mode at 100% duty cycle: 125 A]
Max. travel speed 600 m/min; higher travel speeds upon request
Pressing force 28 N
Lateral deviation ± 100 mm
Working stroke in insertion direction ± 40 mm
Connection cable 70 mm2, 1.5 m long, high-flexibility; longer connection cable available upon request
Distance between the extension arm axis
125 mm (important functional dimension)
and contact surface of the rail
Temperature range cable - 15 °C up to + 55 °C (Ambient)

Max. Current depending used cable type, ambient temperature and cable arrangement.

Installation note
The user must ensure that the Current Collector's center line is exactly aligned with the center line of the conductor rail during installation, and that the specified
installation spacing between the extension arm axis and the contact surface of the rail is being observed (see installation examples on page 27).

The connection cables must be highly flexible to ensure free movement of the Current Collectors and be secured with the cable binder on the Current Collector
in such a way that no tension or torsion forces are transmitted to the Current Collector head.

Part No.
PH (Phase) PE (Potential Earth)
Designation Weight [kg]
Fastening Fastening elements Fastening Fastening elements
elements galvanized in stainless steel elements galvanized in stainless steel
Current collector 250 A with vertical
081301-01* 081301-11* 081301-02* 081301-12* 2.800
insertion
Current collector 250 A with horizontal
081303-01 081303-11 081303-02 081303-12 3.000
insertion
Current collector 250 A with vertical
insertion for intersection1) with 081304-01 081304-11 081304-02 081304-12 3.225
Pickup Guides 081382
1)
 urrent Collectors for intersections are used if the path of the conductor rail installation is interrupted by branch tracks, crossing beams, etc.
C
These Current Collectors are equipped with a middle centering device and are used with Pickup Guides.
2)
It is recommended to carry out PE current collector always redundant.
* Standard range (SAP KONFIG 08130X-PXL)

Installation Examples see page 27

18
Current Collectors

Dual Current Collectors 500 A

125
40

ca.185
930

Technical data
Max. current capacity 500 A (2 x 250 A 30 °C / 100% duty cycle), [for aluminum rails in standstill mode at 100% duty cycle: 250 A]
Max. travel speed 600 m/min; higher travel speeds upon request
Pressing force 2 x 28 N
Lateral deviation ± 100 mm
Working stroke in insertion direction ± 40 mm
Connection cable 70 mm2, 1.5 m long, high-flexibility; longer connection cable available upon request
Distance between the extension arm axis
125 mm (important functional dimension)
and contact surface of the rail
Temperature range cable - 15 °C up to + 55 °C (Ambient)

Max. Current depending used cable type, ambient temperature and cable arrangement.

Installation note
The user must ensure that the Current Collector's center line is exactly aligned with the center line of the conductor rail during installation, and that the specified
installation spacing between the extension arm axis and the contact surface of the rail is being observed (see installation examples on page 27).
The connection cables must be highly flexible to ensure free movement of the Current Collectors and be secured with the cable binder on the Current Collector
in such a way that no tension or torsion forces are transmitted to the Current Collector head.
It is recommended to carry out PE current collector always redundant.

Part No.
PH (Phase) PE (Potential Earth)
Designation Weight [kg]
Fastening Fastening elements Fastening Fastening elements
elements galvanized in stainless steel elements galvanized in stainless steel
Current collector 250 A with vertical
081301-2X01* 081301-2X11* 081301-2X02* 081301-2X12* 5.700
insertion
Current collector 250 A with horizontal
081303-2X01 081303-2X11 081303-2 x 02 081303-2X12 6.100
insertion
Current collector 250 A with vertical
insertion for intersection1) with 081304-2X01 081304-2X11 081304-2X02 081304-2X12 6.550
Pickup Guides 081382
1)
 urrent Collectors for intersections are used if the path of the conductor rail installation is interrupted by branch tracks, crossing beams, etc.
C
These Current Collectors are equipped with a middle centering device and are used with Pickup Guides.
19
* Standard range (SAP KONFIG 08130X-2XPXL)
 Current Collectors – Installation Instructions

Installation of the PE conductor Current Collector for installations without Pickup Guides

Deflector Deflector
L1 L2 L3 PE L1
L1 L2
L2 L3
L3 PE
PE
L1 L2 L3 PE angle angle

Collector Insulation
No insertion possible

Diagram 1 Diagram 2

Non-interchangeability of PE (Potential Earth) conductor Current Collectors

To comply with safety standards, Current Collectors for PE rails must be designed in such a way that they are not easily interchangeable with other Current Collectors.
When determining the position of the PE conductor, you must take into consideration that the standard PE conductor Current Collector (with deflector angle) can only be
mounted on the outside, since the deflector angle is fastened onto the exposed side of the PE Conductor Collector Insulation. The deflector angle ensures that the PE
conductor Current Collector can never come in contact with a phase line (see Diagram 2).

