Insulated Conductor Rail

SinglePowerLine Program 0812

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Table of Contents

System Description 5

Technical Data 6

General Instructions 7

System Structure 8
Components and their use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Insulated Conductor Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Clamps and Connectors 10

Hanger Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Compact Hanger Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Anchor Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rail Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power Feed Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
End Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Expansion Units 14
Expansion Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pickup Guide for Intersections 16

Current Collectors 17
Current Collectors (Plastic Arm Type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Current Collectors (Parallel Arm Metal Type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation spacing for Current Collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dual Current Collectors (Parallel Arm Metal Type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation Instructions and Assembly Help for Current Collectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Dimensioning and Layout of Conductor Rail System 22

System Layout 25
Layout Schematic and Component Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Example Material Overview / Example Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Mounting Accessories 27
Support Arms 30 × 32 × 2 mm - perforated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Support Arms 40 × 40 × 2.5 mm - perforated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Permissible Load for Support Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Holders for Support Arm 30 × 30 × 2 for Screw Mounting with 2-holed Connector Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Holders for Support Arm 40 × 40 × 2.5 for Screw Mounting with 2-holed Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Girder Clips, Clamping Thickness 4 - 20 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Girder Clips, Clamping Thickness 18 - 36 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Girder Clips, non-twistable, Clamping Thickness 6 - 25 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Towing Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
End Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Notch-type Cable Lugs for Power Feed Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Connector Cables for Current Collector Head 081209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Spring Assembly (lateral insertion) for Current Collector Head 081209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Tools and Assembly Accessories 32

Mounting Comb 081045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Bending Device 081010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Contact Grease for Connection Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Replacement Parts 33
Complete Current Collector Head for Current Collector 081209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Stabilization Springs for Current Collector Head 081209. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Replacement Copper Graphite Shoes with insulation for Current Collector Head 081205... / 081206... / 081207... / 081208... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Replacement Parts for Current Collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3
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System Description

The SinglePowerLine 0812 conductor For conductor materials, copper and The plastic insulation of the conduc-
rail system is used as a standard stainless steel are available, as well as tor rails is colored safety yellow in
product to power bridge, portal and aluminum in seawater-resistant alloys accordance with general marking
process cranes, but can also be used with stainless steel contact surfaces. regulations, and the PE ("grounding")
in a wide variety of other applications conductor rail components are green
such as amusement rides and people With the partial expansion compensa- and yellow (continuous green color
movers. For over 35 years, it is a speci- tion system (compensation for thermal strips). Other colors are available upon
fied, reliable, and approved product in expansion in every rail part), systems up request, with minimum order quantities.
these applications. to 200 m in length can be implemented
without the use of additional expansion Safety conductor rail with a finger-
As an insulated single-pole safety elements.1) safe design. Testing of contact pro-
conductor rail, the contact-protected tection with IEC / UL / NEMA jointed
system meets requirements for conduc- The safe, refined connector system and test fingers (12 mm foreign bodies).
tor rails according to European (CE) and clip-on rail holders, in combination with
current international standards. optional mounting brackets, permit fast,
economical assembly.
With different insulation materials, the
0812 system can be used with applica- With the SinglePowerLine 0812 system
tions with conductor temperatures of and the 0813 product line extension
up to 115 °C. This is equivalent to a for higher power ranges, Conductix-
constant ambient temperature of 85 °C Wampfler offers a reliable, proven and
at 100% duty cycle under continuous robust solution for your application.
load. The conductor rail can temporarily Present around the world, our repre-
withstand up to 125 °C. sentatives and sales partners will be
at your side from planning to imple-
mentation and service.

System Advantages: • Can be formed into circular according to European standards

slip rings and curves either • Self-aligning hanger clamps
• Available in different conductor at the factory or on site
• Seawater-resistant
materials • Self-extinguishing insulation
• Special seamless and corrosion-
• Finger-safe design compliant with UL-94 standard
resistant process for connection of
• Used around the world • Yellow safety-color aluminum rails and stainless steel
• Modular, expandable system • Designed for 100% duty cycle contact surfaces

1)
Take arrangement and ambient temperature into consideration.

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 Technical Data

Conductor Rails Aluminum Copper Stainless Steel

Type 081213 081214 081215 081216 081217
Current load [A]
At 100% duty cycle and 35 °C
(rated value) 200 320 250 400 25
At 60% duty cycle and 20 °C 260 380 320 480 32
Rated voltage [V] 690 (UL 660 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
Installation orientation Horizontal with collector entry on bottom side; collector entry sideways optional, for indoor use only
Application area Cranes, people movers, and similar applications
Environment Indoors and outdoors (see protection class)
Rated suspension spacing [m] 1.5 (59.1 inches) typically 1.4 to 1.5
Rail length [mm] 4000 (157.5 inches) (rated dimensions at 20 °C / tolerance ± 3 mm)
System length [m] unlimited (depending on power feed design, temperature, and expansion connectors)
Exterior dimensions [mm] 18 x 26 (rail cross section)
Rated rail spacing [mm] 50 (1.97 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 -30 °C to +55 °C (85 °C in heat-resistant design / PPE + SB)
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)
Conductor materials Depending on type, electrolytic copper, seawater-resistant aluminum with stainless steel contact surfaces, or stainless steel
Rail insulation Stabilized hardened PVC (standard material) and PPE + SB (heat-resistant design for interior use)
Dielectric strength 22.4 kV/mm as defined by DIN 53481
Leakage current resistance 400 < CTI as defined by IEC 112 / VDE 0303
Meets requirements for insulating materials as defined by UL 94 V-0;
Flammability / fire safety
flame-retardant and self-extinguishing (IEC DIN EN 60895-11-10B), halogen-free PPE-SB
Local approvals UL / CSA / GOST-R
Coloration Rail insulation in safety warning color RAL 1018 Zinc yellow or RAL 1021 Rape yellow in heat-resistant design

