Festoon Systems for Square Rails

Program 0270 | 0280

DISTRIBUTED BY:

ENERGY SOLUTIONS FOR CRANES, HOISTS AND MONORAILS

Toll Free: 1.888.822.2024 Fax: 1.519.822.2140

Email: info@ipandc.com Web: www.ipandc.com
Contents

System Arrangement 5
Square Rails for Curved Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cable Trolley System for Flat Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cable Trolley System for Round Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Square Rails and Accessories for Curved Track Program 0270 6

Square Rails 30 x 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
90° Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Support Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
End Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drilling Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
End Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cable Trolleys for Flat Cable Program 0270 8

Plastic Cable Trolley and Cable Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steel Cable Trolley and Cable Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Cable Trolleys for Round Cable and Hose Program 0270 10

Plastic Cable Trolleys with Ball Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Plastic Cable Trolleys with Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Ideal Control Unit Trolley Program 0270 12

Ideal Control Unit Trolley with Plug and Socket Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ideal Control Unit Trolley with Plastic Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Square Rails and Accessories for Curved Track Program 0280 13

Square Rails 40 x 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
90° Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Track Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Support Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
End Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drilling Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
End Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cable Trolleys for Flat Cable/Round Cable Program 0280 15

Steel Cable Trolleys for Flat Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steel Cable Trolleys for Round Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Accessories for Cable Trolley Program 0270/0280 16

Support Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Towing Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tow Ropes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Girder Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Example of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Project Planning 20
Determining the Support Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Load Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calculating the number of Cable Loops, required Cable Length and Loop Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3
System Arrangement

Square Rails for Curved Track

Support Arm

Girder Clip Support Bracket

Square Rail

Track Coupler
Towing Arm (for Towing Trolley)

Curved Track

Cable Trolley System for Flat Cables

Towing Trolley

Cable Trolley

Towing Arm Ideal

Control Unit
End Clamp End Stop Trolley

Cable Trolley System for Round Cables

Towing Trolley

Cable Trolley

Ideal
Towing Arm Control Unit
End Clamp
Trolley
Cable Clip
Round Cable

5
 Square Rails and Accessories for Curved Tracks
Program 0270
Square Rails 30 x 30
L
2
30 Static Weight
Part No. Material L [mm]
Values [kg/m]
027200-6 Galvanized 6000
027200-4* Steel 4000
30
lx = 2.95 cm4
1.77
027400-6 Stainless 6000 Wx = 1.39 cm3
027400-4 Steel (V4A) 4000
* Standard range

90° Curves

R Stretched Cable Loop Weight

Part No. Material
[mm] Length [mm] max. 0.7 x R [kg]
027203-00400 400 630 280 1.10
°
90

027203-00600 600 945 420 1.70

027203-00800 800 1260 560 2.25
R
027203-01000 1000 1570 700 2.80
Galvanized
027203-01200 1200 1885 840 3.35
Steel
027203-01400 1400 2200 980 3.90
027203-01600 1600 2510 1120 4.45
027203-01800 1800 2890 1260 5.00
027203-02000 2000 3140 1400 5.55
027403-01000 1000 1570 700 2.80
027403-01200 1200 1885 840 3.35
027403-01400 Stainless 1400 2200 980 3.90
027403-01600 Steel (V4A) 1600 2510 1120 4.45
027403-01800 1800 2890 1260 5.00
027403-02000 2000 3140 1400 5.55
* Standard range

Track Couplers
30 M6
Part No. Material Weight [kg]
Galvanized
027210* 0.10
Steel
40
70

Stainless Steel
027410 0.10
(V4A)
* Standard range

6
Square Rails and Accessories for Curved Tracks
Program 0270
Track Support Brackets
For ceiling mounting
For mounting on Support Arms 30 x 32 x 2 and 40 x 40 x 2.5 mm
80 63 80 63
50 50 50 50
Ø7 M6

