Engineering Guidelines

Festoon Systems for I-Beams

Conductix-Wampfler – Proven Expertise
with Heavy Duty Cable and Hose Trolleys
Whenever materials need to be Heavy Duty trolleys carry flat and This engineering guide will assist
moved, Conductix-Wampfler can round cables for the transmission of you with the layout of non-motorized
provide customized solutions for electrical energy and data as well as festoon systems and provides the
flexible energy, data, air, and fluid hoses for the transmission of liquids, basic data for the calculation
transmission. air or gases. of the system.

Conductix-Wampfler is well known Conductix-Wampfler festoon systems

for its many years of experience and are used in various applications all
wide know-how in the development over the world, such as steel works,
and manufacturing of festoon ports, galvanizing lines, bulk material
systems. handling, and composting plants.

Info
This symbol indicates
further Information
about relevant facts.

Content

Components 4

System illustration 5

Layout

• Step 1 6
Selection and arrangement of cables

• Step 2 8
Selection of the cable trolley program

• Step 3 14
Calculation of the system

Sizes and units 16

3
 Typical Components
of an I-Beam Cable Trolley
n Main Roller n Anti-Lift Roller n Horizontal Guide Roller

Function: Allows movement of cable Function: Protection against lifting, Function: Precise guidance
trolley, carries the cable trolley increased protection of the cable trolley
and cable weight against tilting

Design: Cylindrical or flanged roller Design: Cylindrical roller Design: Cylindrical roller

Material: Steel or polyurethane bandage Material: Steel bandage Material: Steel or polyurethane bandage

Specific Specific Specific

feature: Precision ball bearing lubri- feature: Precision ball bearing lubri- feature: Precision ball bearing lubri-
cated for lifetime with addi- cated for lifetime with addi- cated for lifetime with addi-
tional sealing disk (2RS1) tional sealing disk (2RS1) tional sealing disk (2RS1)

n Side Shield

Function: Arrangement of the rollers

in a minimum space

Material: Steel, hot-dip galvanized

Specific
feature: Three-point fixation for
optimum distribution of forces

n Clamping Bar

Function: Secures the cables

on the cable support

Material: Rubber clamping pad

Steel, hot-dip galvanized body
Specific
feature: Segmented to clamp
different cable diameters

Figure:
0360 Series

n Large-volume Bumper n Center Plate n Cable Support

Function: Minimize the impact load of Function: Attachment of cable supports, Function: Support of cables according
the cable trolley buffers and chassis to minimum bending radii

Design: One-piece (max. stability

and bending strength)
Material: Rubber / polyurethane Material: Steel, hot-dip galvanized Material: Steel, hot-dip galvanized

Specific Specific Specific

feature: Optimized composition feature: For maximum stability feature: Riveted nut for easy assembly

4
System 2

Illustration 1

1. Tow trolley/Tow clamp

2. Cable trolley
4
3. Cable clamp
4. Cables
5. Damping device
6. Tow rope
7. End clamp

System with Tow trolley

b1 Cable trolley width

b2 Max. permissible clamping width
CE Beam clearance end clamp side
CM Beam clearance tow side
da Cable support diameter
e Free space within storage distance
h Cable loop depth
Cable trolley height from lower edge of beam
ha
to upper edge of cable support
Cable loop depth from lower edge of beam
hges
to loop bottom
k Drill hole distance for tow rope connection
lb Storage distance including free space (e)
lE End clamp length
lges Track beam length
LinstE Installation length end clamp side
LinstM Installation length tow side
lK Tow clamp length
lM Tow trolley length
Distance from middle of tow trolley
lMF
to middle of tow trolley twindow
ls Active travel (e.g. main trolley or crane travel)
lw Cable trolley length System with Tow clamp

5
Layout Step 1
Cable Selection and Arrangement
The first steps to lay out a festoon n Arrangement of flat cables
system are: on the cable support

• Prepare a list of required cables and The flat cable package must be The larger size power cables (e.g.
their cross sections. arranged so that all cables are 4 x 50) should be placed on top of
• Select the appropriate type of cable tightly clamped on the cable the cable package. This will assure
(flat or round cable) and the appro- support and cannot slip. good heat dissipation and proper
priate composition for the respective clamping of the smaller cables.
application (PVC or Neoprene cable) The cable package should not
from our cable offering. be too tall in relation to the width.
Otherwise the cable package
Prior to selecting the required cable will be unstable and individual,
trolleys it is important to follow the especially smaller cables, will not
recommendations listed on the right stay sufficiently clamped.
for the layout of the cable package:

Dynamic forces that occur as the

festoon system moves can be partly
absorbed by the larger cables.

