System Description
The SinglePowerLine 0812 conductor rail system is a standard product for powering bridge, portal, and process cranes, as well as amusement rides and people movers. With over 35 years of specified, reliable application, it serves as an insulated, single-pole safety conductor rail with contact protection, meeting European (CE) and international standards.
The system supports conductor temperatures up to 115°C (equivalent to 85°C ambient at 100% duty cycle), with temporary withstand up to 125°C. Conductor materials include copper, stainless steel, and a saltwater-resistant aluminum alloy with stainless steel tread. The special CopperECO III material offers an alternative with enhanced conductivity and corrosion protection for high current requirements, even during standstill.
A partial expansion compensation system allows for systems up to 200m without additional expansion elements. The system features a safe connector system and clip-on rail holders, enabling fast and economical assembly, especially when combined with optional mounting brackets. The 0813 product line extension offers higher power ranges.
Insulation is typically safety yellow, with PE (grounding) conductor rails in green and yellow (continuous green strips). Other colors are available upon request with minimum order quantities. The design is finger-safe, tested with 12mm foreign bodies.
System Advantages:
- Available in various conductor materials
- Finger-safe design
- Globally used
- Modular and expandable
- Can form circular slip rings and curves
- Self-extinguishing insulation (UL-94 compliant)
- Yellow safety color
- Designed for 100% duty cycle
- Compliant with European standards
- Self-aligning hanger clamps
- Saltwater-resistant
- Special seamless and corrosion-resistant connection process
Technical Data
The SinglePowerLine 0812 system is available in various conductor materials and types, including Stainless Steel (081217), Aluminum (081213), CopperECO III (08121C, 08121D), and Copper (081215, 081216). Current loads range from 25A to 480A (at 100% duty cycle) and 32A to 480A (at 60% duty cycle). The rated voltage is 690V (UL 600V). Protection type is IP23 for vertical collector insertion and IP21 for horizontal. The system is finger-safe and designed for horizontal installation orientation. Applications include cranes and people movers, suitable for indoor and protected outdoor environments.
Key specifications include a rated suspension spacing of 1.4-1.5m, rail length of 4000mm, exterior dimensions of 18x26mm, and a travel speed of up to 600 m/min. System length is unlimited with expansion connectors, and expansion elements are required for lengths over 200m. Permitted ambient temperature ranges from -15°C to +55°C (or +85°C for heat-resistant designs), with maximum conductor temperatures of +85°C (or +115°C heat-resistant, +125°C temporary). Conductor materials include copper, aluminum with stainless steel tread, CopperECO III, and stainless steel. Rail insulation is typically PVC or heat-resistant PPE+SB. The system complies with Overvoltage Category III and relevant standards like DIN EN 60664-1, DIN EN 60204-1, and DIN EN 60529.
Program 0812 Applications: Power supply for cranes, slip ring assemblies, transfer carriages, cable trays, and other applications in indoor and weatherproof outdoor environments (IP2x).
Relevant Standards: DIN EN 60664-1, VDE 0110-1:2008-1; DIN EN 60204-1, 60204-32, VDE 0113-1:2007-06; DIN EN 60529, VDE 0470-1:2000-09.
General Instructions
Application Area: The system powers mobile machines up to 400A and 690V/1000V, suitable for cranes, people movers, and storage/retrieval systems. Arc and curve elements can be produced on-site or at the factory.
Materials & Environment: Insulation materials resist industrial environments. Metal parts are available in copper, stainless steel, or saltwater-resistant aluminum. Consult the factory for use in critical environments like galvanizing or pickling plants.
Layout: Key factors include load current, rail type, voltage drop (target 2-5%, max 10%), and ambient conditions. Rated current is based on 30°C ambient and 100% duty cycle; higher currents are possible with lower duty cycles or temperatures. A graph illustrates current adjustment for duty cycles.
Electrical Safety: The system is designed to international standards, offering contact protection (IP21/IP23) and finger-safe operation. Additional protection is required where collectors leave rails (intersections, switch points). Installations in public areas above 48V AC/60V DC need covers or isolation. Insulators and warning signs are necessary in high-voltage, high-contamination areas.
PE Conductor: Marked green/green-yellow, it must not be used as a phase component. Redundant PE with dual collectors is recommended.