Installation of the PE conductor Current Collector for installations with Pickup Guides

In installations with intersections, it is impossible to move the standard PE conductor Current Collector (with deflector angle)
through the Pickup Guide. Thus the PE conductor Current Collector is used for intersections whose holders are equipped
with a bolt for the Towing Arm. This fixes the position of the PE conductor Current Collector by being inserted into a hole
drilled into the Towing Arm using the Drilling Jig listed below.
This ensures that the PE conductor Current Collector can only be mounted in the place provided for it.

Drilling Jig 08-W100-0223

To comply with regulations and guidelines, installations with Pickup Guides must have a hole drilled into the Towing Arm 020197 using Drilling Jig 08-W100-0223,
which is then used to hold the bolt on the PE conductor Current Collector.

Installation note:
The phase Current Collectors needed are lined up on the preassembled Towing Arm 020197 and adjusted to the conductor rails. The next-to-outside phase Current Collector
is used as a stop for the Drilling Jig. The Drilling Jig must be attached so that the drill sleeves point outwards – see illustration below. In this position, the mounting spacing is
80 mm.

Designation Part No. Weight [kg]

Drill Sleeve
Drilling Jig 08-W100-0223 0.700

20
21
 Dimensioning and Layout of Conductor Rail System

The dimensioning and layout of a conductor rail system is done as follows:

A: Determine the load current
B: Select the rail type
C: Check the voltage drop for the selected rail type
D: Check of ambient conditions
E: Select accessories and Current Collectors

A. Determining the load current (total rated current /NG)

 To determine the total expected load current, individual currents of the highest draw consumers that can operate simultaneously are added up. If the entire installed
power is summed, the rail capacity will be over-specified. To avoid overdimensioning, the individual currents are evaluated for simultaneity. To optimizes the system,
it is always wise to consider individual consumers that cannot be operated simultaneously (e.g. a crane's slewing gear can only be operated when the crane trolley is
stopped), and then only the consumer (the slewing gear or the trolley) with the higher current consumption is used.
If multiple units are installed on a single track, for example three cranes on one crane track, the probability of simultaneous operation in the same load should be
used to calculate the current. In practice, the following simple table has proved useful in calculating the total rated current /NG for multiple consumers:

I N of the most powerful I N of the second most I N of the third most I N of the fourth most
motor of all the powerful motor of all the powerful motor of all the powerful motor of all the
Number of cranes
cranes cranes cranes cranes
I N* I N* I N* I N*
1 × ×
2 × × ×
3 × × ×
4 × × × ×
5 × × × ×
According to work with 2 cranes × × × ×

* = For dual drives, use 2 · I N

B. Rail current capacity depends on duty cycle and ambient temperature

 The specified rated currents for the conductor rail are based on the definitions in European standards and are relative to an ambient temperature of 35 °C and a duty
cycle (DC) of 100%. If the duty cycle is shorter, such as might be the case for a crane with finite movement, the rail can conduct higher current than the rated cur-
rent.

Adjusting the rail rated current for shorter duty cycles

[A] 3000
The load current of the conductor rail can be increased for shorter
2750 duty cycles.

2500 Note: When comparing the rated currents of rails from different
manufacturers, always take into consideration the reference
2250
ambient temperature and the duty cycle!
2000
Consumptions with 100% duty cycle such as lighting,
1750 air conditioning or magnetic grippers must be taken
into consideration.
1500

1250 A Copper rails 100% DC ^

= t ≥10 min. (according to EN standards)
1250

1000 1000 A Aluminum rails

800 A Copper rails
750 800 A Aluminum rails
500 A Copper rails
500
500 A Aluminum rails
250

0
0 10 20 30 40 50 60 70 80 90 100 % DC
22 (duty cycle)
Dimensioning and Layout

If the ambient temperatures differ from the standard value of 35 °C, the loads must be adjusted. At lower temperatures, the heat release (convection) is better and the rail
can handle higher current loads. At higher temperatures, the release of thermal energy to the surrounding air is slower and the load must therefore be reduced.