52

52
85

85
Part No. Material Max. Load [kg] Weight [kg] Part No. Material Max. Load [kg] Weight [kg]
027220* Galv. Steel 125 0.14 027222* Galv. Steel 125 0.14
027420 SST (V4A) 125 0.14 027422 SST (V4A) 125 0.14
* Standard range * Standard range

End Stops for Plastic Cable Trolleys

32 22 Part No. Material Weight [kg]
027112* Galvanized Steel; Rubber Buffer 0.21
027408 Stainless Steel (V4A); Rubber Buffer 0.21
* Standard range

69

End Stop for Steel Cable Trolleys

32 22
Part No. Material Weight [kg]
027111* Galvanized Steel; Rubber Buffer 0.21
* Standard range

69

Drilling Fixture
For drilling holes into rails and curves
Part No. Material Weight [kg]
Body: Aluminum
86

027211 Drill Sleeve: Hardened Steel 1.00

Fasteners: Galvanized Steel

80

End Cap
For closing Rail Ends 40 21
Part No. Material Weight [kg]
35 5
020662-31* Plastic 0.004
* Standard range
40
35

7
 Cable Trolleys for Flat Cables
Program 0270
Plastic Cable Trolley and Cable Support

110 100 110

Ø25

27
110 50

153
200

44
s

92
36

s
54
d
Rollers: 80

s
Ball Bearings, galvanized; Cable Trolley Towing Trolley End Clamp
Cover Plate ZZ.
Max. Load Capacity: 16 kg

32 22
Cable Trolley Towing Trolley End Clamp d s
Part No. [kg] Part No. [kg] Part No. [kg] [mm] [mm]
027261* 0.60 027267* 1.01 027268* 0.21 50 25
027271* 0.62 027277* 1.03 027278* 0.23 80 15
End Stop 0274611) 0.60 0274671) 1.01 0274681) 0.21 50 25
Part No. 027112 69
027471 1)
0.62 027477 1)
1.03 027478 1)
0.23 80 15
* Standard range 1)
Stainless Steel (V4A) / Acid-resistant plastic

Galvanized Steel Cable Trolley and Cable Support; Light Series

Cable Trolley Towing Trolley End Clamp d s

Part No. [kg] Part No. [kg] Part No. [kg] [mm] [mm]
027339-125x100* 2.10 027349-125x100* 2.63 027329-100x042* 0.54 50 30
027340-125x100* 2.15 027350-125x100* 2.68 027330-100x068* 0.61 80 15
* Standard range

125 Ø32 125 106 32 22

80
35

Ø 25
154

188
242

69
s

72
s

80

40
d 100
s

End Stop
Cable Trolley Towing Trolley End Clamp
Part No. 027111

8
Cable Trolleys for Flat Cables
Program 0270
Galvanized Steel Cable Trolley and Cable Support; Heavy Duty Series

Cable Trolley Towing Trolley End Clamp da lw b1 b2 s k

Part No. [kg] Part No. [kg] Part No. [kg] [mm] [mm] [mm] [mm] [mm] [mm]
027310-160x100* 2.87 027320-200x100* 3.52 027330-100x068* 0.68 100 72
160 38 101
027310-160x160* 3.11 027320-200x160* 4.03 027330-160x068* 0.92 160 132
80
027310-200x100 2.99 027320-200x100* 3.52 027330-100x068* 0.68 100 72
200 58
027310-200x160 3.23 027320-200x160* 4.03 027330-160x068* 0.92 160 132
141
027312-200x100* 3.09 027322-200x100* 3.69 027332-100x048* 0.78 100 72
125 200 35
027312-200x160* 3.42 027322-200x160* 4.22 027332-160x048* 1.11 160 132
Rollers: 027313-250x100* 3.34 027323-250x100* 3.94 027333-100x048* 0.98 115 72
Ball Bearings, galvanized; 160 250 42 181
027313-250x160* 3.76 027323-250x160* 4.56 027333-160x048* 1.38 175 132
Cover Plate ZZ.
Max. Load Capacity: 25 kg * Standard range

lw Ø32
200 250
35
154

180

210
236

286
k b2
s

74

112
44
52
d b1
s

s
Towing Trolley Towing Trolley
Cable Trolley lW 200 lW 250

106
80
s

End Clamp

9
 Cable Trolleys for Round Cable and Hose
Program 0270
Plastic Cable Trolleys with Ball Joints for Cable Clips (Part No. 020131 below)
110
110 100
Ø 25 50