Very good – 100% clamping Whenever possible wider cables

should be used instead of
multiple smaller cables, e.g.:
1 piece of 12 x 1.5 instead
of 3 pieces of 4 x 1.5

Good – 50% clamping

Bad

6
 Layout Step 1

n Arrangement of flat cables n Arrangement of round cables on n Arrangement of round cables

within the cable clamp the cable support within the cable clamp

Cable clamps maintain proper The diameters of the round cables Cable clamps maintain proper spacing
spacing of the cable package should not vary too much in order to of the cable package within the cable
within the cable loop. The larger allow proper clamping onto the cable loop. The outer cables are clamped;
diameter power cables (e.g. 4 x 50) support. all other cables are guided in the inner
are clamped in the upper window; all windows and can move freely.
other cables are guided in the lower
windows and can move freely. The Unshielded power cables with larger
arrangement of the cable package copper cross sections should be
must fit properly within the respective favored for the outer cables
clamping window. (e.g. 1 x 120 or 4 x 25).

Additional spacers can be installed in

Very good the cable clamp to avoid overlapping
of cables when there are large
differences in diameter.

Bad

Spacer
Clamping of shielded (screened)
cables should be avoided. If deviations in diameters of adjacent
cables are more than 15 mm use Applies for all cables:
additional clamping pieces for a Make sure to balance the
proper clamping. cable load on the cable support.

Very good

Additional clamping piece

Bad

7
 Layout Step 2
Cable Trolley Selection
1 n Determine the cable 2 n Select the main roller size
trolley load (FLW)
The approximate cable trolley Once the approximate cable trolley load (FLW) is determined, the required main roller
load (FLW) is determined with the size can be selected from the following table. The material for the roller is chosen
following formula: based on operating conditions:

Specification Material
FLW = 2 x h x GL
Standard Rollers made of hardened steel
- For low noise emission and low beam wear Hydrolysis resistant rollers with
FLW = cable trolley load in kg - In tropical or subtropical climate polyurethane wheels
h = cable loop depth in m
GL = cable package weight
in kg/m
Main rollers Travel speed v in m/min
with steel wheels up to 63 80 100 125 160 200 250 300

Ø in mm Permissible cable trolley load FLW in kg

40 40 36 32
50 75 68 60 51
63 125 110 95 85 75
80 220 190 162 142 125 110
100 355 305 265 230 200 185 160
125 590 550 500 450 410 380 350 310
160 1150 1090 1050 1015 990 970 950 925
Duty Cycle : ~16h / day
Ambient temperature : -30 °C ... +80 °C

Main rollers Travel speed v in m/min

with polyurethane up to 63 80 100 125 160 200 250 300
wheels
Ø in mm Permissible cable trolley load FLW in kg
40 30 28 25
50 60 53 47 42
63 110 98 90 80 70
80 195 170 155 135 115 100
100 325 280 250 215 185 165 140
112 430 395 360 330 305 275 250 210
125 540 515 460 410 380 350 320 290
160 840 795 750 705 660 615 570 505
Duty Cycle : ~16h / day
Ambient temperature : -30 °C ... +50 °C

8
 Layout Step 2

3 n Determine the cable trolley series

With the size of the main roller selected, the suitable cable trolley program and the possible chassis types can be determined
from the following table:

Main rollers vmax Possible chassis types

Type of cable Series
Ø in mm in m/min Track beam
Parallel flange Tapered flange
40 50 flat/round 0314 S S
40 75 flat 0315 - H
40 100 flat/round 0320 S, SG H, HG, S, SG
50 120 flat/round 0325 S, SG H, HG, S, SG
63 150 flat/round 0330 S, SG H, HG, S, SG
50/63/80/100 160 flat 0350 HF, HFG, S, SG H, HG, HF, HFG, S, SG
50/63/80/100/112/125 160 round 0360 HF, HFG, S, SG H, HG, HF, HFG, S, SG
100/112/125 180 round 0364 HFG HFG
112/125 300* round 0365 HMG, HMP HMG, HMP
125/160 210 flat 0370 HMG, HMP HMG, HMP
125/160 300* round 0375 HMG, HMP HMG, HMP
125/160 300 round 0380 HMG, HMP -
160 300 round 0385 HMG, HMP -
Chassis type overview see next page >>>
nn Motorized programs highlighted in gray
* in combination with motorized systems

n Minimum beam dimension

The following beam dimensions are necessary to accommodate the trolley wheel
diameter.
roller-Ø