The corresponding values f A are taken from the following table:

Ambient temperature 35 °C 40 °C 45 °C 50 °C 55 °C 60 °C 65 °C 70 °C 75 °C 80 °C 85 °C
Aluminum rails* 1.0 0.92 0.81 0.76 0.68
Standard insulation fA
Copper rails 1.0 0.93 0.87 0.82 0.78

Heat-resistant Aluminum rails* 1.0 0.92 0.81 0.76 0.68 0.63 0.59
fA
insulation Copper rails 1.0 0.93 0.87 0.82 0.78 0.74 0.72

* The correction factors for CopperECO ||| correspond to those for aluminum-stainless steel
ISCHL G zul = ISCHL G zul 35 °C · f A ISCHL = rated current of the conductor rail for the specific ambient temperature

C. Calculating the voltage drop

After selecting the rail type based on the calculated total current depending on duty cycle and ambient temperature, the voltage drop must be checked. The calcu-
lated voltage drop must be under the value specified by the customer. Typical values here are 2-5%, or 10% in exceptional cases. If the voltage drop is too high, the
voltage might be too low to all the drives to start.

The following formulas are used for the calculation:

U 35 °C = voltage drop at 35 °C [V]

For direct current U 35 °C = 2 · I · IG · R [V]
IG = total current [A]
R = resistance of the conductor rail [Ω/m]
For alternating current U 35 °C = 2 · I · IG · Z [V]
Z = impedance of the conductor rail [Ω/m]
I = feed length [m] 1)
For three-phase power U 35 °C = √3 · I · IG · Z [V]
L = conductor rail length [m]

1)
see feed variants
Note: IG here is the portion of the load current “drawn” during start-up.
This consists of the basic load, like lighting and air conditioners, and the start-up currents of the drives IA.

For start-up current, the following applies: Three-phase asynchronous drive in direct start IA = IN x 5 to 6 (up to max. 21 kW permitted) IG = total current
Slip ring rotor motor IA = IN x 3 to 5 IA = Total current con-
sumption when starting
Frequency converter IA = IN x 1.4 to 1.8

The length l is the distance between the power feed and end position of the conductor rail segment on which the consumer is located when starting.
If the average ambient temperature is significantly over 35 °C, the voltage drop must be calculated using the following formulas:

U 35 °C U = voltage drop at higher ambient temperature than 35 °C [V]

U = ——— [V]
fV
U % = voltage drop at ambient temperature over 35 °C [%]

U UN = rated voltage [V]

U % = ——— · 100 [%]
UN f V = reduction factor

To calculate the value f V , the working temperature must first be calculated.

AT = working temperature [°C]

= + = + 30 [°C] UT = ambient temperature [°C]

AT UT SW UT

SW = temperature increase due to current heating [°C]

(use a constant +30 °C)

The value f V is based on the working temperature and the conductor rail selected and should be taken from the table “Correction factors for the voltage drop U
for different ambient temperatures” on page 24.
23
 Dimensioning and Layout

Correction factors for the voltage drop U at different ambient temperatures

Ambient temperature 35 °C 40 °C 45 °C 50 °C 55 °C 60 °C 65 °C 70 °C 75 °C 80 °C 85 °C
Working temperature / conductor temperature 65 °C 70 °C 75 °C 80 °C 85 °C 90 °C 95 °C 100 °C 105 °C 110 °C 115 °C
Aluminum rails 500 A* 0.965 0.960 0.954 0.948 0.943
Aluminum rails 800 A* 0.976 0.972 0.968 0.964 0.960
Aluminum rails 1000 A* 0.983 0.980 0.977 0.974 0.971
Standard insulation fV
Copper rails 500 A 0.959 0.952 0.945 0.938 0.932
Copper rails 800 A 0.983 0.980 0.977 0.974 0.971
Copper rails 1250 A 0.993 0.992 0.991 0.990 0.989
Aluminum rails 500 A* 0.943 0.937 0.932 0.926 0.920 0.915 0.909
Aluminum rails 800 A* 0.960 0.956 0.952 0.948 0.944 0.940 0.936
Aluminum rails 1000 A* 0.971 0.968 0.965 0.962 0.959 0.956 0.953
Heat-resistant insulation fV
Copper rails 500 A 0.932 0.925 0.919 0.912 0.905 0.899 0.893
Copper rails 800 A 0.971 0.968 0.965 0.961 0.958 0.955 0.952
Copper rails 1250 A 0.989 0.987 0.986 0.985 0.984 0.982 0.981