27

153

44
210
138

8
92

11
36
80

Cable Trolley Towing Trolley End Clamp

Part No. 027291 Part No. 027297 Part No. 027298
32 22
Rollers:
Ball Bearings, galvanized; Cable Trolley Towing Trolley End Clamp
Cover Plate ZZ. Part No. [kg] Part No. [kg] Part No. [kg]
Max. Load Capacity: 16 kg 027291* 0.59 027297* 0.97 027298* 0.18

Several Cable Clips End Stop 0274911) 0.59 0274971) 0.97 0274981) 0.18
69
can be combined Part No. 027112 * Standard range 1)
Stainless Steel (V4A) / Acid-resistant plastic

Cable Clips - to be connected to the Trolley Ball Joint

I
b c
hmax.

ød
r

for Cables Weight

Part No. r [mm] l [mm] h [mm] b [mm] c [mm] Body Material Hardware Finish
ø d [mm] [kg]
020131-16* 10…16 80 70 38 35 42 0.04
020131-25* 17…25 125 100 47 50 50 Plastic Galvanized Steel 0.06
020131-36* 26…36 180 140 58 70 64 0.12
020431-16 10…16 80 70 38 35 42 0.04
020431-25 17…25 125 100 47 50 50 Acid-resistant Plastic Stainless Steel V4A 0.06
020431-36 26…36 180 140 58 70 64 0.12
* Standard range

10
Cable Trolleys for Round Cable and Hose
Program 0270
Plastic Cable Trolleys with Brackets for Cable Clips (Part No. 020133 below)
110 100 110 50
Ø 25

27

44
153
142

50
210

92
36

Cable Trolley Towing Trolley End Clamp

Part No. 027281 Part No. 027287 Part No. 027288
32 22

Rollers:
Ball Bearings, galvanized;
Cover Plate ZZ. Cable Trolley Towing Trolley End Clamp
Max. Load Capacity: 16 kg Part No. [kg] Part No. [kg] Part No. [kg]
End Stop
Part No. 027112 69 027281* 0.57 027287* 0.99 027288* 0.21
* Standard range

Cable Clips - to be connected to the Trolley Bracket

I I
b b c c for Cables r l h b c Weight
Part No.
ø d [mm] [mm] [mm] [mm] [mm] [mm] [kg]
020133-16* 10…16 80 70 38 35 42 0.05
hmax.
hmax.

ød

020133-25* 17…25 125 100 47 50 50 0.07

ød

020133-36* 26…36 180 140 58 70 64 0.14

r
r

* Standard range
Material: Plastic;
Fasteners: Cable Clips 020131 can be mounted
Galvanized Steel underneath Cable Clips with Brackets 020133

Galvanized Steel Cable Trolleys; Heavy Duty Series

Cable Trolley Towing Trolley End Clamp da lw b1 b2 s k

Part No. [kg] Part No. [kg] Part No. [kg] [mm] [mm] [mm] [mm] [mm] [mm]
027873-200x100 3.44 027883-200x100 4.21 027893-100 1.06 115 65
160 200 16 141
027873-200x160 3.86 027883-200x160 4.75 027893-160 1.18 175 125
027874-250x160 4.21 027884-250x160 5.10 027894-160 1.83 175 125
200 250 20 181
027874-250x200 4.61 027884-250x200 5.38 027894-200 2.23 215 165
027875-320x160 4.66 027885-320x160 5.55 027895-160 2.08 175 125
250 320 25 251
027875-320x200 5.06 027885-320x200 5.83 027895-200 2.48 215 165

lW lW 106
ø32-St 80
Rollers:
35

ø32-St
Ball Bearings, galvanized;
Cover Plate ZZ.
198

210

Max. Load Capacity: 25 kg

k
330

s
112
s

52
b2

da
25

da b1

11
da
 Ideal Control Unit Trolley
Program 0270
Ideal Control Unit Trolley with Plug and Socket Connection