Mechanical Safety: Maintain a minimum 0.5m spacing between moving and fixed system parts to prevent collisions. Seek guidance for exposed installations.
Use of Conductor Rails: Classified under the low voltage directive, the system complies with standards. Installation must adhere to the Machine Directive and local guidelines.
Outdoor Use: Protect from environmental factors. Optional rail heaters are available for aluminum rails in areas prone to frost or ice.
Approvals: The product line meets EU and industrial market standards, including IEC/EN, UL/CSA, and GOST-R approvals.
System Structure
The SinglePowerLine 0812 system comprises several key components:
- Current Collectors (1): Connect to the moving part of the system, maintaining positive contact with the rail. Available as single or dual units.
- Conductor Rails (2): The core conductive element with a contact-safe insulated profile.
- Rail Connectors (3): Clamping connectors with insulated caps, requiring a tool for removal.
- Anchor Clamps (4): Secure the rail, allowing for expansion from the anchor point.
- Hanger Clamps (5): Freely rotating, self-aligning clip-on holders for easy assembly, with adjustable mounting height. They allow the rail to slide during thermal expansion.
- Power Feed Connectors (6): Used instead of rail connectors to connect single strands up to 17mm in diameter.
- End Caps (7): Terminate the rail and provide contact protection.
- Support Arms (8): Structural supports for the conductor rails.
- Pickup Guides (9): Facilitate the entry and exit of current collectors into the conductor rail system.
- Air Gaps: Provide galvanic isolation for specific segments, useful during maintenance.
System Advantages: The system is robust, finger-safe, designed to international standards, highly available, expandable, and offers partial thermal expansion compensation. It features simple installation, optional safety components, a safety warning color (RAL 1018/1021), CE compliance, and can accommodate any number of poles.
Insulated Conductor Rails
Conductix-Wampfler offers conductor rails in electrolytic copper, aluminum with stainless steel contact surfaces, and the special CopperECO III material. Copper is ideal for high conductivity and low voltage drop, though less suited for aggressive environments. Aluminum with stainless steel tread offers a budget-friendly option with good conductivity and wear resistance. Stainless steel is suitable for low current and control signals. CopperECO III provides superior conductivity for high power transmission, especially in demanding outdoor or saltwater conditions.
The rails consist of a conductive body and protective insulation. Standard insulation uses PVC, while heat-resistant applications utilize PPE+SB. The standard rail length is 4000mm. The system is color-coded for safety: yellow for standard insulation and RAL 1021 for heat-resistant insulation.
Technical data tables provide specifications for rated current (100% and 60% duty cycle), conductor cross-section, DC resistance, impedance, and weight for each material type.
Clamps and Connectors
Hanger Clamps
Hanger clamps are designed for suspension, offering self-alignment and low-friction movement for thermal expansion. They are available in galvanized or stainless steel, with hex or square nuts for mounting support arms. Key notes include a rated suspension spacing of 1.5m and a minimum spacing of 250mm from connectors or power feeds. Calculation hints for quantity and installation notes regarding phase spacing and mounting holes are provided.
Compact Hanger Clamps
These clamps facilitate rapid assembly of 3 or 4 rails indoors. They can be surface-mounted or inserted into Conductix-Wampfler Support Arms and mounting brackets. Proper alignment (90° to the rail) is crucial for free slipping during expansion. They are not recommended for aggressive environments or hot-dip galvanized support arms.
Anchor Clamps
Anchor clamps fix rails in a specific location, allowing expansion from that point. They are primarily used for single power feeds or at the center of the conductor rail system. For systems with multiple fixed points or curves, expansion units are necessary to manage length changes. Clamps are secured using a clamping cone on the rail insulator. Two anchor clamps per pole are required for each fixed point.
Rail Connectors
These are compact screw connections used to join rails. Exposed metal contact surfaces require contact grease for corrosion protection. Proper tightening torque is essential during mounting.
Power Feed Connectors
Power feed connectors replace standard rail connectors for electrical connections. They utilize projecting bolts and notch-type cable lugs. Notes specify maximum tightening torque and cable diameter, recommending the use of contact grease.