* The correction factors for CopperECO ||| correspond to those for aluminum-stainless steel.
If the voltage drop is too high, then either the number of power feeds must be increased or a larger conductor rail must be selected. Additional power feeds are usually
a better technical and commercial alternative than larger conductor rails or costly copper rails.
Working temperature: permanent rail temperature occurring at rated current (ambient temperature + electrical thermal heating)
Max. working temperature: short-term (t < 30 sec) 125 °C (in heat-resistant variant)
Possible power feed locations: The power feed arrangement must be appropriate for the specific case, since the voltage drop is calculated with the feed length "l"
that falls between the power feed and the end of the conductor rail. The following power feed options are normally used:

End power feed I=L With an end power feed

I = L/2 With a middle power feed
I = L/4 For power feeds at both ends
I=L I = L/6 For two power feeds each L/6
Middle power feed from the ends
I = L/10 For a power feed in the middle
I = L/2 and L/10 from each end
L I = L/14 For four power feed points

Power feed on both sides L = length of the conductor rail [m]

I = L/4
L/6 power feed

I = L/6 I = L/6
L

L/10 power feed

I = L/10 I = L/10
I = L/2

L/14 power feed

I = L/14 I = L/14
24 I = L 5/14 I = L 9/14

L
System Layout
250 – 400

M10
2500

081346-1X
ca.145
5000
2500

M10
2500

081341-1X
ca.135
2500
5000

M10
2500

081343-0X ca.115
M10

081341-0X
ca.75
930
1750
5000

465

Note: Used outdoors, the conductor rail system must be protected

from direct weather exposure as much as possible, for example
by installing it under a beam and providing covering the Current
Collector (to protect it from snow and ice). Outdoors, insertion of
1750

the Current Collector from below is generally preferable to lateral

insertion. Also, the use of insulated holders is recommended for
outdoor installations. If there is any risk of formation of frost or ice,
250 – 400

specify heating conductors in the rail to de-ice the rail and prevent
rail damage due to sparking effects on frozen rails (Aluminum rails).
125

Distance between insulation elements and steel structure min. 10 mm.

ca.180
ca.360
25
 System Layout

Layout Schematic and Component Overview

Example: 5 m rail
max. 200 m without Expansion Unit

max. 100 m max. 100 m

1750 1750 1250 1250 2500 1250 1250 1250 1250 1250 1750 1750

250 250
- -
400 400

End Center
5000 5000 5000
Rail length Rail length Rail length

Hanger Clamp Hanger Clamp with Fixed Points Rail Connector End Cap Power feed

Installation note
Regarding the first and the last conductor rail a support ­distance of 1750 and 250 mm from the beginning resp. the end of the rail is to be provided. Apart from that the
support spacing is 2.5 m. The earth collector should always be installed on the outside. The centre distance between two conductors can be taken from the table below.
L1 L2 L3 PE
Distance Current collector arrangement
Standard current Offset Current Collector
between centers for installations with
collector arrangement arrangement
of two conductor rails multi‑poled Pickup Guides*
Minimum distance a [mm] 80 70 80 a a a

* See mounting instructions for Pickup Guides.

Example material overview / example order

Here is a typical crane conductor rail system that is 57 m in total length, with 4 poles, 800 A, with all accessories, Current Collectors and Support Arms.
The required Bill of Materials is listed below. The order quantity should be increased by an assembly reserve for the parts marked with an (x).

Part Description Part No. Quantity Needed

Conductor Rail “Phase” 5 m long 081314-5X11* 33
Conductor Rail “Phase” 2 m long 081314*-2X11* 3
Conductor Rail “PE” 5 m long 081314-5X12* 11
Conductor Rail “PE” 2 m long 081314-2X12* 1
Hanger Clamp (x) 081343-01 96
Anchor Clamp 081331-1 8
Rail Connector (x) 081321-2 40
Power Feed 081351-2 4
Tubular Cable Lug 95 mm (x) 2
080052-95 8
End Cap (x) 081371 8
Current Collector “Phase” 081301-2X1 3
Current Collector “PE” 081301-2X2 1
Extension Arm 020197-630 1
Support Arm 020186-500 24
Girder Clip 020286 24
Mounting Comb 081046 1
Conductix-Wampfler Contact Grease (x) 080021 1
Sliding Contact (replacement part) (x) 081003-11 4