Number of Fittings
Part No. Weight [kg]
poles 1 2

027178-16* 16 + PE 25x42 25x21 3.72

027178-24* 24 + PE 25x42 32x29 4.10
* Standard range

460 100

398
1
50

2
Rated Voltage 400 V; Rated Current 16 A;
Protection Type IP55 as defined by DIN 40050; Strain Relief for Control Unit
Screw Connection 2.5 mm²

Ideal Control Unit Trolley with Plastic Terminal Box

Number of Fittings
Part No. Weight [kg]
poles 1 2

027174-16* 16 + PE 50x42 25x21 5.46

027174-24 24 + PE 50x42 32x29 5.86
* Standard range

460 100
482

50
200

Rated Voltage 400 V; Rated Current 16 A;

2
Protection Type IP55 as defined by DIN 40050;
Terminal Block 4 mm² Strain Relief for Control Unit 55
160 115

12
Square Rails and Accessories for Curved Tracks
Program 0280
Square Rail 40 x 40

Static Weight
Part No. Material L [mm]

40

40
Values [kg/m]
Galvanized lx = 9.91 cm4
028100-6* 6000 3.32
Steel Wx = 3.66 cm3

3
* Standard range

90° Curves

R Stretched Cable Loop Weight

Part No. Material
[mm] Length [mm] max. 0.7 x R [kg]
028102-01000* 1000 1570 700 5.20
°
90

028102-01200* 1200 1885 840 6.25

R 028102-01400* Galvanized 1400 2200 980 7.30
028102-01600* Steel 1600 2510 1120 8.30
028102-01800* 1800 2890 1260 9.60
028102-02000* 2000 3140 1400 10.40
* Standard range

Track Coupler
100
Part No. Material Weight [kg]
60 M8
028105* Galvanized Steel 0.33
* Standard range
72

Track Support Bracket for Ceiling Mounting

106
86 ø9 80
Part No. Material Max. Load [kg] Weight [kg]
4

028120* Galvanized Steel 250 0.33

* Standard range
71
112

60 M8

Track Support Bracket for mounting on Support Arm 40 x 40 x 2.5 mm

106
86 80
Part No. Material Max. Load [kg] Weight [kg]
028121* Galvanized Steel 250 0.39
* Standard range
71
112

60 M8

13
 Accessories
for Program 0280
End Stop

32 22
Part No. Material Weight [kg]
028111* Galvanized Steel; Rubber Buffer 0.22
* Standard range

ø6
.4
22
69

Drilling Fixture

For drilling holes into rails and curves

Part No. Materials Weight [kg]
Body: Aluminum
100

028107 Drill Sleeve: Hardened Steel 1.09

Fasteners: Galvanized Steel

80

End Cap

For closing Rail Ends

40 21
Part No. Material Weight [kg]
35 5 020662-40* Plastic 0.004
* Standard range
40
35

14
Cable Trolleys for Flat Cable/Round Cable
Program 0280
Galvanized Steel Cable Trolleys; for Flat Cables

Cable Trolley Towing Trolley End Clamp da lw b1 b2 s k lm

Part No. [kg] Part No. [kg] Part No. [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
028250-200x100* 4.62 028260-200x100* 5.26 028230-100x068* 0.57 100 72
80 200 45 130 100
028250-200x160* 4.86 028260-200x160* 5.62 028230-160x068* 0.86 160 132
028252-250x100* 4.91 028262-250x100* 5.55 028232-100x068* 0.68 100 72
125 250 50 180 125
028252-250x160* 5.24 028262-250x160* 6.00 028232-160x068* 1.34 160 160
028253-250x160* 5.34 028263-250x160* 6.10 028233-160x068* 1.50 175 132
250 35 180 125
028253-250x200* 5.73 028263-250x200* 6.37 028233-200x068* 1.95 215 172
160
028253-290x160 5.44 028263-320x160* 6.20 028233-160x068* 1.50 175 132
2881) 50 250 160
028253-290x200 5.83 028263-320x200* 6.47 028233-200x068* 1.95 215 172
* Standard range 1)
Cable Trolley with Rubber Buffer on one side
2 x lm-25
lm
lw
lw 1)
Rollers: ø40 106
Ball Bearings, galvanized; 80
39

Sealing Disk RS.