Air gap A (between main roller and beam flange) = min. 10 mm

Minimum beam width bmin in mm = 2 x ( )

roller-Ø + r + s + 10
4

9
 4 n Select the chassis type

Chassis with cylindrical main rollers

Type Guidance of the chassis at the radius of the beam web
H Guidance of the chassis simple optimal
Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

• For simple applications I-beam tapered flange
with low lateral forces Beam width max. 100 mm
• Not suitable for tow trolleys Travel speed < 120 m/min
Main roller material steel, polyurethane

Chassis with cylindrical main rollers

Type and anti-lift rollers
HG Guidance of the chassis at the radius of the beam web
Guidance of the chassis simple optimal
Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

• For simple applications with low I-beam tapered flange
to medium lateral forces and Beam width max. 100 mm
tilting torques Travel speed < 120 m/min
• Suitable for tow trolleys Main roller material steel, polyurethane

Chassis with cylindrical main rollers

Type and horizontal guide rollers
HF Guidance of the chassis at the beam flange
Guidance of the chassis simple optimal
Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

• For applications with low to medium I-beam parallel/tapered flange
lateral forces Beam width max. 140 mm
• Not suitable for tow trolleys Travel speed < 150 m/min
Main roller material steel, polyurethane

10
 Layout Step 2

Chassis with cylindrical main rollers

Type with horizontal guide rollers and anti-lift rollers
HFG Guidance of the chassis at the beam flange
Guidance of the chassis simple optimal
Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

• For applications with medium to high I-beam parallel/tapered flange
lateral forces and tilting torques Beam width max. 140 mm
• Suitable for tow trolleys Travel speed < 180 m/min
Main roller material steel, polyurethane

Chassis with flanged main rollers

Type Guidance of the chassis at the beam flange
S Guidance of the chassis simple optimal
Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

• For applications with low to medium I-beam parallel/tapered flange
lateral forces Beam width max. 140 mm
• Not suitable for tow trolleys Travel speed < 80 m/min
Main roller material steel

Chassis with flanged main rollers

Type and anti-lift rollers
SG Guidance of the chassis at the beam flange
Guidance of the chassis simple optimal
Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

I-beam parallel/tapered flange
• For applications with low to medium
lateral forces and tilting torques Beam width max. 140 mm
• Suitable for tow trolleys Travel speed < 80 m/min
Main roller material steel

11
 4 n Select the chassis type

Chassis with cylindrical main rollers with horizontal guide

Type rollers at the beam center web and anti-lift rollers
HMG Guidance of the chassis at the beam center web

Guidance of the chassis simple optimal

Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

• For applications under very difficult I-beam parallel/tapered flange
conditions (e.g. STS container cranes) Beam width max. 200 mm
• Suitable for tow trolleys Travel speed < 300 m/min
Main roller material polyurethane

Chassis with cylindrical main rollers withhorizontal guide

Type rollers at the beam center web and anti-lift plate
HMP Guidance of the chassis at the beam center web
Guidance of the chassis simple optimal
Protection against tilting low high
Protection against lifting low high
Wear of beam/rollers high low

Standard application data

• For applications with motorized cable
I-beam parallel/tapered flange
trolleys and heavy cable packages
Beam width max. 200 mm
• Suitable for tow trolleys
Travel speed < 300 m/min
Main roller material polyurethane

12
 Layout Step 2

Ød
a

5 n Determine the cable support diameter

To determine the required cable support diameter da, calculations must be performed based on the cables being installed.

The smallest permissible cable support diameter da is determined on the basis of the largest cables:

Thickness of flat cable Thickness of flat cable Outer diameter of round cable
SFL ≤ 12.5 mm SFL ≥ 12.5 mm dRL = outer diameter

Min support-Ø
8 x SFL 10 x SFL 10 x dRL
da in mm

Example of calculation flat cable:

The thickness SFL of the largest flat cable is 13 mm

Accordingly the minimum support diameter is:

SFL

dRL

da = 10 x 13 mm = 130 mm

Example of calculation round cable:

The outer diameter dRL of the largest round cable is 20 mm

Accordingly the minimum support diameter is:

SFL

dRL

da = 10 x 20 mm = 200 mm

13
 Layout Step 3
Calculate the system
1 n Determine the number of 2 n Determination of the required 3 n Determination of the cable
loops storage distance from middle of system length from middle of end
First define the cable loop depth h, end clamp to middle of tow trolley clamp to middle of tow trolley and
then choose the additional cable length For further calculations round up the of the order length of the cable
factor f from the table below. number of loops.