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, Safety of machines - electrical equipment of machines - Part 1: General requirements (IEC 60204 - 1:2005, modified); German
VDE 0113-1:2007-06 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
DIN EN 60243-2, Electrical dielectric strength of insulating materials - testing procedures - part 2: Additional requirements for testing with direct
VDE 0303-22:2001-10 current (IEC 60243-2:2001); German edition EN 60243-2:2001
DIN EN 60093, Testing procedures for electrical insulation: Specific dielectric strength and specific surface resistance of solid, electrically
VDE 0303-30:1993-12 insulating materials (IEC 60093:1980); German edition HD 429 S1:1983
DIN EN 60167, Testing procedures for electrical insulation: Insulation resistance of solid, insulating materials (IEC 60167:1964);
VDE 0303-31:1993-12 German edition HD 568 S1:1990
DIN EN 60112, Process for determining the test figures and comparison figures for creepage path formation in solid,
VDE 0303-11:2003-11 insulating materials (IEC 60112:2003); German edition EN 60112:2003

6
General Instructions
Application Area ambient temperature and 100% duty cycle impossible to engage the ground Current
This product is intended to supply electric (according to IEC 10 min ON). If the duty Collector into a phase pole, or to mix phases.
power to mobile machines at the rated cycle or ambient temperature is lower, higher We recommend laying out the PE ("ground-
current range up to 400 A and voltages up to currents can be transmitted. Further informa- ing") contact redundantly with dual Current
690 V / 1000 V. Target applications are crane tion about the layout of conductor rails and Collectors.1)
installations, people movers, and other rail corrections to rated current specifications is
systems, as well as storage/retrieval systems listed starting on page 22. Mechanical Safety
and similar applications with one or more Please note that the layout of conductor
mobile units. The production of arcs / curve Electrical Safety rails and Current Collectors between fixed
elements can be done either at the factory or Insulated SinglePowerLine 0812 conductor and moving system parts must maintain a
on-site using appropriate bending tools. rails are designed according to applicable safety spacing of at least 0.5 m to reduce the
international standards and guidelines, meet possibility of collisions between the moving
The insulation materials used are resistant today's requirements for the safety of a con- machine and the rail system – or measures
to many ingredients used in the industrial ductor rail, and have contact protection com- must be taken to prevent this risk. In exposed
environment, depending on concentration and pliant with DIN EN 60529 (protection class IP installation situations, for example over traffic
exposure time. All metal parts are available in 23). They meet the general requirements for ways, please ask for recommendations.
copper, stainless steel, or seawater-resistant classification and evaluation defined in DIN
aluminum depending on construction type, EN 60204 part 32 - electrical requirements Use of Conductor Rails
and should be evaluated in accordance with for hoisting machines. Conductor rails are classified as components
the general suitability of these basic materials. or incomplete machines according to the Ma-
Conductor rails and rail components have a chine Directive MRL 2006/42/EC. The con-
Before using 0812 conductor rails in critical high level of safety. With contact protection, ductor rails of Program 0812 meet current
environmental conditions such as galvanizing direct contact between body parts and elec- standards and guidelines for the intended
plants, pickling plants, compost works and lo- trically conducting parts is prevented (finger use of the components. For installation into
cations with high concentrations of chemicals protection with DIN VDE and EN /NEMA test the final product, the specifications valid for
(e.g. solvents, aromatics, benzols, etc.), please fingers / 12 mm foreign bodies). The Current this product must be taken into consideration
contact the factory. Collectors are also designed finger-safe when and you must proceed in accordance with the
engaged in the rails, but in areas where Machine Directive or with the guidelines valid
Layout they leave the rails, such as intersections for the place of installation.
There are several decisive factors in the and switch points, they must be additionally
selection and layout of conductor rails. One protected using power switches, covers, Use outdoors
main characteristic is the current load that or distance. Installations with voltages over Outdoors, the conductor rail should be
actually occurs (total current to be expected 25 V DC and 60 V AC in publically accessible protected from environmental influences as
during operation – not to be confused with areas must be secured by covers, installation much as possible. Use in high humidity and
the installed power or the resulting maximum away from accessible areas, or other suitable low temperature areas runs the risk of con-
current) and the resistance values of the means. densation, the formation of frost and ice build-
system. Here we look at the longest segment up on the contact surfaces. For installations
between the power feed and the position Installations in which the insulation character- in this environment, the rails, in particular
of the moving vehicle during start-up. The istics may be reduced by conductive dust or aluminum rails, must be equipped with an
criterion in question is the resulting voltage moisture must be installed away from access optional rail heater. Our sales department
drop. Depending on the conductor material by people and be marked as high-voltage will be glad to assist you with the layout.
and cross section, different losses can result electrical equipment with warning signs. In
for the same length and current. A conductor areas with high operating voltage (> 690 V) Approvals
rail is properly dimensioned from the point of and installations in a highly contaminated en- This conductor rail product line meets the
view of voltage drop when the drop lies within vironment with conductive dust or moisture, product parameters required for interna-
the permitted tolerance range, generally insulators must be used. tional use for these products and has been
2-5% and at most 10% including the con- developed in accordance with the existing
nection feed cable. The single-pole system can be built with any standards and guidelines in the EU and the
number of poles and extended in a modular important industrial markets. In addition to
Conductor rails are classified by their rated manner. Components for the ground conduc- IEC/EN standard compliance, the product line
current. This corresponds to the maximum tor are marked in green or green/yellow and also has local UL/CSA and GOST-R approvals.
continuous current for the conductor rail and may not be used as phase components.
is based on the standard parameters of 35 °C Using installed parts and position coding, it is 1)
Partly specified as standards
7
 System Structure

Components and their use

8 6

4
8
3

1
7
2

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
longer than 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

• Safe conductor rail with contact protection (finger-safe design)
• Designed to national and international standards
• High availability
• Expandable
• Partial compensation for thermal expansion
• Simple installation
• Optional safety components / functions
• Rails in safety warning color RAL 1018/1021
• CE-compliant design
• Available with any number of poles

8
System Structure

Insulated Conductor Rails

The standard product line offers electrolytic copper and aluminum as conductor materials. Copper, with its good conductivity, is the ideal conductor, with restrictions in
applications in aggressive or corrosive environments. As a budget-priced alternative, aluminum rails with a stainless steel contact surface are also available. Using a special
procedure, stainless steel and seawater-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. As another option, for low current and control signals, there are
stainless steel rails available as well.

The conductor rails consist of the conductive rail body and the
18
protective insulation in a contact-safe design.

As insulation material, PVC is used in standard applications.