66

242

Max. Load Capacity: 36 kg

ø7
318

35
147

M8

s
k b2 112
s

52
ø7 da
d a
b1
s

da

Galvanized Steel Cable Trolleys; for Round Cables

Cable Trolley Towing Trolley End Clamp da lw b1 b2 s k lm

Part No. [kg] Part No. [kg] Part No. [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
028464-250x100 5.15 028474-250x100* 5.92 028394-100* 1.38 115 65
200 250 20 180 125
028464-250x160* 5.72 028474-250x160* 6.61 028394-160* 1.93 175 125
028465-320x160* 6.17 028475-320x160* 7.10 028395-160* 2.18 175 125
250 320 25 250 160
028465-320x250 6.87 028475-320x250* 7.76 028395-250* 2.88 265 215
028467-400x160* 7.03 028477-400x160* 7.92 028397-160* 2.78 175 132
320 400 32 330 200
028467-400x250 7.83 028477-400x250* 8.72 028397-250* 3.58 265 215
* Standard range

lw 2 x lm-25 106
ø40
Rollers: lm 80
39

Ball Bearings, galvanized;

Sealing Disk RS.
66

Max. Load Capacity: 36 kg

242
192

ø7 ø7
363

k
35
112

52
s

b2
s

da

da
b1
da

15
 Accessories for Cable Trolleys
Program 0270/0280
Perforated Support Arms 30 x 32 x 2 mm for Program 0270

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

020185-0250 250 200 0.39
020185-0315 315 260 0.50
020185-0400 400 340 0.63
020185-0500* 500 340 Galvanized 0.78
020185-0630 630 340 Steel 0.98
020185-0800 800 340 1.25
020185-1000* 1000 340 1.55
L1 32 020185-1250 1250 340 1.95
* Standard range

30
2

ø9 12

20 20
40 L2

Perforated Support Arms 40 x 40 x 2.5 mm for Program 0270/0280

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

020186-0250 250 200 0.63
020186-0315 315 260 0.79
020186-0400 400 340 1.00
020186-0500* 500 340 Galvanized 1.25
020186-0630 630 340 Steel 1.58
020186-0800 800 340 2.00
020186-1000* 1000 340 2.50
020186-1250 1250 340 3.13
L1 40 * Standard range
40

2,5
2.5
ø9 14

20 20
40 L2

16
Accessories for Cable Trolleys
Program 0270/0280
Non-Perforated Support Arms 30 x 32 x 2 mm for Program 0270

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

020275-0250 250 0.39
020275-0400 400 0.63
020275-0500* 500 0.78
Galvanized
020275-0630 630 0.98
Steel
020275-0800 800 1.25
020275-1000* 1000 1.55

L
020275-1250 1250 1.95
32
* Standard range

30
2

12

Non-Perforated Support Arms 40 x 40 x 2.5 mm for Program 0270/0280

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

020276-0450 450 1.13
020276-0550 550 1.38
020276-0650* 650 1.63
Galvanized
020276-0840 840 2.10
Steel
020276-0950 950 2.38
020276-1000 1000 2.50
020276-1150* 1150 2.88
L1 40
* Standard range
40

2,5
2.5
ø9 14

Permissible Load for Support Arms

20 20
40 L2 F Note:
• Calculated with σ = 140 N/mm2 tension
• f = associated max. deflection
f