End Caps
End caps serve as rail terminators and provide contact protection. They are fastened to the rails using clamping screws.
Air Gaps
Air gaps are used for galvanic isolation of system sections, such as for maintenance. Two air gaps are mounted at each separation point to prevent power carryover through current collectors.
Expansion Units
Expansion units are essential for compensating thermal expansion in conductor rail systems longer than 100m or segments connected between fixed points like pickup guides or curves. Each expansion unit features two expansion points, capable of absorbing 25mm of expansion per point. The system design allows for up to 200m of rail without additional expansion units, provided the power feed is centrally located and the rail can expand freely on both sides.
For systems exceeding 200m, or with complex layouts and fixed points, expansion units must be installed at specific intervals. The selection and installation of these units depend on the rail material, rated current, and ambient temperature range. A diagram illustrates how to determine the required air gap based on temperature variations.
Layout Notes: The system incorporates partial thermal expansion compensation within each rail. Self-aligning hanger clamps facilitate rail movement without friction. For longer installations or those with multiple fixed points (e.g., pickup guides, curves), expansion joints are critical to manage length changes.
Mounting Instruction: A minimum distance of 10mm should be maintained between insulating caps and the steel construction.
Pickup Guides for Intersections
Pickup guides are used with specific current collectors (081206... / 081208...) to enable collectors to enter or exit the conductor rail system. They are designed for a maximum entry speed of 60 m/min and are considered wearing parts. Precise installation tolerances are required, with simultaneous alignment gaps not permitted.
The guides center the current collector with a lateral and vertical alignment tolerance of ±25mm, though settings below ±10mm are recommended. It is crucial to ensure the correct number of current collectors are installed and that they are disconnected from power or protected against accidental contact when between pickup guides.
Installation notes specify the necessary spacing between pickup guides and hanger clamps (750mm) and the adjustment of the conductor rail spacing to ensure smooth collector entry.
Current Collectors
Plastic Arm Type
The plastic arm type current collectors (e.g., 081209-xxx) are suitable for warehouse systems, EOT cranes, and amusement parks. They are available as single or dual units and are fastened to a towing arm. For single-direction movement, they are towed to minimize wear. For bidirectional movement, reversible operation variants are used. Technical data includes maximum power capacity (80A/160A), travel speed (600 m/min), and connection cable specifications.
Parallel Arm Metal Type
These collectors feature a robust, fully metallic design and are available as single or dual units. PE collectors are marked green and include a deflector to prevent insertion into phase rails. They can be installed horizontally (from the side) or vertically (from underneath). Technical data specifies maximum current capacity (98A for single, 2x98A for dual) and travel speed (600 m/min).
Tables detail part numbers, fastening elements (galvanized or stainless steel), and weights for various configurations, including those for intersections with pickup guides. Installation spacing for collectors is also provided, along with instructions for the non-interchangeability of PE collectors and the use of a drilling jig for PE conductor collector installation at intersections.
Dimensioning and Layout of Conductor Rail System
Proper dimensioning and layout involve several steps: determining load current, selecting the rail type, checking voltage drop, considering ambient conditions, and choosing accessories and current collectors.
Load Current Determination:
Calculate total load current by summing simultaneous consumer currents, avoiding over-specification. A selection help table is provided for standard EOT crane applications, factoring in the power of multiple cranes.
Rail Current Capacity:
Rated currents are based on 35°C ambient temperature and 100% duty cycle. The system can handle higher currents with shorter duty cycles, as illustrated by a graph. Correction factors (fA) are provided in tables for adjusting loads based on ambient temperature and insulation type.
Voltage Drop Calculation:
Formulas are given for calculating voltage drop for DC, AC, and three-phase power, considering current, resistance/impedance, and feed length. Start-up currents (IA) for various motor types are also detailed. For ambient temperatures significantly above 35°C, reduction factors (fv) are used, calculated from working temperature.
Power Feed Locations:
Diagrams illustrate various power feed options (end, middle, both sides) and define the feed length ('l') for voltage drop calculations, crucial for system optimization.
System Layout
The system layout requires protection from weather for outdoor use, with insertion from below preferred and insulated holders recommended. Optional heating conductors can prevent frost and ice buildup. A minimum 10mm distance between insulation elements and the steel structure is necessary.