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

26
Rated length: 4000 mm

Colour: Safety warning RAL 1018 (PVC) / RAL 1021 (PPE+SB)

PH = Phase PE = Potential Earth ("grounding")

Stainless steel Aluminum (with stainless steel contact surface) Copper

Rated current
25 A 200 A 320 A 250 A 400 A
(100% duty cycle)
Rated current
32 A 260 A 380 A 320 A 480 A
(60% duty cycle)
Cu figure – – – 0.59 kg/m 0.92 kg/m

Part No. Standard insulation for ambient temperatures up to +55 °C

PH 081217- 4 × 11 081213- 4 × 11* 081214- 4 × 11* 081215- 4 × 11 081216- 4 × 11*
PE (green color stripes) 081217- 4 × 12 081213- 4 × 12* 081214- 4 × 12* 081215- 4 × 12 081216- 4 × 12*

Part No. Insulation for ambient temperatures up to +85 °C

PH 081217- 4 × 21 081213- 4 × 21 081214- 4 × 21 081215- 4 × 21 081216- 4 × 21
PE (green color stripes) 081217- 4 × 22 081213- 4 × 22 081214- 4 × 22 081215- 4 × 22 081216- 4 × 22
Short lengths of 1, 2 and 3 m are available upon request for an additional price for cutting costs
Part No. for semistandard: 0812xx__ length x __ (length = 1 for 1 m, 2 for 2 m, and 3 for 3 m) short lengths upon request – example 1m: 0812xx-1 x 11
* Standard range

Technical data
Conductor cross section (mm2) 70 100 120 70 110
DC resistance
1.160 0.358 0.267 0.278 0.168
[Ω/1000m] 20 °C
DC resistance
1.163 0.377 0.282 0.298 0.178
[Ω/1000m] 35 °C
Impedance [Ω/1000m]
1.160 0.361 0.297 0.307 0.209
20 °C/50Hz
Impedance [Ω/1000m]
1.163 0.347 0.306 0.321 0.217
30 °C/50Hz
Weight [kg] 2.5 1.7 1.8 2.7 4.1
Min. bending radius
horizontal
Upon request (depending on outdoor/indoor use, horizontal/vertical orientation and materials)
Min. bending radius
vertical

9
 Hanger Clamps

Hanger Clamps

M8

M8

max.25
max.12

98
45
73
36.7

60
51 25
25 40
40

Suspension is carried out using freely swivelling clip-on Hanger Clamps that Note:
are self-aligning and permit low-friction slipping in case of thermal expansion. - Rated suspension spacing 1.5 m, typically 1.4 to 1.5 m
Hanger Clamps are available with hex nuts or square nuts for the mounting of - Max. suspension spacing 1.5 m
Support Arms / C-rails (see installation accessories). - Minimum spacing from connectors or power feed 400 mm

Part No. Weight [kg]

Hanger Clamp galvanized with hex nut 081241-01* 0.050
Hanger Clamp galvanized with square nut 081243-01* 0.095
Hanger Clamp in stainless steel with hex nut 081241-02* 0.050
Hanger Clamp in stainless steel with square nut 081243-02* 0.095
* Standard range

Hanger Clamps with Insulators

M8
M8

max. 13
max.20
130

130
84

84
100

100

25
25 40
40
Ø 50 Ø 50

Part No. Weight [kg]

Hanger Clamp galvanized with hex nut 081241-11* 0.16
Hanger Clamp galvanized with square nut 081243-11* 0.20
Hanger Clamp in stainless steel with hex nut 081241-12* 0.16
Hanger Clamp in stainless steel with square nut 081243-12* 0.20
* Standard range

L SYSTEM
Calculation Hint for Hanger Clamps: Quantity n = + 1 + spare part
1.5 m (hanger distance)
10
Compact Hanger Clamps and Anchor Clamps

Compact Hanger Clamps

32

30

65
22

22
50 50 50 50 50
40
150 200
2-8
2-8

63
30

30

43
50 50 50 50 50 40
150 200

Compact Hanger Clamps for fast assembly of 3 or 4 rails indoors. Available for surface mounting or insertion into Conductix-Wampfler C-rails and mounting brackets in
galvanized or stainless steel with 30 mm rated dimensions.

Part No. Number of poles Phase spacing [mm] Variant Weight [kg]
081246-350 For C-rails 0.123
3
081246-351 For extension arms 0.087
50
081246-450 For C-rails 0.138
4
081246-451 For extension arms 0.102

Note: In contrast to self-aligning rotating single Hanger Clamps, Compact Hanger Clamps and their substructure must be aligned exactly 90° to the rail to ensure free
slipping of the rails during expansion. Not suitable for aggressive environments.

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 Expansion Units
are installed, please refer location in accordance with diagram 3 on page 15.
If multiple fixed points are planned, for example at intersections or curves (natu-
ral 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. Type Weight [kg]

081231-2* Anchor Clamp 0.050
For each fixed point, order two Anchor Clamps per pole
* Standard range

11
 Rail Connectors and Power Feed Connectors

Rail Connectors (Splice Joints)

150

51
27.5

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]

081221-2* Connectors for aluminum rails 0.130
Galvanized
081221-3* Connectors for copper rails 0.150
081221-4* Connectors for aluminum rails 0.140
081221-5* Connectors for copper rails Stainless Steel 0.150
081221-6 Connectors for stainless steel rails 0.180
080021* Contact grease, one 20 g tube (for approx. 200 connection points) 0.035
* Standard range The standard parts of the connectors are in stainless steel

Power Feed Connectors

255
Ø 35

64

The power feed uses a power connector; these replace the normal Rail Connectors. Note:
Electrical connection is provided using projecting bolts and notch-type cable Lugs - Tightening torque max. 9.75 Nm
(cable and cable lugs not included; please order separately). - Max. outer cable diameter 17.5 mm
- Use contact grease 080021

Part No. Designation Weight [kg]

081251-4* Power feed connector for aluminum rails 0.21
081251-5* Power feed connector for copper rails Stainless Steel 0.22
081251-6 Power feed connector for stainless steel rails 0.25
* Standard range The standard parts of the connectors are in stainless steel

Notch-type Cable Lugs see page 31

12
End Caps and Air Gaps

End Caps

90
22

41

30
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]

081271-2* End Cap Stainless Steel (DIN parts) 0.040
* Standard range To use End Caps in combination with accompanying heating / heating conductors: see assembly instructions

Air Gaps

500

8
188

Air Gaps are used for the galvanic isolation of sections, such as maintenance 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]

081294-2 Air Gap Stainless Steel 0.040

13
 Expansion Units

Expansion Units
106

285

0 - 25 570

825

4000 bei 20°C

at 20 °C

To compensate for changes in length due to temperature for systems > 100 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 25 mm of expansion. The expansion elements / expansion unit parts are, like the rails, designed as 4 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.