Note:
To avoid strand breakage due to external force on the Current Collector, the connection cable should be fine-stranded and highly flexible. The transition to the customer-
provided fixed cabling should be directly behind the Current Collector in a terminal box provided by the customer. Long connection cables to Current Collectors should be
avoided to reduce maintenance problems.
26
Layout Examples

Standard Current Collector Layout

Horizontal installation of conductor rails / Lateral installation of conductor rails /

insertion of Current Collectors from below insertion of Current Collectors from the side

Offset Current Collector Arrangement

Vertical and horizontal

insertion of Current Collectors

a a a
177.5
177,5
125

For installations without transfer points the current collectors for vertical and horizontal operation can be stag­gered.
This way the centre distance between two conductor rails is reduced by 10 mm.

Distance Current collector arrangement

Standard current Offset Current Collector
between centers for installations with
collector arrangement arrangement
of two conductor rails multi‑poled Pickup Guides*
Minimum distance a [mm] 80 70 80
* See mounting instructions for Pickup Guides.

Installation note
Please note that the centre line of the current collector is mounted to the centre line of the conductor rail. The distance between towing arm and conductor rail must be
set according to the dimension indicated in above table and sketches.

27
 Mounting Accessories

Support Arms 40 × 40 × 2,5 mm - perforated

L1 40

40
2.5
2,5
ø9 14

20 20
40 L2

Part No. L1 [mm] L2 [mm] Material Weight [kg]

020186-0250 250 200 0.625
020186-0315 315 260 0.785
020186-0400* 400 340 1.000
Galvanized steel
020186-0500* 500 340 1.250
020186-0630* 630 340 1.575
020186-0800 800 340 2.000
* Standard range

Permissible load for Support Arms 40 x 40 mm

F
I [m]
0.25 0.32 0.40 0.50 0.63 0.80 1.00 1.25
F [daN]* 164.5 128.5 103.0 82.5 65.5 51.3 41.0 32.9
f [cm] 0.06 0.10 0.16 0.25 0.40 0.63 1.07 1.68
f

I
* Calculated with σ = 140 N/mm2 voltage f = associated max. deflection

28
Mounting Accessories

Holder for Support Arms 40 × 40 × 2,5 for screw mounting with 2-holed connector plate

ø1
1

41,3
41.3 4

110
41

80
45 6 125

Part No. Description Suitable for Support Arm Weight [kg]

020282 Galvanized steel 020186 1.000

Holder for Support Arms 40 × 40 × 2,5

125
41,3
41.3 4 12 x 45˚

41
Part No. Description Suitable for Support Arm Weight [kg]
020286 Unplated steel with galvanized hardware 020186 0.730

29
 Mounting Accessories

Girder Clips, clamping thickness 4 - 20 mm

60

M8

Part No. Description Weight [kg]

020180-08* Galvanized steel 0.150

50
020480-08 Stainless steel (V4A) 0.150

s
* Standard range

h
Clamping thickness s [mm] 4 6 8 10 12 16 20
Installation height h [mm] 31 32 33 34 35 37 40

Girder Clips, clamping thickness 18 - 36 mm

70

M8

Part No. Description Weight [kg]

020180-08X36 Galvanized steel 0.220
020480-08X36 Stainless steel (V4A) 0.220 8
s

h
Clamping thickness s [mm] 18-20 20-24 24-28 28-32 32-36
Installation height h [mm] 42-44 44-48 48-52 52-56 56-60

Girder Clips, non-twistable, clamping thickness 6 - 25 mm

M8 8

Part No. Description Weight [kg]

50

020181-08 Galvanized steel 0.190

s

Clamping thickness s [mm] 6-25

Installation height h [mm] 32-40

30

30
Mounting Accessories

Towing Arms

L 6

10 0
40

0
8
Ø11

Part No. Description L [mm] Weight [kg]

020197-400 400 2.0
020197-630* Galvanized steel 630 2.5
020197-800 800 3.0
* Standard range

End Caps

a s
c h
b
d

Part No. For C-rails Description a [mm] b [mm] c [mm] d [mm] s [mm] h [mm] Weight [kg]
020662-30 023200 30 32 27 29 4 18 0.005
Plastic
020662-31 023201 30 30 28 28 5 16 0.004

31
 Mounting Accessories

Insulators
Insulators for indoor applications with high contamination and/or applications outdoors, up to 1000 V rated voltage
Only for suspended installation.