A layout schematic shows the arrangement of components like power feeds, air gaps, hanger clamps, rail connectors, end caps, fixed points, expansion units, and pickup guides, with specified minimum distances between components (e.g., 250mm between hanger clamps, joints, etc., and 350mm for power feeds).
An example material overview details a typical 52m system, 4-pole, 320A configuration, listing required parts such as conductor rails, hanger clamps, anchor clamps, connectors, power feeds, end caps, current collectors, and support arms, along with their part numbers and quantities. Notes emphasize the need for flexible connection cables and proper transition to fixed cabling to prevent strain on the collector head.
Mounting Accessories
Support Arms
Support arms are available in 30x32x2mm and 40x40x2.5mm sizes, made of galvanized steel. Tables provide dimensions, part numbers, weights, and permissible load capacities, including static values for bending resistance and deflection.
Holders
Holders for support arms are offered for screw mounting with 2-holed connector plates. These are available for both 32x30x2mm and 40x40x2.5mm support arm sizes, in galvanized or unplated steel with galvanized hardware, along with their respective weights.
Girder Clips
Girder clips are provided for various clamping thicknesses (4-20mm, 18-36mm, and 6-25mm non-twistable). They are available in galvanized steel and stainless steel (V4A), with specified weights, clamping thicknesses, and installation heights.
Towing Arms
Towing arms, made of galvanized or stainless steel, are available in a 630mm length, with options for on-site length adaptation.
End Caps
Plastic end caps are available for support arms, with specified dimensions and weights.
Insulators
Insulators are designed for indoor applications with high contamination or outdoor use, rated up to 1000V. They feature a 62mm creepage distance, cantilever strength over 350 daN, and an ambient temperature range of -30°C to +85°C. Various hardware options are available, including threaded bolts in galvanized or stainless steel.
Notch-type Cable Lugs
These copper, tin-plated cable lugs are for power feed lines, available in various cross-sections (6mm² to 95mm²), with detailed dimensions and weights per 1000 units.
Connector Cables
Connector cables for Current Collector Head 081209 are offered in different cross-sections (6, 10, 16mm²) and lengths, specifying cable diameter, rated current, and weight. Custom lengths are available upon request. Notes advise on cable stress during operation and recommend junction boxes for fixed cabling.
Spring Assembly
Spring assemblies for lateral insertion into the Current Collector Head 081209 are available in left-hand and right-hand versions, each weighing 0.100kg.
Tools and Assembly Accessories
Mounting Comb
The mounting comb (Part No. 081045) aids in setting rail holder spacing during support arm mounting, weighing 0.190kg.
Bending Device
A bending device is available for creating horizontal and vertical curves for Program 812 conductor rails. It includes roller sets for different curve types and a bending manual. Replacement parts for the device are also listed.
Contact Grease
Contact grease (Part No. 080021) is used to prevent corrosion at connection points. A thin film is applied to conductor rail faces and connector clamping areas. One tube serves approximately 200 connection points.
Replacement Parts
Replacement parts are available for current collectors, including complete collector heads for the 081209 model, stabilization springs, and replacement sliding contacts with insulators for models 081205 through 081208. These parts ensure the continued optimal performance and safety of the conductor rail system.
Specific items include sliding contacts (80A, 100A, 40A), collector insulation, connection repair sets containing contact sheets, cable lugs, heat shrinkable tubing, screws, lock-nuts, and washers. Connecting cables are also available, with custom lengths offered on request.
Your Applications – our Solutions
Conductix-Wampfler offers a comprehensive range of energy and data transmission systems tailored to specific applications. A combination of different systems can provide advantageous solutions, supported by expert engineering. The product portfolio includes:
- Cable and Hose Reels
- Festoon Systems
- Conductor Rails
- Inductive Power Transfer (IPT®)
- Non-insulated Conductor Rails
- Radio Remote Controls
- Reels, Retractors and Balancers
- Jib Booms
- Slip Ring Assemblies
- Mobile Control Systems
- ProfiDAT data transfer systems
Conductix-Wampfler's mission is to provide energy and data transmission systems that ensure continuous operation, 24/7/365. For contact information, visit www.conductix.contact.