Part No.
Rails/ PH (Phase) PE (Potential Earth)
rated current Standard variant Heat-resistant variant Standard variant Heat-resistant variant Weight [kg]
For aluminum rails
081261-4 x 2121* 081261-4 x 2221 081261-4 x 2122* 081261-4 x 2222 2.9
200 and 320 A
For copper rails
081261-4 x 2131* 081261-4 x 2231 081261-4 x 2132* 081261-4 x 2232 4.8
250 and 400 A
For stainless steel rails
081261-4 x 2141 081261-4 x 2241 081261-4 x 2142 081261-4 x 2242 3.6
25 A
Design: Fastening and DIN parts in stainless steel – rated length 4000 mm (13.12 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 0812 conductor rail system
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 are to be considered as fixing points.

14
 Expansion Units

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

tmin lowest temperature that occurs in the application

+90 tmax
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 tinst as a horizontal line.
+50 3. Draw a vertical line down from the point of intersection of these two
+40 tinst lines, and read off the air gap to be used during installation.
+30
+20
+10 Example:
0 Temperature range: from -15 °C to +85 °C
-10 Ambient temperature during installation: +30 °C
tmin
-20 Air gap: 14 mm per expansion point = 2 x 14 mm for the expansion element
-30
0 5 10 14 15 20 25
Air gap [mm]

Number of Expansion Units for systems over 100 m in length / 200 m with middle power feed
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
1 2 3 4 5 Intermediate length a
Expansion Units
Material SS Al Cu SS Al Cu SS Al Cu SS Al Cu SS Al Cu SS Al Cu
Total length of the conductor rail [m]
10 400 400 400 600 600 600 800 800 800 1000 1000 1000 1200 1200 1200 200 200 200
20 400 304 347 600 408 494 800 512 641 1000 616 788 1200 720 935 200 104 147
30 340 270 298 480 340 396 620 410 494 760 480 592 900 550 690 140 70 98
40 304 252 274 408 304 348 512 356 422 616 408 496 720 460 570 104 53 74
50 283 242 258 366 284 316 449 326 374 532 368 432 615 410 490 83 42 58
ttot

60 270 235 249 340 270 298 410 305 347 480 340 396 550 375 445 70 35 49
70 260 226 242 320 256 284 380 284 326 440 312 366 500 340 410 60 28 42
80 252 226 236 304 252 272 356 278 308 408 304 344 460 330 380 52 26 36
90 246 223 232 292 246 264 338 269 295 384 292 328 430 315 360 46 23 32
100 242 220 229 284 242 258 326 263 287 368 284 316 410 305 345 42 22 29
SS = stainless steel, Al = aluminum, Cu = copper
L ≤ 200 m
ttot = tU+ tsw
Diagram 3

t U = Temperature range of the ambient temperature

1 EU
tsw = Temperature increase due to electric current (electrical thermal load)
Recommended values for tsw: 2 EU
10 °C up to 40% duty cycle
20 °C up to 65% duty cycle 3 EU

30 °C up to 100% duty cycle

4 EU
a
For longer systems than those in the table above, use: 5 EU

L - 200 100 m AC (Anchor Clamp) 100 m

= number of Expansion Units
a EU (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 EU PG (Pickup Guide)

15
 Pickup Guides for Intersections

Only for Current Collectors 081206... / 081208...

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 60 m/min and 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.

138
295
400

130

M8 0 - 15
80
125

c
20

46 46 46

Dimensions [mm] Number of poles

1 2 3 4 5 6
b 120 166 212 258 304 350
c 78 124 170 216 262 308

- 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. 081281-12 1-pole Pickup Guide 0.850
- In installations with Pickup Guides, a corresponding number of Current Collectors
081281-22 2-pole Pickup Guide 1.200
must be available, and mounted in intervals that ensure that just the necessary
081281-32 3-pole Pickup Guide 1.550
number of Current Collectors needed for momentary power requirements are in use.
081281-42 4-pole Pickup Guide 1.900
081281-52 5-pole Pickup Guide 2.100
The user must ensure that the Current Collectors between the Pickup Guides
are disconnected from power or are protected against accidental contact. 081281-62 6-pole Pickup Guide 2.300

Installation note
The middle distance between two conductors is 50 mm. This is reduced to 46 mm using the last Hanger Clamps 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. Keep distance of 750 mm between the Pickup Guide and the first Hanger Clamp.

Hanger Clamp spacing for installations with Pickup Guides

ca. 750 260 + x ca. 750

x
ca. 90

081241-01
Please note also the instructions
for mounting the PE Current Collector
200 + x for installations with Pickup Guides.
16
Current Collectors 081209...
Not suitable for Pickup Guides
Types of Construction
For the SinglePowerLine 0812 system there are two basic types of Current Collectors available. In addition to the smaller 081209-xxx variant in plastic, there is also a robust metal
parallel arm type available that has proved useful for crane installations. Both types are available as single and dual Current Collectors and are fastened to a Towing Arm with clamps.

Current Collectors (Plastic Arm Type)

Plastic collectors are used in warehouse systems, EOT cranes, and amusement park installations. For installations with one direction of movement, individual Current
Collectors are towed to reduce wear. By changing the force introduced into the stabilization springs on the Current Collector head, the head is pretensioned and works
against the slanted wear. In installations that move in both directions, such as crane runways or transfer cars, this compensation takes place automatically.
Here, the variant for reversible operation is used.