f x (ls + e) lb = (n-1) x lW + lE +lM + e LSyst = f x (ls + lb)

n=
2 x h + 1.25 x da - f x lW
LBest = LSyst + LinstE + LinstM

n = Number of loops lb = Storage distance from LSyst = Required cable system

ls = Active travel in m middle of end clamp to length from middle of end
f = Additional cable length middle of tow trolley in m clamp to middle of tow
factor (see table below) n = Number of loops trolley/tow clamp in m
h = Cable loop depth in m lW = Length of cable trolley in m f = Additional cable
da = Cable support diameter in m lE = Length of end clamp in m length factor
lW = Cable trolley length in m lM = Length of tow trolley/ ls = Active travel in m
e = Free space in storage tow clamp in m lb = Storage distance in m
distance (recommendation e = Free space in storage LinstE = Installation length
≥ 0.5 m) distance (recommendation end clamp side in m
≥ 0.5 m) LinstM = Installation length
n determines the number of tow side in m
required cable trolleys: LBest = Cable order length, including
installation length - in m
Number of cable trolleys = n-1

n Determination of the additional cable length factor f

Additional length factor f Cable loop depth h in m
Travel speed nn For the cells highlighted in orange
< 0.8 0.8 - 1.2 1.3 - 2.0 2.1 - 3.2 3.3 - 5.0 5.1 - 8.0
vmax in m/min we recommend the use of damping
32 1.10 1.10 1.10 1.10 1.10 1.10
devices or motorized systems to
33 - 40 1.15 1.10 1.10 1.10 1.10 1.10
41 - 50 1.20 1.15 1.10 1.10 1.10 1.10 stabilize the cable loops.
51 - 63 1.25 1.20 1.15 1.10 1.10 1.10
64 - 80 1.25 1.20 1.15 1.10 1.10
81 - 100 1.25 1.20 1.15 1.10
101 - 125 1.25 1.20 1.15 nn Motorized programs highlighted
126 - 160 1.25 1.25 1.20 in gray.
161 - 200 1.25 1.25 1.25
201 - 250 1.25 1.25 1.25
251 - 300 1.25 1.25 1.25

14
 Layout Step 3

4 n Determine the actual cable loop 5 n Determine the tow rope lengths 6 n Select damping device

LSyst LSyst LZug

h= - (0.63 x da) LZug = 0.95 x - (k + 0.084) LGum =
2xn n 1.5

h = Cable loop depth For travel speeds higher than LGum = Shock cord length in m
LSyst = Required cable system 50 m/min, we recommend the use of LZug = Tow rope length in m
length measured from tow ropes.
middle of end clamp to
middle of tow trolley or Please take the dimension k for the tow
tow clamp in m rope fixation from the respective cable
da = Cable support diameter in m trolley program.
n = Number of loops The selection of the correct damping
device (quantity and diameter of
the shock cords) depends on the
application.
– Please contact us –

15
 Symbols and Units

b1 mm Cable trolley width

b2 mm Max. permissible clamping width
cE m, mm Beam clearance end clamp side
cM m, mm Beam clearance tow side
da mm Cable support diameter
dRL mm Outer diameter round cable
e m, mm Free space within the storage distance
f Additional cable factor length
FLW kg Cable trolley load
GL kg/m Cable package weight
h m, mm Cable loop depth
ha m, mm Cable trolley height from lower edge of beam to upper edge of cable support
hges m Cable loop depth from lower edge of beam to loop bottom
k m, mm Drill hole distance for tow rope connection
lb m Cable trolley storage including free space (e)
LBest m Cable order length
lE m, mm End clamp length
lges m Track beam length
LGum m Shock cord length
LinstE m Installation length end clamp side
LinstM m Installation length tow side
lK m, mm Tow clamp length
lM m, mm Tow trolley length
lMF m, mm Distance from middle of tow trolley to middle of tow trolley window
ls m Active travel (e.g. main trolley or crane travel)
LSyst m Cable system length
lW m, mm Cable trolley length
LZug m Tow rope length
n Number of loops
s mm Clamping height at the cable trolley
sFL mm Thickness of flat cable
v m/s, m/min Travel speed

16
 Conductix-Wampfler – the complete program

Your Applications – our Solutions

Festoon Systems from Conductix-Wampfler represent only one of the many solutions made possible by the broad spectrum of
Conductix-Wampfler components for the transport of energy, data and fluid media. 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 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.

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Motorized reels and spring reels by It‘s hard to imagine Conductix- Whether they‘re enclosed conductor Extremely robust, non-insulated
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