LI

L [mm]
0.25 0.40 0.50 0.65 0.80 1.00 1.25 1.52 2.00
Support Arm F [kg] 76.0 47.5 38.0 29.0 24.0 19.0 15.0 12.5 9.50
30 x 32 x 2 mm f [cm] 0.08 0.20 0.32 0.60 0.90 1.40 2.20 3.30 5.70
Support Arm F [kg] 164.5 103.0 82.0 63.0 51.5 41.0 33.0 27.0 20.5
40 x 40 x 2.5 mm f [cm] 0.07 0.20 0.30 0.45 0.70 1.10 1.70 2.50 4.30

17
 Accessories for Cable Trolleys
Program 0270/0280
Towing Arms

63 4 L
40 Weight
Part No. L [mm] Material
[kg]
020195-400 400 Galvanized 0.60

63
40
020195-630* 630 Steel 1.00
* Standard range

25
9

Tow Ropes

Type A Type B
21 LZugl 21 21 LZug 21

ød
ød

Part No. ød [mm] Type Material Weight [kg] for Program

020316-04* 4 A Plastic 0.12 0270 Plastic Cable Trolleys
020329-04* 4 B Galv. Steel; PVC jacket 0.16 0270 Steel Cable Trolleys; 0280
020328-04* 4 B Galvanized Steel 0.20 0270 Steel Cable Trolleys; 0280
* Standard range

Girder Clips, clamping thickness range 4 - 20 mm

60
M8
50
s

Part No. Material Weight Clamping

[kg] s 4 6 8 10 12 16 20
thickness
020180-08* Galvanized Steel 0.15 Installation
h 31 32 33 34 35 37 40
020480-08 Stainless Steel V4A 0.15 height
* Standard range

18
Accessories for Cable Trolleys
Program 0270/0280
Application Example

L 32 (40)

30 (40)
max.
40
max.
20

M6
Track Support Bracket
60
M8

Girder Clip Support Arm Square Rail 60

19
 Project Planning

Determining the Support Distance for Square Rail Program 0270

Technical Data / Calculation Assumptions
The required support distance of the square rail can be determined using the diagram below. The following calculation assumptions have been taken into consideration:

1. Simply-supported beam, uniform load symmetrical to middle of the beam

2. The load of one trolley FLW [kg/trolley] is distributed over trolley length lW as a uniform load p [kg/m]
3. Total length of the uniform load results from the cable trolley storage length lb [m] of all trolleys side by side
4. σ bzul = 100 N/mm²
5. f = IA/250 permissible deflection from the load and net weight of the rail
6. As track support bracket load the load of a field symmetrical to the mounting (bracket) is assumed

Example:
Given:
FLW = Cable Trolley Load: 3.6 kg (X axis value on the left-hand graph below)
lw = Cable Trolley Length: 110 mm (blue line on the left graph)
Z = Overall number of Cable Trolleys: 9
lb = Cable Trolley Storage Length: 0.99 m (X axis on the right-hand graph below)
(m) = Z x lw / 1000

Load Diagram for Square Rail 30 x 30 x 2 (020275)

16

11
0 0 0 0 0 0

160
0.9
Cable Trolley Length lW [mm]

20 25 32 40 50

125
28 36 45
0 0 0

1.0
100
1.12
80
1.25
63
1.4
50
40 1.6

Support Distance lA [m]

32 1.8
p [kg/m]

25
2.0
20
16 2.24
12.5
10 2.5
8 2.8
6.3
5
3.2
4
3.2 4.0
2.5 3.6
25
20
16
12.5
10
8
6.3
5
4
3.2
2.5
2
1.6
1.25
1
0.8
0.63

0.1
0.125
0.15
0.2
0.25
0.32
0.4
0.5
0.63
0.8
1
1.25
1.6
2
2.5
3.2
4

Cable Trolley Load FLW [kg/trolley] Cable Trolley Storage Length lb [m]

Result for Square Rail 30 x 30 x 2

From Diagram:
Required Support Distance lA = 2.0 m
Note: Support distance in curves should not exceed two thirds of the required support distance for a straight track.