Single Current Collector set up for reversible operation Dual Current Collector set up for reversible operation
18
80 5 80 18
5
8

8
12

100
100

115
115

ca. 180
ca. 180

Anschlussleitung
Connection cable
und
and Gummitülle
rubber sleeve
muss separat
must be bestellt
ordered
werden.
separately.
25

304 560

Mounting ofZugfeder
Montage Tension Springs
Note: Leave sufficient room in the installation for free movement of the cables.
When using horizontal insertion, the weight forces of the Current Collectors
Schleppbetrieb Direction of travel
Fahrtrichtung
must be equipped with compensation springs (For Towing Arms see page 30,
Towing mode
(Fahrtrichtung)
(direction of travel) for Accessories and Cables see page 31).
Reversierbetrieb
Reversal mode

Technical data
Max. power capacity in straight and 80 A (for aluminum rails in standstill mode at 160 A (for aluminum rails in standstill mode at
curved segments (radius > 1800 mm) 100% duty cycle: 40 A) 100% duty cycle: 80 A)
Max. current capacity in curved segments 40 A (with special carbon brush 081001-15)
(bending radius from 1000 mm - 1800 mm) (for aluminum rails in standstill mode at 100% duty cycle: 20 A)
Max. travel speed 600 m/min; higher travel speeds upon request (straight segment without Pickup Guides)
Pressing force 10 N
Lateral deviation max. ± 50 mm
Working stroke in insertion direction max. ± 50 mm
6, 10, or at most 16 mm2, 1.5 m long, high-flexibility; longer connection cable upon request;
Connection cable
order separately (see page 31)
Distance between the Support arm axis and contact
115 mm (see system schematic on page 25)
surface of the rail (rated installation dimensions)

Single Current Collector Dual Current Collector

80 A 160 A
Operation: PH PE PH PE
Variant Weight [kg] Weight [kg]
vertical (Phase) (Potential Earth) (Phase) (Potential Earth)
Part No. Part No.
Fastening elements Reversible operation 081209-012* 081209-022* 0.300 081209-2 × 012* 081209-2 × 022* 0.520
galvanized Towing operation 081209-013* 081209-023* 0.300 081209-2 × 013* 081209-2 × 023* 0.520
Fastening elements Reversible operation 081209-112 081209-122 0.300 081209-2 × 112 081209-2 × 122 0.520
in stainless steel Towing operation 081209-113 081209-123 0.300 081209-2 × 113 081209-2 × 123 0.520
Connection cables not included – order separately from page 31
Note: 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. 17
* Standard range
 Current Collectors

Current Collectors (Parallel Arm Metal Type)

Parallel arm type Current Collectors come in a fully metallic design
and are available as single or dual Current Collectors. PE Current

115

ca. 190
Collectors are color-marked with a green Current Collector head and
provided with a deflector to prevent insertion into a phase rail.

25
Horizontal insertion = insertion into the rail from the side
355 Vertical insertion = insertion into the rail from underneath

Technical data
Max. current capacity in straight and curved 100 A
segments (bending radius > 1800 mm) (for aluminum rails in standstill mode at 100% duty cycle: 50 A)
Max. current capacity in curved segments 40 A with radius brushes (upon request)
(bending radius from 1000 mm - 1800 mm) (for aluminum rails in standstill mode at 100% duty cycle: 20 A)
Max. travel speed 600 m/min (without rail breaks and curves); higher travel speeds upon request
Pressing force 20 N
Lateral deviation max. ± 50 mm
Working stroke in insertion direction max. ± 50 mm
16 mm2, 1.5 m long, high-flexibility; longer connection cable available upon request; avoid connection cables > 3 m
Connection cable
and provide terminal boxes for service and replacement. (SAP CONFIG 3054705)
Distance between Support arm axis and contact
115 mm
surface of the rail (expected dimension)
Towing Arms, see page 30

Part No.
PH (Phase) PE (Potential Earth)
Type Weight [kg]
Fastening Fastening elements Fastening Fastening elements
elements galvanized in stainless steel elements galvanized in stainless steel
Current Collector 100 A with vertical insertion 081205-01* 081205-11* 081205-02* 081205-12* 1.150
Current Collector 100 A with vertical insertion for
081206-01* 081206-11* 081206-02* 081206-12* 1.260
intersection 1) with Pickup Guides
Current Collector 100 A with horizontal insertion 081207-01 081207-11 081207-02 081207-12 1.185
Current Collector 100 A with horizontal insertion for
081208-01 081208-11 081208-02 081208-12 1.265
intersection 1) with Pickup Guides
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.
* Standard range

Installation spacing for Current Collectors

L1 L2 L3 PE Center spacing a [mm]

Standard Current
Standard Current Collector arrangement 50
Collector arrangement
Offset Current Collector arrangement 40
Current Collector arrangement when using
50
Pickup Guides

Offset Current Collector

arrangement
a

PE deflector
angle

18 a a a
Current Collectors

Dual Current Collectors (Parallel Arm Metal Type)

25

115
ca. 190
710

Technical data
Max. current capacity in straight and curved 200 A
segments (bending radius > 1800 mm) (for aluminum rails in standstill mode at 100% duty cycle: 100 A)
Max. current capacity in curved segments 40 A with radius brushes (upon request)
(bending radius from 1000 mm - 1800 mm) (for aluminum rails in standstill mode at 100% duty cycle: 20 A)
Max. travel speed 600 m/min; higher travel speeds upon request (straight segment without Pickup Guides)
Pressing force 20 N
Lateral deviation max. ± 50 mm
Working stroke in insertion direction max. ± 50 mm
16 mm2, 1.5 m long, high-flexibility; longer connection cable available upon request; avoid connection cables > 3 m
Connection line
and provide terminal boxes for service and replacement. (SAP CONFIG 3054707)
Distance between Support arm axis and contact
115 mm
surface of the rail (expected dimension)
Towing Arms, see page 30

Part No.
PH (Phase) PE (Potential Earth)
Type Weight [kg]
Fastening elements Fastening elements Fastening elements Fastening elements
galvanized in stainless steel galvanized in stainless steel
Current Collector 200 A with vertical insertion 081205-2 × 01* 081205-2 × 11* 081205-2 × 02* 081205-2 × 12* 2.300
Current Collector 200 A with vertical insertion for
081206-2 × 01* 081206-2 × 11* 081206-2 × 02* 081206-2 × 12* 2.520
intersection 1)
Current Collector 200 A with horizontal insertion 081207-2 × 01 081207-2 × 11 081207-2 × 02 081207-2 × 12 2.370
Current Collector 200 A with horizontal insertion for
081208-2 × 01 081208-2 × 11 081208-2 × 02 081208-2 × 12 2.530
intersection 1)
1)
 urrent Collectors for intersections are used if the path of the conductor rail installation is interrupted by branch tracks, crossing beams, etc. These Current Collectors are
C
equipped with a middle centering device and are used with Pickup Guides.
* Standard range

Order code for Current Collectors with custom cable length 08120x - 2 x P x L
x = Current Collector type (5,6,7, or 8) L = cable length in whole meters – example for 3 m connection cable: 081206 - 2 x P x 3

Horizontal rail installation with vertical insertion Vertical rail installation with horizontal insertion
of Current Collectors: of Current Collectors:

19
 Current Collectors – Installation Instructions

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

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

Current Collector Shoe 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 Current Collector Shoe. 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-W100-0206

To comply with regulations and guidelines, installations with Pickup Guides must have a hole drilled into the Towing Arm 020195 using Drilling Jig 08-W100-0206, 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 020195 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 50 mm.