Creepage distance 62 mm
Cantilever strength > 350 daN
Ambient temperature -30 °C to +85 °C
d

l1
d

SW40

9
SW40

40

14
9

d d

Part No. Hardware d I1 [mm] Weight [kg]

080401-10X10 Inner threading on both ends M10 / M10 – 0.09
080402-1030X10 Threaded bolts, galvanized M10 / M10 30 0.98
080403-1030X10 Threaded bolts, stainless steel M10 / M10 30 0.98

Mounting Comb 081046

For setting the rail holder spacing while mounting the Support Arms
Part No. Designation Weight [kg]
081046* Mounting Comb 0.190
* Standard range
4 x 70 (= 280)
70
35

80
4 x 80 (= 320)
350

32
Tools and Assembly Accessories

Grounding- and Short-circuit Device

Protective device during service and maintenance work on the conductor rail

160

322
Part No. Designation Weight [kg]
08-V015-0441* Grounding Device 813 with one pole 2.2
* Standard range

Note: Several devices have to be used, depending on the number of poles (all live rails + ground rail). The modular design of the Devices allows for any number of them
to be connected. Four Devices have to be used for a 3-phase system (1 x PE + 3 x PH = 4).

Contact Grease for Connection Points (Aluminum rails/CopperECO ||| rails)

Part No. Designation Weight [kg]

080021* Contact Grease 0.250

* Standard range
** Packing unit: 5 tubes each 50 gram

Application: Use contact grease to avoid corrosion at contact points.

A thin film is applied with a spatula or brush. One tube will last for about
200 connection points. Observe the information on the safety data sheet.

Disassembly Tool (Set) for Hanger Clamp removal

Part No. Designation Weight [kg]

08-V015-0493 Disassembly Tool 0.396

Application: The Disassembly Tool set comprises two separate tools and eases parting the
hanger clamps from the conductor rails.

33
 Replacement Parts

Sliding Contacts

Sliding Contact
160

Plastic Insulator

63
The sliding contact is protected by a plastic insulator, so that accidental contact with live parts of the engaged Current Collector is not possible.

Part No. Designation Ampere [A] Wearing Height X Weight [kg]

081003-11* Sliding contact 250 15 0.30
* Standard range

Installation note: When replacing the sliding contact, it is not necessary to remove the collector insulation, it is designed as a plug-in contact (not a screw contact).
Plastic insulator is included.

Replacement Parts for Current Collectors

Sliding Contact – scope of delivery

Part No. Designation Weight [kg]

Sliding Contact
08-A150-0006-001 Collector Insulation PH 0.1
08-A150-0006-002 Collector Insulation PE 0.1

Plastic Insulator Connection Repair Set, including:

1× Contact Sheet (1847)
Contact Sheet 1× Tubular Cable Lug (27633)
1× Heat Shrinkable Tubing
 black, 55 mm (25662)
10 ×Heat Shrinkable Tubing yellow/
08-K154-0394 green, 50 mm (3041397) 0.6
Collector Insulation 1 × Hexagonal Screw
DIN933 M8 x 20 (998)
1 × Lock-nut
DIN985-M08-A4 (581)
1 × Washer
DIN125-A8, 4-A4 (686)

Connecting Cable
Connection
Repair Set

Connecting Cable (pre-assembled)

– on request

* Standard range (SAP KONFIG 08130X-KOPF-PXL)

Heat Shrinkable
Tubing (yellow/green)

34
 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
Motor driven and spring driven reels Conductix-Wampfler cable trolleys can Available as enclosed or multiple The no-contact system for transferring
by Conductix-Wampfler provide be used in virtually every industrial unipole systems, Conductix-Wampfler energy and data. For all tasks that
energy, data and media over a variety application. They are reliable, robust conductor rails reliably move people depend on high speeds and absolute
of distances, in all directions, fast and available in an enormous variety and material. resistance to wear. Flexible installation
and safe. of dimensions and designs. 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 Charging Solutions

Whenever things are really “moving Mobile control solutions for your This data transfer system is a Whether inductive or conductive, this
in circles”, the proven slip ring plant – wether straightforward or compact slotted waveguide and bundle of products offers always the
assemblies by Conductix-Wampfler intricate. Control and communication furthermore can be used as perfect solution for all industrial
ensure the flawless transfer of energy systems from LJU have been tried Grounding rail (PE) as well as charging tasks including the matching
and data. Here, everything revolves and tested in the automotive industry positioning rail at the same time. battery with integrated battery
around flexibility and reliability! for decades. management system.
 www.conductix.com
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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.

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sales office, please refer to:
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