20
 Project Planning

Determining the Support Distance for Square Rail Program 0280

Technical Data / Calculation Assumptions
The required support distance of the square rail can be determined using the diagram below. The following calculation assumptions have been taken into consideration:

1. Simply-supported beam, uniform load symmetrical to middle of the beam

2. The load of one trolley FLW [kg/trolley] is distributed over trolley length lW as a uniform load p [kg/m]
3. Total length of the uniform load results from the cable trolley storage length lb [m] of all trolleys side by side
4. σ bzul = 100 N/mm²
5. f = IA/250 permissible deflection from the load and net weight of the rail
6. As track support bracket load the load of a field symmetrical to the mounting (bracket) is assumed

Example:
Given:
FLW = Cable Trolley Load: 18 kg (X axis value on the left-hand graph below)
lw = Cable Trolley Length: 200 mm (blue line on the left graph below)
Z = Overall number of Cable Trolleys: 6
lb = Cable Trolley Storage Length: 1.20 m (X axis value on the right-hand graph below)
(m) = Z x lw / 1000

Load Diagram for Square Rail 40 x 40 x 3 (020276)

16 20 25 32 400 500
0 0 0 0

250 1.0
Cable Trolley Length lW [mm]
28 36

200 1.12
0 0

160 1.25
125 1.4
100 1.6
80 1.8
p [kg/m]

Support Distance lA [m]

63 2.0
50 2.24
40
2.5
32
25 2.8
20
16 3.2
12.5
10 3.6
8
6.3 4.0
40.0
32.5
25.0
20.0
15.0
12.5
10.0
8.0
6.3
5.0
4.0
3.2
2.5
2.0
1.6
1.25

0.16
0.2
0.25
0.32
0.4
0.5
0.63
0.8
1.0
1.25
1.6
2.0
2.5
3.2
4.0

Cable Trolley Load FLW [kg/trolley] Cable Trolley Storage Length lb [m]

Result for Square Rail 40 x 40 x 3

From Diagram:
Required Support Distance lA = 1.8 m
Note: Support distance in curves should not exceed two thirds of the required support distance for a straight track.

21
 Project Planning

Technical Data

lges

lb ls

lE e lW lM lz
da

k
Linst E Linst M
Terminal Box

H
h
> 0.1 m

Calculating the number of Cable Loops, required Cable Length, and Loop Length

Number of loops: Cable Trolley storage length:

da [m] = Cable Support diameter
f (ls + e) e [m] = Tolerance in the Cable Trolley storage length
n= lb ≈ n • lw + e [m]
2 • h + 1.25 da - f • lw (recommended ≥ 0.1 m)
f = Length factor for cables
(1.2 for square rails)
Cable system length: Total cable length: h [m] = Loop depth
(measured from top edge of Cable Support)
H [m] = Overall installation space
LSyst = f (ls + lb) [m] LBest = LSyst + LinstE + LinstM [m] lb [m] = Cable Trolley storage length incl. tolerance “e”
ls [m] = Travel distance
lw [m] = Cable Trolley length
lz [m] = Length of tension relief
Required length of tension relief:
LBest [m] = Total cable length
LinstE [m] = Length for fixed installation, End Clamp side
1.05 (ls+lb) For plastic Cable Trolleys: k = 0.08 [m] LinstM [m] = Length for fixed installation, Towing Trolley side
lz = -k [m]
n For steel Cable Trolleys: k = lw - 0.06 [m] LSchl [m] = Loop length
LSyst [m] = Required cable length measured from
middle of the End Clamp to middle of
Loop length: Loop depth: the Towing Trolley / Cable Clamp
n = Number of loops
Rmin [m] = Smallest radius for curved track
LSyst LSchl < 0.7 · Rmin [m]
LSchl = [m] h= - 0.63 • da =
n 2

The maximum permissible cable loop depends on the smallest radius to be passed.
Loops which do not pass this radius can be larger accordingly.

22