Type Part No. Weight [kg]

Drill Sleeve
Drilling Jig 08-W100-0206 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 optimize 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:

Selection help for standard EOT crane applications

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 current.

Adjusting the rail rated current for shorter duty cycles

[A] 700 The load current of the conductor rail can be increased for shorter duty
cycles. Note: When comparing the rated currents of rails from different
600 manufacturers, always take into consideration the reference ambient
temperature and the duty cycle! Consumptions with 100% duty cycle
such as lighting, air conditioning or magnetic grippers must be taken into
500 consideration. 100% DC ^ = t ≥10 min. (according to EN standards)

400 400 A Copper rails

320 A Aluminum rails

300
250 A Copper rails
200 200 A Aluminum rails

100

25 A Stainless Steel rails

0
0 10 20 30 40 50 60 70 80 90 100
22 % DC (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.
Use with voltages under 230 V must be tested in each specific case. The minimum current should be 1A. The corresponding values f A are taken from the following table:

Ambient temperature 35 ºC 40 ºC 45 ºC 50 ºC 55 ºC 60 ºC 65 ºC 70 ºC 75 ºC 80 ºC 85 ºC
Stainless steel rails 1.0 0.97 0.94 0.91 0.88
Standard
Aluminum rails fA 1.0 0.92 0.81 0.76 0.68
insulation
Copper rails 1.0 0.93 0.87 0.82 0.78
Stainless steel rails 1.0 1.0 0.97 0.94 0.91 0.88 0.85 0.83
Heat-resistant
Aluminum rails fA 1.0 0.92 0.81 0.76 0.68 0.63 0.59
insulation
Copper rails 1.0 0.93 0.87 0.82 0.78 0.74 0.72

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 calculated
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 for 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 = IG x 5 to 6 (up to max. 21 kW permitted) IG = total current
Slip ring rotor motor IA = IG x 2 to 3 IA = Total current consumption
when starting
Frequency converter IA = IG x 1.2 to 1.5

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 higher ambient temperature than 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]

UT = ambient temperature [°C]

AT = UT + SW = UT + 30 [°C]
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 200 A 0.916 0.904 0.891 0.879 0.868
Aluminum rails 320 A 0.921 0.909 0.897 0.886 0.875
Standard insulation Copper rails 250 A fV 0.912 0.899 0.887 0.874 0.862
Copper rails 400 A 0.927 0.916 0.905 0.894 0.883
Stainless steel rails 25 A 0.993 0.991 0.990 0.989 0.988
Aluminum rails 200 A 0.868 0.856 0.845 0.834 0.824 0.813 0.803
Aluminum rails 320 A 0.875 0.864 0.853 0.843 0.833 0.822 0.813
Heat-resistant insulation Copper rails 250 A fV 0.862 0.850 0.838 0.827 0.816 0.805 0.795
Copper rails 400 A 0.883 0.873 0.863 0.853 0.843 0.833 0.824
Stainless steel rails 25 A 0.988 0.986 0.986 0.985 0.984 0.982 0.981
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
I = L/4 For power feeds at both ends
Middle power feed
I = L/6 For two power feeds each L/6
from the ends
I = L/2 I = L/10 For a power feed in the middle
L
and L/10 from each end
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
L/14 power feed

I = L/14 I = L/14
I = L 5/14 I = L 9/14
24 L
System Layout
> 220
150

081246
115

M8
ca. 35

081246
280
4000
250

226

M8
ca. 43

081243
M8
ca. 750

ca. 113.5
1500

295

081241
M8
4000

710

ca. 90
260 + x

200 + x
x
355
1500

081243
M8

ca. 75
081241
ca. 750

M8
4000
250

ca. 90

ca. 51

115
150
> 220

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 covering the
Current Collector (to protect it from snow and ice). Outdoors, insertion of 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, specify heating conductors in the rail to de-ice the rail and prevent rail damage
due to sparking effects on frozen rails. 25
 System Layout

Layout Schematic and Component Overview

max. 100
max. mm
100 max.100
max. 100mm

350 350 14001400 1500 1500 1500

1500 1500 1500 1500
1500 1500
1500 1500
1500 1500
1500 1500 1500
1500 1500 1500 1500
1500 1500 1500
1500 1400
1400 350350

4000
4000 4000
4000 4000
4000 4000
4000 4000
4000 4000
4000

max.200
max.
max. 200mmmwithout
200 ohne Dehnverbinder
ohne Dehnverbinder
Expansion Unit

Power Feed
Einspeisung
Einspeisung
Lufttrennstelle
Air Gap Current Collector arrangement
Lufttrennstelle Middle distance between Standard Current Offset Current Collector
Schleifleitung
Conductor Rail for installations with
Schleifleitung two conductors Collector arrangement arrangement
Schienenhalter
Hanger Clamp multi‑poled Pickup Guides*
Schienenhalter
Schienenverbinder
Rail Connector
Schienenverbinder Minimum distance a [mm] 50 40 50
End Cap
Endkappe
Endkappe
Fixpunkt
Fixed Point
Fixpunkt
Dehnverbinder
Expansion Unit * See mounting instructions for Pickup Guides. Minimum distance between Hanger Clamps, Joints, Pickup Guides, Air Gaps, etc. is
Dehnverbinder
TrichterGuide
Pickup  250 mm! Minimum distance for Power Feeds is 350 mm.
Trichter

Example Material Overview / Example Order

Here is a typical crane conductor rail system that is 52 m in total length, with 4 poles, 320 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" 4 m long 0812-4 × 11 39
Conductor Rail "PE" 4 m long 0812-4 × 12 13
Hanger Clamp (x) 081243-01 152
Anchor Clamp 081231-1 8
Rail Connector (x) 081221-2 52
Power Feed 081251-2 4
Notch-type Cable Lug 16 mm2 (x) 080051-16 4
End Cap (x) 081271-1 8
Current Collector "Phase" 081205-01 3
Current Collector "PE" 081205-02 1 (Recommendation: 2 units or dual Current Collector)
Support Arm 020195-400 1
Support Arm 020185-0500 38
Girder Clip 020180-08 76
Mounting Comb 081045 1
Conductix-Wampfler Contact Grease (x) 080021 1
Copper Graphite Shoe (replacement part) (x) 081001-11 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
Mounting Accessories

Support Arms 30 x 32 x 2 mm – also suitable for Compact Hanger Clamps

L1 32

30
L2 12
26

Part No. L1 [mm] L2 [mm] Material Weight [kg] Static values:

I x = 2.11 cm4
020185-0250 250 200 0.390 40 20 ø9 Wx = 1.36 cm3
020185-0315 315 260 0.500
Galvanized
020185-0400 400 340 0.625
steel
020185-0500 500 340 0.780
020185-0630* 630 340 0.980
* Standard range

Permissible load for Support Arms 30 x 32 x 2 mm F I [m]

0.25 0.32 0.40 0.50 0.63 0.80 1.00 1.25
F [daN]* 76.0 59.5 47.5 38.0 30.0 24.0 19.0 15.2
f [cm] 0.08 0.13 0.20 0.32 0.50 0.80 1.25 2.23
f

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

Support Arms 40 × 40 × 2.5 mm – not suitable for Compact Hanger Clamps

L1 40

40
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 Galvanized 1.000
020186-0500 500 340 steel 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
27
 Mounting Accessories

Holder for Support Arms 30 × 30 × 2 for screw mounting with 2-holed connector plate
8.5

10.8
3 33.3

106
31
80
40 6 100

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

020280 Galvanized steel 020185, 020275 0.700

Holder for Support Arms 30 × 30 × 2

100 32.5 3
9 x 45º

30.5
50
Part No. Description Suitable for Support Arm Weight [kg]
020285 Unplated steel with galvanized hardware 020185, 020275 0.420

Holder for Support Arms 40 × 40 × 2.5 for screw mounting with 2-holed connector plate
ø1
1

41.3 4
110
41

80

45 6 125

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

020282 Galvanized steel 020186, 020276 1.000

Holder for Support Arms 40 × 40 × 2.5

125
41.3 4 12 x 45˚
41

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

020286 Unplated steel with galvanized hardware 020186, 020276 0.730

28
Mounting Accessories

Girder Clips, clamping thickness 4 - 20 mm

60
M8

50
Part No. Description Weight [kg]

s
020180-08* Galvanized steel 0.150

h
020480-08 Stainless steel (V4A) 0.150
* Standard range

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]

s
8
020180-08 × 36 Galvanized steel 0.220

h
020480-08 × 36 Stainless steel (V4A) 0.220

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
50
s

Part No. Description Weight [kg]

h

020181-08 Galvanized steel 0.190

Clamping thickness s [mm] 6-25 30

Installation height h [mm] 32-40

29
 Mounting Accessories

Towing Arms
63 I

40

63
40

25
ø9 4

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

020195-630 Galvanized steel 630 1.000
020495-630 Stainless steel (V4A) 630 1.000
* Standard range Length adaptation on site

End Caps

a s
c h

b
d

Part No. For Support Arm Description a [mm] b [mm] c [mm] d [mm] s [mm] h [mm] Weight [kg]
020662-30 020185 30 32 27 29 18 5 0.005
Plastic
020662-40 020186 40 40 35 35 21 5 0.004

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

d
Creepage distance 62 mm
Leakage current resistance KC 575 V (CTI) Ø 50
Cantilever strength > 350 daN d
l1

Ambient temperature -30 °C to +85 °C

15
36
15

15

d d

Ø 25 Ø 50

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

080401-08 × 08 Inner threading on both ends M8 / M8 – 0.09
080403-830 × 08 Threaded bolts, galvanized M8 / M8 30 0.98
080403-830 × 08 Threaded bolts, stainless steel M8 / M8 30 0.98

30
Mounting Accessories

Notch-type Cable Lug for Power Feed Line

øb

øc
a

Part No. Cross section [mm2] a [mm] b [mm] c [mm] d [mm] Weight [kg/1000]
080051-06* 6 23.5 3.5 6.6 1.5 6.000
080051-10* 10 26.8 4.5 7.0 1.5 7.000
080051-16* 16 32.0 5.5 8.5 2.2 11.000
080051-25* 25 32.5 7.0 10.0 2.6 14.000
080051-35* 35 34.0 8.5 12.0 3.5 20.000
080051-50* 50 40.0 10.0 14.0 3.9 32.000
080051-70* 70 47.0 12.0 16.6 4.6 51.000
080051-95* 95 51.0 13.5 18.0 4.6 60.000
Material: Copper, tin-plated Order lot size 10 pcs. per size * Standard range

Connector Cable for Current Collector Head 081209

Part No. Cable diameter

Cross section [mm2] Length* [m] Rated current [A] Weight [kg]
PH (Phase) PE (Potential Earth) [mm]
6 081209-1.5 × 06 × 81 081209-1.5 × 06 × 92 1.5 6 54 0.086
10 081209-1.5 × 10 × 91 081209-1.5 ×10 × 92 1.5 7 73 0.147
16 081209-1.5 × 16 × 81 081209-1.5 × 16 × 82 1.5 10 98 0.234
* Custom lengths and bulk cables by request

Note: The connection cables are stressed by movement during operation and must be inspected along with the carbon collector shoes at regular intervals, then replaced
after every five replacements of the carbon collector shoes. We recommend connecting the cables to a junction box, then installing fixed cabling from the junction box on.

Spring Assembly (lateral insertion) for Current Collector Head 081209

Left-hand version Right-hand version

FG FG

FF FF
93 93
Spring assembly 081209 Part No. Weight [kg]
69.5

69.5

Right-hand version 08-F030-0100 0.100

Left-hand version 08-F030-0101 0.100 105 105

31
 Tools and Assembly Accessories

Mounting Comb 081045

For setting the rail holder spacing while mounting the Support Arms
Part No. Description Weight [kg]
081045* Mounting Comb 0.190
* Standard range
10 x 30 (= 300)
30

35
50
6 x 50 (= 300)

350

Bending Device 081010

Part No. Description Weight [kg]

081010* Bending Device 20.000
081011* Spring band package 5.000
* Standard range

Horizontal and vertical curves for all conductor rails in the Program 812
can be bent using the Bending Device 081010 (see also Technical Information
Sheet TI0812-0019-E). For bending curves, the spring band package is also
included and must be inserted into the profile form.

Buy
or
When the Bending Device is ordered, a complete set of spring bands (inserts)
and a bending manual are included.
Rent

Contact Grease for Connection Points

Part No. Type Weight [kg]

080021* Contact Grease 0.030
* Standard range

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

film is applied with finger or brush to the faces of the conductor rail and the
clamping area of the connectors.
One tube will last for about 200 connection points.

32
Replacement Parts

Complete Current Collector Head for Current Collector 081209

max. wear height

80 5

66
Part No.
Description Weight [kg]
PH (Phase) PE (Potential Earth)
Copper Graphite Shoe 812, 80 A, reversible operation 081001-12* 081001-22* 0.090
Copper Graphite Shoe 812, 80 A, towing operation 081001-32* 081001-42* 0.090
Note: The carbon brush and plastic insulation should always be replaced together. * Standard range

Stabilization Springs for Current Collector Head 081209

Type For Current Collectors Operating type Part No.

012
022
081209- Reversible operation RZ-081 GI
112
122
Stabilization spring
013
023
081209- Towing operation RZ-0561
113
123

Replacement Copper Graphite Shoes with Insulators for Current Collector Head 081205... / 081206... / 081207... / 081208...

Copper Graphite Shoe 5

a

Plastic Insulator
8
36

28

The copper graphite shoe is protected by a plastic insulator, so that accidental contact with live parts of the engaged Current Collector is not possible.
Smallest bending radius for 100 A copper graphite shoe R = 1800 mm – smallest bending radius for 40 A copper graphite shoe R = 1000 mm

Part No. Type Amperes [A] a [mm] Weight [kg]

081001-11* Copper graphite shoe 100 90 0.098
08-K154-0090 Copper graphite shoe for outdoor applications 100 90 0.098
081001-15 Copper graphite shoe 40 63 0.058
Installation note: When replacing the Copper graphite shoe, it is not necessary to remove the collector head because the shoe is designed as a plug-in contact (not a screw
contact). Insulator is included.
* Standard range 33
 Replacement Parts

Replacement Parts for Current Collectors

Part No. Type Weight [kg]

Copper Graphite Shoe
08-A150-0001-2* Collector Head PE 0.1
08-A150-0001-1* Collector Head PH 0.1

Connection Repair Set, including:

Plastic Insulator
1 × Contact Sheet (1846)
1 × Tubular Cable Lug (24120)
1 × Heat Shrinkable Tubing
Contact Sheet
 black, 55 mm (24121)
10 × Heat Shrinkable Tubing yellow/
08-K154-0397* green, 50 mm (24139) 0.6
1 × Hexagonal Screw
DIN933 M8 x 20 (1120)
Collector Head 1 × Lock-nut
DIN985-M08-A4 (580)
1 × Washer
DIN125-A8, 4-A4 (685)

Connecting Cable

Connecting Cable (pre-assembled)

– on request
Connection
Repair Set

* Standard range

Heat Shrinkable
Tubing (yellow/green)

34
 Conductix-Wampfler – the complete program

Other Products from Conductix-Wampfler

The products described in the this catalog represent a few of the products from the broad spectrum of Conductix-Wampfler components
and systems for the transfer of energy, data, gases, and fluids. The solutions we deliver for your applications are based on your specific
requirements. In many cases, a combination of several different Conductix-Wampfler products are needed to fill the application. You can
count on all of Conductix-Wampfler’s business units for hands-on engineering support - coupled with the perfect solution to meet your
energy management and control needs.

Motor driven cable reels Slip ring assemblies Conductor bar Spring driven cable reels
Motor driven reels by Conductix- Whenever powered machinery needs Whether they are enclosed conductor We have 60 years experience and
Wampfler are the perfect solution to rotate 3600, field proven slip ring rails, expandable single-pole bar trusted brands such as Insul-8,
for managing long lengths of heavy assemblies by Conductix-Wampfler systems, or high amperage bar Wampfler, and IER. We offer small
cable and hoses in very demanding can flawlessly transfer energy and for demanding steel mill use up to cord reels all the way to large
industrial applications. Monospiral, data. Here, everything revolves 6000 amps. Conductix-Wampfler‘s multi-motor units, a wide range of
level wind, and random wind spools. around flexibility and reliability. conductor bar is the proven solution accessories, and hazardous location
to reliably move people and material. reels.

Cable Festoon systems Push Button Pendants Radio remote controls Inductive Power Transfer IPT®
It‘s hard to imagine Conductix- Our ergonomic pendants are Safe, secure, and reliable radios The contact-less system for
Wampfler cable trolleys not being ideally suited for industrial control use the latest in microprocessor transferring energy and data. For all
used in virtually every industrial applications. They are available in technology. Available in several tasks that depend on high speeds
application. They are reliable and a wide range of configurations for models for overhead crane control and absolute resistance to wear.
robust and available in an enormous overhead cranes and other machinery. and other types of machinery.
variety of sizes and models.

Energy guiding chains Air hoists and balancers Bumpers Spring balancers and retractors
The “Jack of all Trades“ when it comes ENDO Air hoists accurately place Conductix-Wampfler offers a ENDO spring balancers by Conductix-
to managing energy and data cables delicate loads and continuously vary complete range of bumpers for the Wampfler are rugged, reliable
and air and fluid hoses. A wide range of the speed for precise positioning. auto industry, cranes, and heavy high-precision positioning devices that
energy guiding chains are available for They run cool in continuous machinery. These include rubber, reduce operator fatigue and assist
many industrial applications. operations. rubber/metal, and cellular types. with accurate tool placement.
 www.conductix.us

USA / LATIN AMERICA CANADA MÉXICO BRAZIL

© Conductix-Wampfler | 2017 | Subject to Technical Modifications Without Prior Notice

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Customer Support Customer Support Customer Support Customer Support
Phone +1-800-521-4888 Phone +1-800-667-2487 Phone (+52 81) 1090 9519 Phone (+55 11) 4813 7330
(+52 81) 1090 9025
(+52 81) 1090 9013
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[email protected]

Contact us for our Global Sales Offices

KAT0812-0002-US